O&M Manual 500 MW TurboGenerator

OPERATION & MAINTENANCE
MANUAL
FOR
500 MW TURBOGENERATOR
WITH
WATER COOLED STATOR WINDING &
DIRECT HYDROGEN COOLED ROTOR WINDING
Project : NCTPP Stage -2 DADRI-2 x 490MW

Customer : NTPC
BHEL Order no : 10550A12901 DADRI UNIT 1
10554A12901 DADRI UNIT 2
HARIDWAR
BHARAT HEAVY ELECTRICALS LIMITED
Heavy Electrical Equipment Plant
Turbogenerators
Table of Contents
General
Cover Sheet
0.0-0000
GENERAL
Table of Contents . . . . . . . . . . . . . . . . . .
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes on the Use of the Manual . . . . . . . . .
Operation Beyond Contract Commitment . .
Safe Disposal of Turbogenerator Items
2.0-0010
2.0-0030
2.0-0040
2.0-0050
2.0-0200
DESCRIPTION
Brief Description
Rating Plate Data . . . . . . . . . . . . . . . . . . .
Generator Cross Section . . . . . . . . . . . .
Generator Outline Diagram . . . . . . . . . .
Exciter Outline Diagram . . . . . . . . . . . . .
Design and Cooling System . . . . . . . . .
Generator Cooling Gas Circuit . . . . . . .
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator Winding . . . . . . . . . . . . . . . . . . . . .
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrogen Cooler . . . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . .
Oil Supply for Bearings and Shaft Seals . .
Seal Oil System (Simplified Diagram)
Gas System . . . . . . . . . . . . . . . . . . . . . . .
Gas System (Simplified Diagram) . . . .
Primary Water System . . . . . . . . . . . . . .
Primary Water System (Simplified Diagram) .
2.1-1002
2.1-1050
2.1-1056
2.1-1058
2.1-1100
2.1-1150
2.1-1210
2.1-1230
2.1-1300
2.1-1440
2.1-1450
2.1-1460
2.1-1510
2.1-1511
2.1-1520
2.1-1521
2.1-1530
2.1-1531
Technical Data
General and Electrical Data . . . . . . . . .
Mechanical Data . . . . . . . . . . . . . . . . . .
Seal Oil System . . . . . . . . . . . . . . . . . . .
Gas System . . . . . . . . . . . . . . . . . . . . . . .
Primary Water System . . . . . . . . . . . . . .
Waste Gas System . . . . . . . . . . . . . . . .
Excitation System . . . . . . . . . . . . . . . . . .
Cooler Data . . . . . . . . . . . . . . . . . . . . . . .
Reactive Capability Curve . . . . . . . . . . .
Load Characteristic of pilot exciter . . .
Gas Specification . . . . . . . . . . . . . . . . . .
Primary Water Specification . . . . . . . . .
Specification for Ion Exchange Resins
Additive Specification for Alkalizer Unit
2.1-1810
2.1-1820
2.1-1825
2.1-1826
2.1-1827
2.1-1828
2.1-1829
2.1-1830
2.1-1850
2.1-1860
2.1-1883
2.1-1885
2.1-1887
2.1-1888
Stator
Stator Frame . . . . . . . . . . . . . . . . . . . . . .
BHEL,Haridwar
2.1-2100
Stator End Shields . . . . . . . . . . . . . . . . .

Generator Terminal Box . . . . . . . . . . . .
Hydraulic Testing and Anchoring of Stator
Anchoring of Generator on Foundation
Stator Core . . . . . . . . . . . . . . . . . . . . . . . .
Mounting of Stator Core in Stator Frame
Spring Support of Stator Core . . . . . . . .
Stator Winding . . . . . . . . . . . . . . . . . . . . .
Connection Diagram of Stator Winding
Stator Slot . . . . . . . . . . . . . . . . . . . . . . . . .
Transposition of Stator Bars . . . . . . . . .
Micalastic High Voltage Insulation . . . .
Construction of High Voltage Insulation
Corona Protection . . . . . . . . . . . . . . . . . .
Coil and End Winding Support System
Stator End Winding. . . . . . . . . . . . . . . . .
Electrical Connection of Bars, Water Supply
and Phase Connectors . . .
Electrical Bar Connections and Water Supply
Terminal Bushings. . . . . . . . . . . . . . . . .
PW Connection for Terminal Bushings and
Phase Connectors . . . . . . . . . .
Cooling of Terminal Bushings . . . . . . .
Components for Water Cooling of Stator
Winding . . . . . . . . . . . . . . . . . .
Grounding of Stator Cooling Water Manifold . .
2.1-2150
2.1-2170
2.1-2190
2.1-2191
2.1-2200
2.1-2201
2.1-2220
2.1-2300
2.1-2301
2.1-2303
2.1-2305
2.1-2320
2.1-2321
2.1-2330
2.1-2340
2.1-2341
2.1-2350
2.1-2351
2.1-2370
2.1-2371
2.1-2372
2.1-2380
2.1-2389
Rotor
Rotor Shaft . . . . . . . . . . . . . . . . . . . . . . . .
Cooing of Rotor Winding . . . . . . . . . . . .
Cooling Scheme of Rotor Winding . . . .
Rotor Winding. . . . . . . . . . . . . . . . . . . . . .
Rotor Slot . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor End Winding . . . . . . . . . . . . . . . . .
Rotor Retaining Ring . . . . . . . . . . . . . . .
Rotor Field Connections . . . . . . . . . . . .
Electrical and Mechanical Connection of EE
Coupling . . . . . . . . . . . . . . . . .
Rotor Fan . . . . . . . . . . . . . . . . . . . . . . . . .
2.1-3000
2.1-3100
2.1-3101
2.1-3300
2.1-3301
2.1-3310
2.1-3350
2.1-3370
2.1-3373
2.1-3600
Cooler
Hydrogen Cooler (Description) . . . . . . .
Hydrogen Cooler (Drawing) . . . . . . . . .
2.1-4000
2.1-4001
Generator Bearings
Generator Bearing (Description) . . . . .
Generator Bearing (Drawing) . . . . . . . .
Measurement of Bearing Temperature
Generator Bearing Insulation . . . . . . . .
2.1-5000
2.1-5001
2.1-5003
2.1-5005
2.0-0010-10550/1
0209E
Shaft Seal
Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Seal (Drawing) . . . . . . . . . . . . . . .
2.1-6000
2.1-6001
Tripping Scheme for Generator Electrical

Protection . . . . . . . . . . . . .
Rotor Grounding System . . . . . . . . . . .
Arrangement of Brush Holders for Rotor
Grounding System. . . . . . . . .
2.1-8331
2.1-8350
2.1-8351
Seal Oil System

Seal Oil System . . . . . . . . . . . . . . . . . . .
Differential pressure Valve A . . . . . . . . .
Differential Pressure Valve C . . . . . . . .
Pressure Equalizing Control Valve. . .
Seal Oil System Schematic Diagram .
List of Valves for Seal Oil System. . . .
Bearing Vapour Exhauster. . . . . . . . . . .
Seal Oil Pumps. . . . . . . . . . . . . . . . . . . .
Seal Oil Cooler and Seal Oil Filter. . . .
Seal oil Cooler (Drawing) . . . . . . . . . . .
Seal Oil Filter (Drawing) . . . . . . . . . . . .
Differential Pressure Meter Syste. . . .
2.1-7100
2.1-7101
2.1-7103
2.1-7104
2.1-7111
2.1-7112
2.1-7120
2.1-7123
2.1-7130
2.1-7131
2.1-7132
2.1-7150
Measuring Devices and Supervisory

Equipment
Introduction. . . . . . . . . . . . . . . . . . . . . . . .
Temperature Transducers. . . . . . . . . . .
Supervision of Generator. . . . . . . . . . . .
Generator measuring points. . . . . . . . .
List of Valves for Generator System. . . . .
Supervision of Bearings. . . . . . . . . . . . .
Supervision of Seal Oil System. . . . . .
Supervision of Gas System. . . . . . . . .
Supervision of Primary Water System
Supervision of Exciter. . . . . . . . . . . . . .
Exciter Measuring Points. . . . . . . . . . .
2.1-8400
2.1-8410
2.1-8420
2.1-8422
2.1-8423
2.1-8440
2.1-8450
2.1-8460
2.1-8470
2.1-8490
2.1-8491
Gas System
Gas System. . . . . . . . . . . . . . . . . . . . . . .
Gas System Schematic Diagram. . . .
List of Valve for Gas System. . . . . . . . .
CO2 Vaporiser. . . . . . . . . . . . . . . . . . . .
Gas Dryer (Refrigeration type) . . . . . .
2.1-7200
2.1-7211
2.1-7212
2.1-7230
2.1-7270
Primary Water System

Primary Water System. . . . . . . . . . . . . .
Primary Water System Schematic Diagram. .
List of Valves for Primary Water System
Primary Water Pumps. . . . . . . . . . . . . .
Primary Water Cooler. . . . . . . . . . . . . . .
Primary Water Treatment System. . . .
Alkalizer Unit for Primary Water Circuit
Primary Water Filters. . . . . . . . . . . . . . .
Primary Water Main Filter. . . . . . . . . . . .
Primary Water Fine Filter. . . . . . . . . . . .
Protective Screens at Primary Water Inlet
and Outlet. . . . . . . . . . . . . . . . .
2.1-7300
2.1-7311
2.1-7312
2.1-7320
2.1-7330
2.1-7340
2.1-7341
2.1-7343
2.1-7344
2.1-7345
2.1-7349
Automatic Controls
Coolant Temperature Control. . . . . . . .
2.1-8010
Protective Devices
Safety Equipment for Hydrogen Operation. .
Waste Gas System. . . . . . . . . . . . . . . . .
List of Valves for Waste Gas System .
Generator Waste Fluid System . . . . . .
Generator Mechanical Equipment Protection.
Tripping Scheme for Generator Mechanical
Equipment Protection
Generator Mechanical Equipment Protection .
Generator Electrical Protection. . . . . . .
2.0-0010-10550/2
0209E
2.1-8310
2.1-8311
2.1-8312
2.1-8315
2.1-8320
2.1-8321
2.1-8323
2.1-8330
Excitation System
Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Arrangement of Brushless Excitation
System. . . . . . . . . . . . . . .
Rectifier Wheels. . . . . . . . . . . . . . . . . . .
Rectifier Wheels and Coupling. . . . . .
Permanent-Magnet Pilot Exciter Rotor & Fan
Exciter Cross Section. . . . . . . . . . . . . .
Exciter Cooling Air Circuit. . . . . . . . . . .
Stroboscope for Fuse Monitoring . . . .
Exciter Drying . . . . . . . . . . . . . . . . . . . . .
Ground Fault Detection System for Exciter
Field Circuit. . . . . . . . . . . . .
Arrangement of Bursh Holders for Ground
Fault Detection System . .
Brush Holders for Ground Fault Detection
System. . . . . . . . . . . . . .
2.1-9100
2.1-9101
2.1-9102
2.1-9103
2.1-9104
2.1-9110
2.1-9120
2.1-9140
2.1-9150
2.1-9180
2.1-9181
2.1-9182
Operation
Operating and Setting Values-General
Gas Quantities. . . . . . . . . . . . . . . . . . . .
Measuring Point List of Generator . . .
Running Routine-General. . . . . . . . . .
Operating Log-Generator Supervision
Operating Log-Seal Oil System . . . . .
Operating Log-Gas System . . . . . . . .
Operating Log-Primary Water System
Operating Log-Exciter Supervision . .
2.3-4000
2.3-4010
2.3-4030
2.3-4100
2.3-4120
2.3-4150
2.3-4160
2.3-4170
2.3-4190
Start-up
Preparations for Starting-Introduction
Hints for Cooler Operation. . . . . . . . . .
Filling and Initial Operation of Air Side Seal
2.3-5000
2.3-5003
Turbogenerators
Oil Circuit. . . . . . . . . . . . . . . . .
2.3-5110
Filling and Initial
Operation
of
Hydrogen
General
Side Seal Oil Circuit . . .
2.3-5120
Venting of Seal Oil Circuits. . . . . . . . . .
2.3-5130
Setting of Seal Oil Pressures. . . . . . .
2.3-5150
Setting of Operating Values for Seal Oil System 2.3-5160
Measurement of Seal Oil Volume Flows
2.3-5163
Functional Testing of Pumps and Exhausters 2.3-5180
Startup of Air Side Seal Oil Circuit . . .
2.3-5210
Startup of Hydrogen Side Seal Oil Circuit. . . . 2.3-5220
Venting of Seal Oil Circuits and Checking of
Seal Oil Pressures . .
2.3-5230
Checking Automatic Operation of Seal Oil
Pumps. . . . . . . . . . . . . . . .
2.3-5280
Positions of Multi-Way Valves in Gas System 2.3-6107
Scavenging the Electrical Gas Purity Meter
System . . . . . . . . . . . . .
2.3-6110
Setting Electrical Zero of Electrical Gas Purity
Meter System . . . . . . . .
2.3-6120
Purity Measurement During CO2 Filling
2.3-6130
Purity Measurement During H2 Filling
2.3-6140
Purity Measurement During H2 Operation
2.3-6150
Gas Filling-Replacing Air With CO2. . . . . .
2.3-6310
Gas Filling-Replacing CO2 With H2. . . . . .
2.3-6320
N2 Purging After Filling of Primary Water
System . . . . . . . . . . . . . . . . . .
2.3-6810
Filling and Initial Operation of Primary Water
SystemPreparatory Work . . . . . . . . . . . . . . . . . .
Filling External Part of Primary Water Circuit
Filling the Water Treatment System . .
Filling the Terminal Bushings and Phase
Connectors . . . . . . . . . . . . .
Filling the Stator Winding . . . . . . . . . . .
Filling Primary Water Coolers on Cooling
Water Side . . . . . . . . . . . . .
Activating Primary Water System After a
Shutdown of Less Than 48 Hours
Activating Primary Water System After a
Shutdown of More Than 48 Hours
Activating the Primary Water Conductivity
Meter System . . . . . .
Activating the Primary Water Volume Flow
Meter System . . . . . . . . . . . . .
Initial Operation of Primary Water System Checks Prior to Startup . .
Turning Gear Operation and Runup of
Generator . . . . . . . . . . . . . . . . . . . . .
Generator Startup Diagram . . . . . . . . .
Permissible Synchronizing Criteria . .
2.3-7100
2.3-7110
2.3-7120
2.3-7150
2.3-7160
2.3-7180
2.3-7210
2.3-7220
2.3-7530
2.3-7540
2.3-7610
2.3-8010
2.3-8011
2.3-8081
On-Load Running
Permissible Load Limits of Generator
Permissible Loading at Rated PF During
BHEL,Haridwar
2.3-8170
Voltage and Frequency Deviations . .

Generator Capability With Hydrogen Coolers
out of Service on Water Side
Unbalanced Load-Time Curve . . . . . .
Current Overload Capability . . . . . . . . .
Runback for loss of stator coolant . .
Unloading schedule for increased cooling
water inlet temperature . .
2.3-8181
2.3-8184
2.3-8187
2.3-8188
2.3-8190
2.3-8191
Shutdown
Shutdown of Generator . . . . . . . . . . . . .
Generator Shutdown Diagram . . . . . .
2.3-8310
2.3-8311
Supervision of Generator during Standstill

General . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolers . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Oil System . . . . . . . . . . . . . . . . . . .
Shutdown of Seal Oil System . . . . . . .
Draining the air Side Seal Oil Circuit
Draining the Hydrogen Side Seal Oil Circuit
Draining the Seal Oil Signal Lines and Seal
Ring Relief Piping . . . . .
Gas System . . . . . . . . . . . . . . . . . . . . . .
Gas Removal-Lowering Hydrogen Gas
Pressure in Generator . . . . . . .
Gas Removal-Replacing H2 with CO2
Gas Removal-Replacing CO2 With Air
N2 Purging Before Draining of Primary
Water System . . . . . . . . . .
Primary Water System . . . . . . . . . . . . .
Shutdown of Primary Water System for Less
Than 48 Hours . . . . . . . .
Shutdown of Primary Water System for More
Than 48 Hours . . . . . . . .
Draining the Primary Water System- PW
Coolers (Cooling Water Side) . . . .
Draining the Primary Water System- Stator
Winding . . . . . . . . . . . . . . . . .
Draining the PW System-Terminal Bushings
and Phase Connectors
Draining the Primary Water System- Water
Treatment System . . . . . . . .
Draining the Primary Water System- External
Part of Primary Water Circuit
Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3-8400
2.3-8440
2.3-8500
2.3-8510
2.3-8520
2.3-8521
2.3-8522
2.3-8600
2.3-8610
2.3-8620
2.3-8630
2.3-8650
2.3-8700
2.3-8720
2.3-8730
2.3-8732
2.3-8734
2.3-8738
2.3-8746
2.3-8748
2.3-8900
Fault Tracing
General . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator and Generator Supervisory Equipment
Coolant Temperature Control. . . . . . .
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolers . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Vapour Exhausters . . . . . . . . .
2.3-9000
2.3-9200
2.3-9280
2.3-9310
2.3-9440
2.3-9450
2.3-9521
2.0-0010-10550/3
0209E
Seal Oil Pumps . . . . . . . . . . . . . . . . . . .

Seal Oil Pressures and Temperatures
Relief Valves in Seal Oil System
Oil Level in Seal Oil System . . . . . . . .
Gas Pressures . . . . . . . . . . . . . . . . . . .
Gas Purity Meter System . . . . . . . . . . .
Primary Water Pumps . . . . . . . . . . . . . .
Water Pressures and Temperatures in
Primary Water System . . . . . . . .
Filters in Primary Water System . . . . .
Water Level in Primary Water Tank . . .
Conductivity in Primary Water System
Volume Flow Rates in Primary Water System
Alkalizer Unit for Primary Water System
Fuses on Rectifier Wheels . . . . . . . . .
Exciter Temperatures . . . . . . . . . . . . . .
Exciter Cooler . . . . . . . . . . . . . . . . . . . . .
Stroboscope . . . . . . . . . . . . . . . . . . . . . .
Exciter Drying System . . . . . . . . . . . . .
Ground Fault Detection System in Exciter
Field Circuit . . . . . . . . . . . . .
2.3-9523
2.3-9531
2.3-9551
2.3-9561
2.3-9640
2.3-9680
2.3-9720
2.3-9730
2.3-9740
2.3-9760
2.3-9782
2.3-9784
2.3-9785
2.3-9901
2.3-9911
2.3-9914
2.3-9941
2.3-9955
2.3-9980
Maintenance and supervisionIntroduction. . . . . . . . . . . . . . . . . . . .

Stator. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Coolers . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Oil Pumps & Bearing Vapour Exhauster
Seal Oil Coolers . . . . . . . . . . . . . . . . . . .
Seal Oil Filters . . . . . . . . . . . . . . . . . . . .
Gas Consumption . . . . . . . . . . . . . . . . .
Primary Water Pumps . . . . . . . . . . . . . .
Primary Water Filters . . . . . . . . . . . . . . .
Primary Water Coolers. . . . . . . . . . . . .
Water Level in Primary Water Tank . . .
Concutivity Meter System. . . . . . . . . . . .
Alkalizer Unit . . . . . . . . . . . . . . . . . . . . . .
Fuses on Rectifier Wheels. . . . . . . . . .
Exciter Dryer . . . . . . . . . . . . . . . . . . . . . .
Ventilation and Make-Up Air Filters
Exciter Coolers . . . . . . . . . . . . . . . . . . . .
Ground Fault Detection System. . . . . .
2.4-4200
2.4-4210
2.4-4240
2.4-4250
2.4-4310
2.4-4520
2.4-4540
2.4-4550
2.4-4610
2.4-4720
2.4-4740
2.4-4750
2.4-4760
2.4-4780
2.4-4785
2.4-4910
2.4-4925
2.4-4930
2.4-4940
2.4-4990
Inspection
Introduction. . . . . . . . . . . . . . . . . . . . . . . .
Determination of Dewpoint Temperature
Packing,Transport, Storage of Gen Rotors
Preventive Measures for Transport and
Storage of Generator Rotors .
Checking Desiccant in Gen Rotor Packing
Insulation Resistance Measurements on
Rotor and Exciter Windings. . . .
Preparation of Machinery Parts . . . . . .
Checking the Bearing and Seal Insulation . .
Test Norms During Overhaul . . . . . . . .
2.0-0010-10550/4
0209E
2.5-0010
2.5-0019
2.5-0030
2.5-0031
2.5-0032
2.5-0033
2.5-0200
2.5-0300
2.5-0305
Leakage Tests of Generator and Gas System 2.5-0310

Flushing the Oil Piping . . . . . . . . . . . . .
2.5-0320
Measures to Prevent Corrosion During
Inspecitons . . . . . . . . . . . . .
2.5-1003
Preventive Measures to Avoid Stress
Corrosion . . . . . . . . . . . . . . .
2.5-1005
Inspection Schedule-Foreword . . . . . .
2.5-1010
Inspection Schedule-Stator . . . . . . . . .
2.5-1020
Inspection Schedule-Rotor . . . . . . . . .
2.5-1030
Inspection Schedule-Coolers . . . . . . .
2.5-1040
Inspection Schedule-Bearings . . . . . .
2.5-1050
Inspection Schedule-Shaft Seals . . . .
2.5-1060
Inspection Schedule-Seal Oil System
2.5-1071
Inspection Schedule-Gas System . . .
2.5-1072
Inspection Schedule-Primary Water System 2.5-1073
Inspection Schedule-Generator Supervisory
Equipment. . . . . . . . . .
2.5-1080
Inspection Schedule-Excitation System
2.5-1090
Measures for Preservation of Generator
During Standstill. . . . . . . . . . . . . . . . .
2.5-1100
Stator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5-2000
Cementing the Joints of Profiled Gaskets. .
2.5-2120
Sealing Generator End Shield Joints .
2.5-2160
IR Measurements on Stator Winding
2.5-2300
Procedure for carrying out Tan delta test with
End Winding Vibration probes in position 2.5-2305
Drying the Windings . . . . . . . . . . . . . . .
2.5-2310
Test Instruction for Stator Slot Support System
With Top Ripple Springs . .
2.5-2340
Stator Slot Support System-Radial Wedge
Movements-Test Record . .
2.5-2341
Test Equipment for Stator Slot Support System 2.5-2342
Instructions for Checking the Stator Slot
Support System. . . . . . . . . . . . .
2.5-2343
Rewedging of Stator Winding. . . . . . . .
2.5-2345
Cementing Stator Slot End Wedges at Turbine
and Exciter Ends. . . . . .
2.5-2346
Treatment of Bolted Contact Surfaces
2.5-2350
Rotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5-3000
Insulation Resistance Measurements on Rotor
and Exciter Windings
2.5-3300
Ultrasonic Examination of Rotor Retaining
Rings at Power Plant . . .
2.5-3357
Hydrogen Coolers. . . . . . . . . . . . . . . . . .
2.5-4000
Insertion and Removal of Hydrogen Coolers 2.5-4100
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . .
2.5-5000
Shaft Seals. . . . . . . . . . . . . . . . . . . . . . . .
2.5-6000
Seal Oil System. . . . . . . . . . . . . . . . . . . .
2.5-7100
Seal Oil Pumps & Bearing Vapour Exhausters 2.5-7120
Seal Oil Coolers. . . . . . . . . . . . . . . . . . .
2.5-7130
Gas System. . . . . . . . . . . . . . . . . . . . . . .
2.5-7200
Primary Water System. . . . . . . . . . . . . .
2.5-7300
Primary Water Pump. . . . . . . . . . . . . . . .
2.5-7320
Primary Water Coolers . . . . . . . . . . . . .
2.5-7330
Treatment and Cleaning of Pipes in Primary
Water Circuit . . . . . . . . .
2.5-7381
Flushing External Part of Primary Water Circuit2.5-7382
Leakage Test of External Primary Water Circuit2.5-7384
Excitation System-Exciter . . . . . . . . . . .
2.5-9000
Checking the Insulation Resistance of Heat
Sink Insulation . . . . . . . . . .
2.5-9010
Checking the Insulation at Rectifier Wheels
2.5-9011
Turbogenerators
Preface
General
This manual contains information on

operation and maintenance of Turbogenerator
and its auxillary systems.
The information has been prepared on the
assumption that the operating and
maintenance personnel have a basic
knowledge of power plant engineering and
operation. It is an essential prerequisite for
satisfactory operation and maintenance of the
turbogenerator that the operating and
BHEL,Haridwar
maintenance personnel are fully familiar with

the design of the turbogenerator plant and
have aquired thorough training in operation
and maintaining the unit.
The manual is subdevided into following
main sections
-General
-Description
-Operation
-Maintenance
-Inspection
2.0-0030-10550/1
0209E
Turbogenerators
Notes on the Use of the Mannual
General
The turbogenerator instruction manual consists

of the following manual sections:
Q
Q
Q
Q
Q
2.0
2.1
2.3
2.4
2.5
General
Description
Operation
Maintenanceand Supervision
Inspection
For the user of the manual, the identification

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.
Instruction Number
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

Identification number
The manual contains a Table of Contents together

with a List of Effective Pages. Please check your
manual against this list and advise if there are any
omissions.
Identification Number
The identification number consists of the above
mentioned section number, supplemented by a fourdigit code number. It is indicated in the bottom most
line of the pages.
BHEL,Haridwar
Variant number
Page number
2.0 - 0040 - 00009 / 1

1205 E
Language (English)
Date (mm yy)
2.0-0040-10550/1
0209E
Turbogenerators
General
The Turbogenerator set has been designed and

manufactured to meet the contract commitment as
regards to the capability for the continuous operation
or variable load operation below maximum continuous
rating with an aim to achieve objective of securing
long life and trouble free operation.
Because of the margin provided in the design, it
may be possible to operate the turbogenerator at
overloads for the time specified in the manual.
However, such operations although possible for the
short time will encroach upon the design margin built
into the generator.
The Turbogenerator is designed to operate within
the temperature rise in accordance with EC standard.
Operating the generator in excess of the capability
curves which are part of this O & M Manual will cause
BHEL,Haridwar
Operation Beyond Contract

Commitment
increase in Copper temperature, thermal expansion

and higher insulation stresses. Such operation is not
permitted by the manufacturer.
Continued operation of unit without recommended
scheduled maintenance will eventually result in
increased maintenance and reduction in the useful
life of the machine. BHEL cannot be responsible for
any malfunctioning occurring as a result of operation
beyond the contract limits and operation of machine
without carrying out scheduled maintainance/
inspection. Such operation if undertaken by the user
must be at his own risk.
BHEL reserves the right of changing the operation
and maintainance instructions based on experience
gained.
2.0-0050-10550/1
0209E
Turbogenerators
Safe Disposal of Turbogenerator Items
General
In line with ISO 14001 requirements HEEP-BHEL,
Haridwar has adopted an Environmental policy and
has pledged to fulfil its responsibility of protecting
and conserving the environment around itself.
exposure of fluoro-elastomers like O-rings, rubbers etc.

at very high temperature above 400 degree C, in extreme
case of fire etc, should be disposed with great care, such
as very high incineration.
The materials, which are scrapped during

inspections and capital overhaul after consumption of
their useful life, are disposed in an environment friendly
manner to protect our natural resources and control
environment pollution.
b) Insulation:
Insulation material should be disposed by very high
incineration.
c) Plastics and glass:
Guidelines given in the following paragraphs can

go a long way in planning the activity of scrapping the
hazardous material effectively in an echo friendly
manner.
May be disposed as scrap material for recycling and

reuse.
3. Lubricating Oil and Grease:
A proper system of waste disposal should also be

evolved and its compliance ensured and necessary
precautions as published from time to time adhered to
while disposing hazardous material.
These items can be disposed/recycled/ reused as

follows:
a) Lubricating Oil :
Generator is manufactured mainly from three

types of items namely,
1. Metals:
Structured steel, Cast steel, Forged steel, brass,
bronze etc.
2. Non Metals:
Rubber, insulation, plastics, glass etc.
3. Lubricating oil and Greases.
Disposal of Generator wastes:
1. Metals:
May be disposed as scrap metal for recycling and
reuse.
2. Non- Metals:
a) Rubber:
To be recycled after cleaning as far as possible. After

it has become unserviceable, it may be disposed as
follows:
Send the discarded oil to registered refiners who
have facilities to reclaim the oil by
- physio-chemical treatment for further use in
noncritical applications.
- send the used oil to parties who are licensed to
handle and dispose used lubricating oil.
- burn off the discarded oil in boiler furnace by
mixing with fuel oil.
b) Grease:
It may be disposed for
lubrication.
reuse as low-grade
Residue of fluoro-elastomer products, obtained by
BHEL,Haridwar
2.0-0200-10550/1
0209E
Turbogenerators
Rating Plate Data for Generator
General
Project name: NCTPP Stage-II DADRI Unit-1
10550A12901
Unit-2
10554A12901
BHARAT HEAVY ELECTRICALS LTD

KW : 490,000
P.F.
KVA : 577,000
Hz
R.P.M :
Type: THDF 115/59
3000
Rotor
Volts
21000
Amps
16200
Conn.
Volts
334
Coolant: Hydrogen & Water
Amps
3973
Gas Pressure : 3.5 Kg/cm2 (g)
MADE IN INDIA
BHEL,Haridwar
: 50
Spec. IS: 5422

I
I
Phase 3
Insulation : Class F
Stator
0.85 Lag
IEC: 34
YY
DIV : Haridwar
2.1-1002-10550/1
0209E
Turbogenerators
Generator Cross Section
General
BHEL,Haridwar
2.1-1050-10550/1
0209E
Turbogenerators
General Outline Drawing
General
BHEL,Haridwar
2.1-1056-10550/1
0209E
Turbogenerators
Exciter Outline Drawing

ELR 70/90-30/6-20
ELR 50/42-30/16
General
Weights:
Total Weight
Rotor
Coolers (without water)
BHEL,Haridwar
39 300 kg
7 550 kg
1 860 kg
2.1-1058-10550/1
0209 E
1.
Turbogenerators
General Design Features
General
Design and Cooling System
General
The two-pole generator uses direct water cooling

for the stator winding, phase connectors and bushings
and direct hydrogen cooling for the rotor winding. The
losses in the remaining generator components, such as
iron losses, windage losses and stray losses, are also
dissipated through hydrogen.
The generator frame is pressure-resistant and gas
tight and equipped with one stator end shield on each
side. The hydrogen coolers are arranged vertically inside
the turbine end stator end shield.
The generator consists of the following components :
Stator
Stator frame
End shields
Stator core
Stator winding
Hydrogen coolers
Rotor
Rotor shaft
Rotor winding
Rotor retaining rings
Field connections
Bearings
Shaft seals
The following additional auxiliaries are required for

generator operation :
Oil system
Gas system
Primary water system
Excitation system
Cooling System
The heat losses arising in the generator interior are

dissipated to the secondary coolant (raw water,
condensate etc.) through hydrogen and primary water.
Direct cooling essentially eliminates hot spots and
differential temperatures between adjacent components
which could result in mechanical stresses, particularly
to the copper conductors, insulation, rotor body and
stator core.
3.
Hydrogen Cooling Circuit
The hydrogen is circulated in the generator interior

in a closed circuit by one multi-stage axial-flow fan
arranged on the rotor at the turbine end. Hot gas is drawn
BHEL,Haridwar
by the fan from the air gap and delivered to the coolers,
where it is re-cooled and then divided into three flow
paths after each cooler.
Flow path I is directed into the rotor at the turbine
end below the fan hub for cooling of the turbine end half
of the rotor.
Flow path II is directed from the coolers to the
individual frame compartments for cooling of the stator
core.
Flow path III is directed to the stator end winding
space at the excitor end through guide ducts in the frame
for cooling of the exciter end half of the rotor and of the
core end portions.
The three flows mix in the air gap. The gas is then
returned to the coolers via the axial-flow fan.
The cooling water flow through the hydrogen
coolers should be automatically controlled to maintain a
uniform generator temperature level for various loads
and cold water temperatures.
4.
Cooling of Rotor
For direct cooling of the rotor winding, cold gas is

directed to the rotor end windings at the turbine and
excitor ends. The rotor winding is symmetrical relative
to the generator center line and pole axis. Each coil
quarter is divided into two cooling zones. The first cooling
zone consists of the rotor end winding and the second
one of the winding portion between the rotor body end
and the mid-point of the rotor. Cold gas is directed to
each cooling zone through separate openings directly
before the rotor body end. The hydrogen flows through
each individual conductor in closed cooling ducts. The
heat removal capacity is selected such that
approximately identical temperatures are obtained for
all conductors. The gas of the first cooling zone is
discharged from the coils at the pole center into a
collecting compartment within the pole area below the
end winding. From there the hot gas passes into the air
gap through pole face slots at the end of the rotor body.
The hot gas of the second cooling zone is discharged
into the air gap at mid-length of the rotor body through
radial openings in the hollow conductors and wedges.
5.
Cooling of Stator Core
For cooling of the stator core, cold gas is admitted

to the individual frame compartments via separate
cooling gas ducts.
From these frame compartments the gas then flows
into the air gap through slots in the core where it absorbs
2.1-1100-10550/1
0209E
the heat from the core. To dissipate the higher losses in

the core ends, the cooling gas slots are closely spaced
in the core end sections to ensure effective cooling.
These ventilating ducts are supplied with cooling gas
directly from the end winding space. Another flow path
is directed from the stator end winding space past the
clamping fingers between the pressure plate and core
end section into the air gap. A further flow path passes
into the air gap along either side of the flux shield.
All the flows mix in the air gap and cool the rotor
body and stator bore surfaces. The gas is then returned
to the coolers via the axial-flow fan. To ensure that the
cold gas directed to the exciter end cannot be directly
discharged into the air gap, an air gap choke is arranged
within the range of the stator end winding cover and the
rotor retaining ring at the exciter end.
6.
Primary Cooling water Circuit in the Generator
The treated water used for cooling of the stator

winding phase connectors and bushings is designated
as primary water in order to distinguish it from the
secondary coolant (raw water, condensate, etc.). The
primary water is circulated in a closed circuit and
dissipates the absorbed heat to the secondary cooling
water in the primary water cooler. The pump is supplied
with hot primary water from the primary water tank and
delivers the water to the generator via the coolers. The
2.1-1100-10550/2
0209E
cooled water flow is divided into two flow paths as

described in the following paragraphs.
Flow path 1 cools the stator windings. This flow
path first passes to a water manifold on the excitor end
of the generator and from there to the stator bars via
insulated hoses. Each individual bar is connected to the
manifold by a separate hose. Inside the bars the cooling
water flows through hollow strands. At the turbine end,
the water is passed through similar hoses to another
water manifold and then returned to the primary water
tank. Since a single pass water flow through the stator
is used, only a minimum temperature rise is obtained for
both the coolant and the bars. Relative movements due
to different thermal expansions between the top and
bottom bars are thus minimized.
Flow path 2 cools the phase connectors and
bushings. The bushings and phase connectors consist
of thick-walled copper tubes through which the cooling
water is circulated. The six bushings and the phase
connectors arranged in a circle around the stator end
winding are hydraulically interconnected so that three
parallel flow paths are obtained. The primary water enters
three bushings and exits from the three remaining
bushings.
The secondary water flow through the primary water
cooler should be controlled automatically to maintain a
uniform generator temperature level for various loads
and cold water temperatures.
Turbogenerators
Generator Cooling Gas Circuit
General
Section A-B
Section E-F
Note:
The cross section may not match with the generator described in this manual
BHEL,Haridwar
2.1-1150-10550/1
0209E
1.
Turbogenerators
General
Stator
Stator Frame
The stator frame consists of a cylindrical section

body and two end shields which make the stator gastight and pressure-resistant.
The stator end shields are joined and sealed to
the stator frame with an O-ring and bolted flange
connection. The stator frame accommodates the
electricity active parts of the stator, i.e., the stator core
and the stator windings. Both the gas ducts and a
large number of welded circular ribs provide for the
rigidity of the stator frame. Ring-shaped supports for
resilient core suspension are arranged between the
circular ribs. The generator cooler is subdivided into
cooler sections arranged vertically in the turbine side
stator end shield. In addition, the stator end shields
contain the shaft seal and bearing components. Feet
are welded to the stator frame and end shields to
support the stator on the foundation. The stator is
firmly connected to the foundation with anchor bolts
through the feet.
BHEL,Haridwar
2.
Stator Core
T h e s t a t o r c o r e i s s ta c k e d f r o m i n s u l a t e d
electrical sheet-steel laminations and mounted in
supporting rings over insulated dovetailed guide bars.
Axial compression of the stator core is obtained by
clamping fingers, pressure plates, and non-magnetic
through-type clamping bolts, which are insulated from
the core. The supporting rings form part of an inner
frame cage. This cage is suspended in the outer frame
by a large number of separate flat springs distributed
over the entire core length. The flat springs are
tangentially arranged on the circumference in sets
with three springs each, i.e. two vertical supporting
springs on both sides of the core and one horizontal
stabilizing spring below the core. The springs are so
arranged and tuned that forced vibrations of the core
resulting from the magnetic field will not be transmitted
to the frame and foundation.
The pressure plates and end portions of the
stator core are effectively shielded against stray
magnetic fields. The flux shields are cooled by flow
of hydrogen gas directly over the assembly.
2.1-1210-10550/1
0209E
1.
Turbogenerators
General
Stator Winding
Construction
Stator bars, phase connectors and bushings are

designed for direct water cooling. In order to minimize
the stray losses, the bars are composed of separately
insulated strands which are transposed by 540 in the
slot portion and bending, the end turns are likewise
bonded together with baked synthetic resin fillers.
The bars consist of hollow and solid strands
distributed over the entire bar cross-section so that
good heat dissipation is ensured. At the bar ends, all
the solid strands are jointly brazed into a connecting
sleeve and the hollow strands into a water box from
which the cooling water enters and exits via teflon
insulating connection between top and bottom bars
is made by a bolted connection at the connecting
sleeve.
The water manifolds are insulated from the stator
frame, permitting the insulation resistance of the
water-filled winding to be measured. During operation,
the water manifolds are grounded.
2.
Micalastic High-Voltage Insulation
High-voltage insulation is provided according to

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

impregnated bars are formed to the required shape
in molds and cured in an oven at high temperature.
The high-voltage insulation obtained is nearly voidfree and is characterized by its excellent electrical,
mechanical and thermal properties in addition to being
fully waterproof and oil-resistant. To minimize corona
discharges between the insulation and the slot wall,
a final coat of semiconducting varnish is applied to
the surfaces of all bars within the slot range. In
addition, all bars are provided with an end corona
protection, to control the electric field at the transition
from the slot to the end winding and to prevent the
formation of creepage spark concentrations.
3.
Bar Support System
To protect the stator winding against the effects

of magnetic forces due to load and to ensure
permanent firm seating of the bars in the slots during
operation, the bars are inserted with a top ripple spring
located beneath the slot wedge. The gaps between
the bars in the stator end windings are completely
filled with insulating material which in turn is fully
supported by the frame. Hot-curing conforming fillers
arranged between the stator bars and the support ring
ensure a firm support of each individual bar against
the support ring. The bars are clamped to the support
ring with pressure plates held by clamping bolts made
from a high-strength insulating material. The support
ring is free to move axially within the stator frame so
t h a t m o v e m e n ts o f t h e w i n d i n g d u e t o t h e r m a l
expansions are not restricted.
The stator winding connections are brought out
to six bushings located in a compartment of welded
non-magnetic steel below the generator at the exciter
end. Current transformers for metering and relaying
purposes can be mounted on the bushings.
2.1-1230-10550/1
0209 E
1.
Turbogenerators
General
Rotor
Rotor Shaft
The rotor shaft is a single-piece solid forging

manufactured from a vacuum casting. Slots for insertion
of the field winding are milled into the rotor body. The
longitudinal slots poles are obtained. The rotor poles are
designed with transverse slots to reduce twice system
frequency rotor vibrations caused by deflections in the
direction of the pole and neutral axis.
To ensure that only high-quality forging is used,
strength tests, material analysis and ultrasonic tests are
performed during manufacture of the rotor.
After completion, the rotor is balanced in various
planes at different speeds and then subjected to an
overspeed test at 120% of rated for two minutes.
2.
The slot wedges are made of high-conductivity material

and extend below the shrunk seat of the retaining ring.
The seat of the retaining ring is silver-plated to ensure a
good electrical contact between the slot wedges and
rotor retaining rings. This system has long proved to be
a good damper winding.
3.
Retaining Rings
The centrifugal forces of the rotor end windings are

contained by single-piece rotor retaining rings. The
retaining rings are made of non-magnetic high-strength
steel in order to reduce stray losses. Each retaining ring
with its shrink-fitted insert ring is shrunk onto the rotor
body in an overhung position. The retaining ring is
secured in the axial position by a snap ring.
Rotor Winding
4.
The rotor winding consists of several coils which

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

through radial terminal bolts and two semicircular
conductors located in the hollow bores of the exciter and
rotor shafts. The field current leads are connected to
the exciter leads at the exciter coupling with
m u l t i c o n ta c t plug-in contact which allow for
unobstructed thermal expansion of the field current
leads.
2.1-1300-10550/1
0209E
Turbogenerators
General
Hydrogen Cooler
The hydrogen cooler is a shell and tube type heat

exchanger which cools the hydrogen gas in the
generator. The heat removed from the hydrogen is
dissipated through the cooling water. The cooling water
flows through the tubes, while the hydrogen is passed
around the finned tubes.
The hydrogen cooler is subdivided into identical
sections which are vertically mounted in the turbine-end
stator end shield. The cooler sections are solidly bolted
to the upper half stator end shield, while the attachment
at the lower water channel permits them to move freely
to allow for expansion.
The cooler sections are parallel-connected on their
water sides. Shut-off valves are installed in the lines
before and after the cooler sections. The required cooling
water flow depends on the generator output and it is
adjusted by control valves on the hot water side.
Controlling the cooling water flow on the outlet side
ensures an uninterrupted water flow through the cooler
sections so that proper cooler performance will not-be
impaired.
1 Cooler
2 Stator end shield
Fig.1
BHEL,Haridwar
Arrangement of Hydrogen Cooler
2.1-1440-10550/1
0209E
Turbogenerators
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
f o r f i t t i n g v i b r a t i o n p i c k u ps t o m o n i t o r b e a r i n g
vibrations.
1 Connection for shaft lift oil

2 Thermocouple
3 Bearing sleeve
Fig.1
BHEL,Haridwar
Bearing
2.1-1450-10550/1
0209 E
Turbogenerators
General
Shaft Seals
The points where the rotor shaft passes through

the stator casing are provided with a radial seal ring.
The seal ring is guided in the seal ring carrier which is
bolted to the seal ring carrier flange and insulated to
prevent the flow of shaft currents. The seal ring is lined
with babbitt on the shaft journal side. The gap between
the seal ring and the shaft is sealed withseal oil on
hydrogen side and air side. The hydrogen side seal oil
is supplied to the seal ring via an annular groove in the
seal guide. This seal oil is fed to the hydrogen side
annular groove in the seal ring and from there to the
sealing gap via several bores uniformly distributed on
the circumference. The air side seal oil is supplied to
Fig.1
1 Seal ring carrier flange

2 Seal
3 Insulation
4 Seal ring chamber
5 Inner labyrinth ring
6 Seal strip
BHEL,Haridwar
the sealing gap from the seal ring chamber via radial
bores and the air side annular groove in the seal ring.
To ensure effective sealing, the seal oil pressures in the
annular gap are maintained at a higher level than the
gas pressures within the generator casing. The air side
seal oil pressure is set at slightly higher than the
hydrogen side seal oil pressure. The hydrogen side seal
oil is returned to the seal oil system through ducts below
the bearing compartments. The oil drained on the air
side is returned to the seal oil storage tank together with
the bearing oil.
On the air side, pressure oil is supplied laterally to
the seal ring via an annular groove. This ensures free
movement of the seal ring in the radial direction.
Shaft Seal
7 Rotor shaft
8 Oil wiper ring (H2 side)
9 Seal ring carrier
10 Annular groove for hydrogen side seal oil
11 Seal oil inlet bore (H2 side)
12 Annular groove for hydrogen side seal oil
13 Annular groove for air side seal oil

14 Babbit
15 Seal ring
16 Annular groove for pressure oil
17 Oil wiper ring (air side)
18 Seal oil groove
2.1-1460-10550/1
0209 E
Turbogenerators
General
Oil supply for Bearings and Shaft Seals
Bearing Oil System
The generator and exciter bearings are connected

to the turbine lube oil supply.
2
Seal Oil System
2.1 Construction
The shaft seals are supplied with seal oil from two
seal oil circuits which consist of the following principal
components.
Hydrogen Side Seal Oil Circuit :
Q
Q
Q
Q
Q
Q
Q
Q
Seal oil tank

Seal oil pump
Oil cooler 1
Oil cooler 2
Seal oil filter
Differential pressure valve C
Pressure equalizing valve TE
Pressure equalizing valve EE.
The hydrogen side seal oil pressure required at the

seals is controlled separately for each shaft seals by
respective pressure equalizing valves, according to the
preset pressure difference between the hydrogen side
and air side seal oil.
Oil drained from the hydrogen side is returned to
the seal oil tank via the generator pre-chambers. Two
float-operated valves keep the oil level at a
predetermined level, thus preventing gas from entering
the suction pipe of the seal oil pump (hydrogen side).
The low level float-operated valve compensates for the
low oil level in the tank by admitting oil from the air side
seal oil circuit. The high level float-operated valve drains
excess oil into the seal oil storage tank. The hydrogen
entrapped in the seal oil comes out of the oil in the seal
oil storage tank and is extracted by the bearing vapor
exhauster for being vented to the atmosphere above the
power house roof. During normal operation, the high level
float-operated drain valve is usually open to return the
excess air side seal oil, which flowed to the hydrogen
side via the annular gaps of the shaft seals, to the air
side seal oil circuit.
Air Side Seal Oil Circuit :

Q
Q
Q
Q
Q
Q
Q
Q
Q
Seal oil storage tank

Seal oil pump 1
Seal oil pump 2
Standby seal oil pump
Oil cooler 1
Oil cooler 2
Seal oil filter
Differential pressure valve A1
Differential pressure valve A2
2.2 Hydrogen Side Seal Oil Circuit

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

The air side seal oil is drawn from the seal oil
storage tank and delivered to the seals via a cooler and
filter by seal oil pump 1. In the event of its failure, seal
oil pump 2 automatically takes over the seal oil supply.
Upon failure of seal oil pump 2, the standby seal oil pump
is automatically started and takes over the seal oil supply
to the shaft seals. In the event of a failure of the seal oil
pump of the hydrogen side seal oil circuit, the seal oil is
taken from the air side seal oil circuit.
The air side seal oil pressure required at the seals
is controlled by differential pressures valve A1 according
to the preset value, i.e. the required pressure difference
between seal oil pressure and hydrogen pressure. In the
event of a failure, i.e. when the seal oil for the seals is
obtained from the standby seal oil pump, differential
pressure valve A2 takes over this automatic control
function.
The seal oil drained from the air side of the shaft
seals is directly returned to the seal oil storage tank.
2.1-1510-10550/1
0209E
Turbogenerators
Seal Oil System
General
(Simplified Diagram)
Air side seal oil circuit
Hydrogen side seal oil circuit
1
2
3
4
5
6
7
8
9
10
11
12
13
Seal ring
Seal oil pump
A valve
Seal oil cooler
Seal oil filter
Generator Prechamber
Pressure equalizing control valve
Seal oil tank
Seal oil filter
C valve
Seal oil cooler
Seal oil pump
Hydrogen side seal oil

Air side seal oil
Pressure oil for seal ring relief
Hydrogen
BHEL,Haridwar
2.1-1511-10550/1
0209 E
Turbogenerators
General
Gas System
General
The gas system contains all equipment

necessary for filling the generator with CO 2 , hydrogen
or air and removal of these media, and for operation
of the generator filled with hydrogen. In addition, the
gas system includes a nitrogen (N 2 ) supply. The gas
system consists of :
H 2 supply
CO 2 supply
N 2 supply
Pressure reducers
Pressure gauges
Miscellaneous shutoff valves
Purity metering equipment
Gas dryer
CO 2 flash evaporator
Flowmeters
Hydrogen (H 2 ) Supply
2.1 Generator Casing

The heat losses arising in the generator are
dissipated through hydrogen. The heat dissipating
capacity of hydrogen is eight times higher than that
of air. For more effective cooling, the hydrogen in the
generator is pressurized.
2.2 Primary Water Tank
A nitrogen environment is maintained above the
primary water in the primary water tank for the
BHEL,Haridwar
following reasons.
To prevent the formation of a vacuum due to

different thermal expansions of the primary water
& tank.
To ensure that the primary water in the pump
suction line is at a pressure above atmospheric
pressure so as to avoid pump cavitation.
To ensure that the primary water circuit is at a
pressure above atmospheric pressure so as to
avoid the ingress of air on occurrence of a leak.
Carbon Dioxide (CO 2 ) Supply
As a precaution against explosive hydrogen air

mixtures, the generator must be filled with an inert
gas (CO 2 ) prior to H 2 filling and H 2 removal.
The generator must be filled with CO 2 until it is
positively ensured that no explosive mixture will form
during the subsequent filling or emptying procedures.
4
Compressed Air Supply
To remove CO 2 from the generator, compressed

air is to be admitted into the generator.
The compressed air must be clean and dry. For
this reason, a compressed air filter is installed in the
filter line.
5
Nitrogen (N 2 ) Supply
Nitrogen is required for removing the hydrogen

or air during primary water filling and emptying
procedures.
2.1-1520-10550/1
0209E
Turbogenerators
Gas System
General
Simplified Diagram
1
2
3
4
5
6
7
8
9
BHEL,Haridwar
H2 bottle
H2 pressure reducer
N2 bottle
N2 pressure reducer
Primary water tank
Pressure controller
Upper generator gas header
Lower generator gas header
Gas drier heater
10
11
12
13
14
15
16
17
18
Gas drier fan

Gas drier chamber
CO2 /H2 purity transmitter
Dehydrating filter for measuring gas
Pressure reducer for measuring gas
Compressed air hose
Compressed air filter
CO2 flash evaporator
CO2 bottle
2.1-1521-10550/1
0209 E
Turbogenerators
General
General
The primary water required for cooling is

circulated in a closed circuit by a separate pump. To
ensure uninterrupted generator operation, two fullcapacity pumps are provided. In the event of a failure
of one pump, the standby pump is immediately ready
for service and cuts in automatically. Each pump is
driven by a separate motor.
All valves, pipes and instruments coming into
contact with the primary water are made from stainless
steel material.
T h e p r i m a r y w a t e r s y s t e m c o n s i s ts o f t h e
following principal components :
Primary water tank

Primary water pumps
Cooler
Primary water filter
Fine filter
Ion exchanger
Alkalyser unit
As illustrated in the diagram, the primary water

admitted to the pump from the tank is first passed via
the cooler and fine filter to the water manifold in the
generator interior and then to the bushings. After
having performed its cooling function, the water is
BHEL,Haridwar
returned to the primary water tank. The gas pressure

above the water level in the primary water tank is
maintained constant by a pressure regulator.
2
Primary Water Tank
The primary water tank is located on top of the

stator frame on an elastic support, thus forming the
highest point of the entire primary water circuit in
terms of static head.
3
Primary Water Treatment System
The direct contact between the primary water and

the high-voltage windings calls for a low conductivity
of the primary water. During operation, the electrical
conductivity should be maintained below a value of
approximately 1 mho/cm. In order to maintain such
a low conductivity it is necessary to provide for
continuous water treatment. During operation, a small
quantity of the primary water flow should therefore
be continuously passed through the ion exchanger
located in the bypass of the main cooling circuit. The
ion exchanger resin material required replacement
during operation of the generator, since with the water
treatment system out of service, the conductivity will
rise very slowly.
2.1-1530-10550/1
0209E
Turbogenerators
General
(Simplified Diagram)
Primary water circuit, general

Coolant flow : stator winding
Coolant flow : main bushings and phase connectors
Water treatment
Waste gas
Hydrogen
1
2
3
4
5
6
Primary water tank

Pressure regulator
Waste gas to atmosphere
Pump
Cooler
Filter
BHEL,Haridwar
7
8
9
10
11
12
13
Bypass line
Cooling water for stator winding
Ion exchanger
Cooling water for main bushings and phase connectors
Teflon hose
Cooling water manifold
Alkaliser unit
2.1-153110550/1
0209 E
Turbogenerators
Technical Data
Description
General and Electrical Data
General
Project name
NCTPP DADRI Stage II unit I &2
Generator Type
THDF 115/59
Main Exciter Type
ELR 70/90-30/6-20
Pilot exciter Type
ELP 50/42-30/16
Year of manufacture
2008-09
Rated Data and Outputs
Turbogenerator
Main Exciter
Pilot Excitor
577MVA
65 kVA
Apparent power
Active power
490MW
3780 kW
Current
15.85 kA
6300 A
195 A
Voltage
21 kV + 1.05 kV
600 V
220 V + 22 V
50s-1
50s-1
50 s-1
Speed
Frequency
Power factor
50 Hz
400 Hz
0.85 (lag)
Inner connection of stator winding

H2 pressure
YY
3.5 bar (g)
Cont. perm. unbalanced Load
8%
Rated field current for rated output
3973 A
Rated field voltage
334 V
The machines are designed in conformity with IEC-34 and should be operated according to these specifications.
The field current is no criterion of the load carrying capacity of the turbogenerator.
Resistance in Ohms at 20C
Turbogenerator
Main Excitor
U-X 0.001445 ohms

Stator Winding
Pilot Excitor
U-0 0.002518 ohms
V-Y 0.001445 ohms
F1-F2 0.592 ohms
W-Z 0.001445 ohms
V-0 0.002538 ohms

W-0 0.002529 ohms
U-V 0.00046 ohms

Rotor Winding
F1-F2 0.06700 ohms
U-W 0.00046 ohms

V-W 0.00046 ohms
Rectifier Wheel
Number of fuses
30
per rectifier wheel
(800 V, 800 A)
Fuse, resistance
approx. 150 ohms
Number of diodes
per rectifier wheel
60
Number of fuses blown per
2 fuses
Switch off field forcing
bridge arm and rectifier wheel
3 fuses
Shutdown turbine-generator, replace
Action Required:
fuses and diodes.
BHEL,Haridwar
2.1-1810-10550/1
0209E
Turbogenerators
Technical Data
Description
Mechanical Data
Torques, Critical Speed etc.
Torques and
Speeds
Maximum short-circuit torque of stator at

line-to-line single-phase short-circuit
Moment of inertia of generator rotor shaft
h1
h2
h3
Critical speed (calculated)

(Generator + Exciter coupled)
Generator Volume and Filling Quantities
Generator volume (gas volume)
CO2 filling quantity***
H2 filling quantity (to 3.5 bar)**
Weights
Stator with end shields and coolers
Shipping weight of stator
Stator end shield, upper part TE
Stator end shield, upper part EE
Stator end shield, lower part, TE
Stator end shield, lower part, EE
Rotor
H2 cooler section, including water channels
Gas dryer
One seal oil cooler (air side)
One seal oil cooler (H2 side)
One primary water cooler
Exciter rotor
Units
14585
knm
10000
864
2388
4680
kgm2
RPM
Volume
80
160
Units
m3
m3 (s.t.p.)*
480
m3 (s.t.p.)*
Weight
360000
265000
22066
6665
24200
9950
68000
1770
950
320
250
90
7550
Component
Material
Component
Rotor shaft
26NiCrMoV145
Electrical sheet-steel
Rotor copper
Rotor wedges
Retaining rings
Damper wedges
CuAg0.1PF25
CuCoBeZr
X8CrMnN1818K
CuAg0.1F25
Stator copper
Bearing babbitt
Seal rings babbitt
units
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
Material
1.5 W/Kg at 1 Tesla 0.5 mm TK
E-Cu58F20
Babbitt V 738
Babbitt V 738
*
**
***
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.
BHEL,Haridwar
2.1-1820-10550/1
0209 E
Turbogenerators
Technical Data
Description
Seal Oil System
Design Data
Seal oil pumps -1,2 (Air Side) MKW 11 AP 001 and
MKW 21 AP 001
Kind of pump
Type
Capacity
Discharge pressure
Pump motor
Rating
Voltage/ frequency
Current
Speed
Type of enclosure
Nos.
Seal oil pump -3 ( Air side) MKW 31 AP 001
Kind of pump
Type
Capacity
Discharge pressure
Pump motor
Rating
Voltage
Current Armature
Speed
Type of enclosure
Nos.
Seal oil pump (H2 side) MKW 13 AP 001
Kind of pump
Type
Capacity
Discharge pressure
Pump motor
Rating
Voltage/ frequency
Current
Speed
Type of enclosure
Nos.
MKW 51 BT 001, MKW 51 BT 002,
MKW 53 BT 001 & MKW 53 BT 002
Kind of filter
Type
Volumetric flow rate
Degree of filtration
Pressure drop across filter
Nos. for air side
Nos. for H2 side
Three Screw pump

T3S - 52/54
258 LPM
12Kg/Cm2
CGL, ND132M
7.5 KW
415V, 3 Ph AC 50Hz
13.6 A
1455 RPM
TEFC, IP55
2x100% capacity
Three Screw pump

T3S - 52/54
258 LPM
12 Kg/cm2
CGL, AFS 225L
8.5 KW
220 V DC
67 A
1450 RPM
TEFC , IP55
1x100% capacity
Three Screw pump

T3S - 52/46
130 LPM
12 kg/cm2
CGL, ND 132M
4 KW
415V, 3 Ph AC 50Hz
9.3 A
945 RPM
TEFC, IP55
1x100% capacity
Seal oil filters
Strainer-type filter
2.32.9 Ma (M/s Boll & Kirch)
4.16 dm3/s
100 microns
0.3 bar with clean filter *
2x100% capacity
2x100% capacity
* 1.2 bar with 100% blockage
BHEL,Haridwar
2.1-1825-10550/1
0209E
Turbogenerators
Technical Data
Description
Gas System
Design Data
CO 2 vapouriser MKG 51 AH 001
Rating
Voltage
Heat transfer liquid
Volume of heat transfer liquid
Hole in orifice
18 kW
415V, 3 Ph AC 50Hz
HYTHERM 500 (M/s HPCL)
25 dm 3
2.8 mm
Relief valve on high-pressure side

Relief valve on low-pressure side
175 bar
8 bar
Nos.
2x100% capacity
Refrigeration type gas drier

Rating and parameters
As per sub-suppliers manual
Compressed air filter MGK 25 BT 001

Volume of activated carbon
Service hours
Throughput
Nos.
BHEL,Haridwar
3
3 dm
approx. 1500 h to 2000 h
3
80 m /hr at 8 bar
1x100% capacity
2.1-1826-10550/1
0209 E
Turbogenerators
Technical Data
Description
Design Data
Primary water pumps MKF12AP001 and MKF22AP001
Kind of pump
Centrifugal pump
Type
CZ 65-250 (M/s Sulzer Pumps)
Speed
2950 RPM
Capacity
70 m /Hr
Discharge head
80 m
Pump motor
ND200 L (M/s Crompton Greaves Ltd)
Rating
37KW
Voltage
415V, 3 Ph AC 50Hz
Frequency
50 Hz
Speed
2950 RPM
Type of enclosure
TEFC
Nos.
2x100% capacity
Main filters MKF 52 BT 001 and MKF 52 BT 002

Kind of filter
Strainer-type filter with magnet bars
Type
1.53.1 (M/s Boll & Kirch)
25 dm /s max.
Degree of filtration
150 mm
0.1 bar with clean filter

1.2 bar with 100% fouling
Nos.
2x100% capacity
Fine filter MKF 60 BT 001

Kind of filter
1 plug. 1 cartridge
Type
1.55.1 (M/s Boll & Kirch)
0.42 dm /s max.
0.15 bar with clean filter
1.2 bar with 100% fouling

Nos.
1x100% capacity
Ion exchanger MKF 60 BT 001

Volume
83 litres
Resin
Lewatit
Resin volume
56 litres (45 kg)
Nos.
1x100% capacity
BHEL,Haridwar
2.1-1827-10550/1
0209 E
Turbogenerators
Technical Data
Description
Waste Gas System
Design Data
Bearing vapor exhausters MKC 31 AN 001 and
MKQ 32 AN 001
Type
UHPR -100-SWSI (M/S C.DOCTOR INDIA PVT LTD)
Moter Rating
0.75kW
Voltage/frequency
415V, 3 Ph AC 50Hz
Current
1.8A
Speed
2820 RPM
Type of enclosure
IP 55
Type of exhausters
Radial-flow
Nos.
2x100% capacity
BHEL,Haridwar
2.1-1828-10550/1
0209E
Turbogenerators
Technical Data
Description
Excitation System
Design Data
A-wheel (negative polarity)
No./Type of diodes
No./Type of fuses
Resistance/voltage/current per fuse
No. of RC networks
60 Nos./BHdL 1220 (BHEL EDN,Bangalore make)

30 Nos./3NC 9 538
approx. 150 , 800 V, 800 A
6 Nos.
B-wheel (positive polarity)

No./Type of diodes
No./Type of fuses
Resistance/voltage/current per fuse
No. of RC networks
60 Nos./BHdL 1320(BHEL EDN,Bangalore make)

30 Nos./3NC 9 538
approx. 150 , 800 V, 800 A
6 Nos.
Stroboscope
Type
Voltage
Frequency
No. of stroboscope
LX5-30/36-2
240 V
50/60 Hz
1 No.
Exciter air dryer

Type
Rating
Voltage
Frequency
Adsorption air flow rate
Regeneration air flow rate
No. of dryer
BA-1.5 A (M/S BRYAIR MAKE)

4,6 kW
230 V
50 Hz
120 m3/h
35 m3/h
1 No.
BHEL,Haridwar
2.1-1829-10550/1
0209 E
Turbogenerators
Technical Data
Description
Cooler Data
Design Data for the H2 Cooler,

Drg. No. 0-166-01-70006C
(4 x 25% each)
Units
Hydrogen pressure
3.5
Bar (g)
Gas flow (Total)
33
m /s
Heat dissipating capacity (Rated)
4640
kW
Cold gas temperature
45
Hot gas temperature (max.)
72
Gas pressure drop (approx.)
700
Pa
Cooling water flow (Total for 4 sections)
540
m3/hr
Cooling water inlet temperature (design)
38
Water outlet temperature
45.4
Water pressure drop
3.0
MWC
Design Data for One Seal Oil Cooler (Air Side)

Drg. No. 0-165-03-70006 C (1 x 100% )
Units
Oil flow
15
m3/hr
140
kW
Oil inlet temperature
70
Oil Outlet temperature
50
Oil pressure drop (approximate)
0.833
Bar
Cooling water flow
35
m3/hr
38
41.4
Water pressure drop (approximate)*
6.8
mWC
Design Data for One Seal Oil Cooler (H2 Side)

Drg. No. 0-165-03-70005 C (1 x100% )
Units
Oil flow
7.8
m3/hr
90
kW
Oil inlet temperature
70
Oil outlet temperature
50
Oil pressure drop (approximate)
0.85
Bar
Cooling water flow
22
m3/hr
38
41.5
Water pressure drop (approximate)*
7.1
mWC
Materials and Pressures

Materials
Fins
Tubes
Tubesheets
Water channels
Copper
90/10 Cu-Ni
Carbon steel
Carbon steel
Pressures (Tube Side)

Design pressure
10 kg/cm2
Test pressure
15 kg/cm2

Materials
Tubes
Tubesheets
Water channels
Admiralty Brass
Carbon steel
Carbon steel
Cooling water Pressures

Design pressure
16 kg/cm2
Test pressure
24 kg/cm2
Oil Side Pressures
design pressure
Test pressure
16 kg/cm2
24 kg/cm2

Materials
Tubes
Tubesheets
Water channels
Admiralty Brass
Carbon steel
Carbon steel
Cooling Water Pressures

Design pressure
16 kg/cm2
Test pressure
24 kg/cm2
Oil Side Pressures
Design pressure
Test pressure
16 kg/cm2
24 kg/cm2
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.
BHEL,Haridwar
2.1-1830-10550/1
0209 E
Design Data for the Primary Water

Cooler, Drg. No. 0-165-41-70013 C
(2 x 100% )
Units
Primary water flow
65
m3/hr
1715
kW
Primary water inlet temperature
71.7
Primary water outlet temperature
49
Primary water pressure drop
1160
mBar
Cooling water flow
250
m3/hr
Maximum cooling water inlet temperature
38
Cooling water outlet temperature
43.9
Water pressure drop*
2.0
mWC
Design Data for the Exciter Air Cooler,

Drg. No. 0-166-05-70003C
(2 x 50% each)
Units
Air pressure
Bar (g)
Air flow (Total)
15.5
m /s
500
kW
Cold air temperature
45
Hot air temperature (max.)
74
Air pressure drop (approx.)
700
Pa
Cooling water flow
200
m3/hr
38
40.2
Water pressure drop*
3.0
mWC
* Flange-to-flange of equipment only
2.1-1830-10550/2
0209 E

Materials
Shell
Tubes
Tubesheets
Water channels
SS
SS
SS
Carbon Steel
Primary Water Side Pressures

Design pressure
10 kg/cm2
Test pressure
15 kg/cm2
Cooling Water Side Pressures
Design pressure
10 kg/cm2
Test pressure
15 kg/cm2

Materials
Fins
Tubes
Tubesheets
Water channels
Copper
90/10 Cu-Ni
Carbon steel
Carbon steel
Pressures (Tube Side)

Design pressure
10 kg/cm2
Test pressure
15 kg/cm2
Turbogenerators
t
Description
TECHNICAL
DATA
Reactive Capability Curve
BHEL,Haridwar
2.1-1850-10550/1
0209E
Turbogenerators
Technical Data
Description
Load Characteristic of Pilot Exciter
PMG Pilot Exciter Characteristic

240
235
PMG Voltage(volts)
230
225
220
215
210
205
200
0
50
100
150
200
250
PMG field current (amps)
BHEL,Haridwar
2.1-1860-10550/1
0209 E
Turbogenerators
Description
1.
Compressed Air
The compressed air shall be free of-
Gas Specification
Gauge pressure :
Temperature :
Volumetric flow rate :
corrosive contaminants and

hazardous gases, flammable or toxic.
The maximum total oil or hydrocarbon content,

exclusive of non-condensables, shall be as close
to zero (0) w/w or v/v as possible, and under no
circumstances shall it exceed one (1) ppm w/w or
v/v under normal operating conditions.
The compressed air shall be practically free of dust.
The maximum particle size in the air stream shall be
five (5) micrometers.
The oxygen content of the expanded air shall be
between 20 and 21% v/v.
The dew point at line pressure shall be at least 15 K
below the minimum possible generator temperature.
In no case should the dew point at line pressure
exceed 10 C.
The compressed air shall be available at a gauge
pressure between 6 and 9 bar.
Volumetric flow rate: 144 to 216 m3/h.
2.
Carbon Dioxide (CO2)
Carbon dioxide shall be made available with a purity

99.9 % v/v. The remaining 0.1 % v/v shall be free of
corrosive contaminants: traces of ammonia (NH3) and
sulphur dioxide (SO2) shall not be detectable by
analysis.
If obtained from a central bulk supply, the gas shall be

made available at the following conditions:
1 to 2.5 bar
20 to 30 0C
144 to 216 m3/h.
3 Hydrogen (H2)
Q
The hydrogen gas shall be made available with a purity

99.9% v/v. The remaining 0.1 % v/v shall be free of
corrosive contaminants: traces of ammonia (NH3) and
sulphur dioxide (SO 2) shall not be detectable by
analysis.
If obtained from a central bulk supply, the hydrogen
gas shall be made available at the following conditions:
Gauge pressure :
Volumetric flow rate :
4
Q
8 to 9 bar
144 to 216 m3/h.
Nitrogen (N2)
The nitrogen gas shall be made available with a purity
of 99.99 % v/v.
Contaminants (O2, H2O): not applicable
The remaining 0.01% v/v shall be free of corrosive
contaminants; traces of ammonia (NH3) and sulphur
dioxide (SO2) shall not be detectable by analysis.
1) s.t.p. = standard temperature and pressure. 00C and 1.013 bar to DIN 1343.
The gauge pressures and temperatures indicated are those at the inlets of the generator gas supply units.
BHEL,Haridwar
2.1-1883-10550/1
0209E
Turbogenerators
Description
The water used must not contain any contaminants

that might have a harmful effect on the materials used in
the primary water circuit. For this reason, the water must
have the following quality criteria :
Conductivity
pH
Dissolved O2
Dissolved CO2
Chlorides and
other anions
Ammonia
:
:
:
< 10 mho/cm. preferably

0.5 mho/cm
6-8
Minimum, preferably less than 100 ppb
Minimum, permissible conductivity
after a strongly acidic cation
exchanger < 0.2 mho/cm
Minimum, test with Nesslers solution
as a reagent shall not cause a change
in color.
BHEL,Haridwar
Primary Water Specification
Cu, dissolved/
undissolved
Less than 20 ppb
Fe, dissolved/
Undissolved
Less than 20 ppb
Dissolved solids :
The water shall not contain chemicals

from treatment processes, such as
hydrazine, morpholine, levoxine, phosphate, etc.
If the water to be used does not meet these quality

criteria, BHEL Haridwar must be informed for their evaluation and approval.
2.1-1885-10550/1
0209 E
Turbogenerators
Description
1.
Specification for
Ion Exchange Resins
General
The primary water must have a low condictivity since it

comes into direct contact with the high-voltage winding.
To maintain a low conductivity the primary water requires
continuous treatment. This is achieved by continuously
passing a small primary water volume flow through a mixed
bed ion exchanger arranged in the bypass of the main
cooling circuit. The ion exchange resins must be replaced
at certain intervals. The resins may be replaced while the
generator is in operation, since with the water treatment
system out of service the conductivity will continue to rise
only very slowly.
2.
substances having a detrimental effect on the materials

used in the primary water circuit and thus on the availability
of the generator.
Our recommendation to use Lewatit ion exchange
resins is based on many years of service experience and
the close cooperation between the resin supplier and many
power plant operators as well as the high quality standard
of the resins.
The initial charge of the mixed-bed ion exchanger
consists of the following types of resins.
Q
Lewatit S 100 KR/H/chloride-free
Q
Lewatit M 500 KR/OH/chloride-free
Resin Specification
The resins should contain no impurities or soluble
When replacing the resins, use either the above types

or resins available from other manufacturers which must
comply with the specification below.
Cation exchanger
Anion exchanger
(Lewatit S100KR/H/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
40 dm3/h dm3
40 dm3/h dm3
(1.9 - 2.2) mol/dm3
(1.1 - 1.6) mol/dm3
Specific load
up to
Total capacity of swollen resin

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
Unlimited
Unlimited
5 years
3 years
Stability in pH range
Shelf life
(in original packing
at temperatures of +1oC to +40oC
BHEL,Haridwar
min.
2.1-1887-10550/1
0209 E
Turbogenerators
Additive Specificaiton
for Alkalizer Unit
Description
Despite the use of oxygen-poor water, corrosion of

copper in the primary water circuits of water-cooled
windings, cannot be completely avoided, and in isolated
cases the corrosion products can reduce the crosssectional flow area of the water distribution system.
The severity of the corrosion attack can be
substantially reduced by alkalizing the oxygen-poor water.
In addition, the system becomes less susceptible to
disturbances resulting from air in-leakage.
Operating the generator with alkaline water at pH 8 to
9 will improve the reliability and availability of the turbine
generator.
For operation of the alkalizer unit [1], dilute sodium
hydroxide for continuous injection into the primary water
circuit and lime are required.
1
Sodium Hydroxide Solution

The sodium hydroxide solution should have a
concentration of 10 to 20 g of NaOH per dm3.

Sodium hydroxide solution should be prepared from :
Q
Caustic Soda [NaOH] of P.A. quality, containing.

NaOH
: > 98%
Carbonates [Na2CO3]
: < 1%
Water
in conformity with the primary water
specification [2].
Lime
A lime filter to be provided in the NaOH tank vent serves
to bind the carbon dioxide (CO2) contained in the inlet air in
order to prevent the formation of carbonates in the sodium
hydroxide solution.
The lime filter consists of equal parts of sodium
hydroxide (NaOH) and calcium hydroxide (Ca(OH)2 ). This
mixture is commercially available and known as soda lime.
Also refer to the following information

[1] 2.1-7341 Alkalizer Unit for Primary Water Circuit
[2] 2.1-1885 Primary Water Specification
BHEL,Haridwar
2.1-1888-10550/1
0209 E
Turbogenerators
Stator Frame
Description
To facilitate manufacture, erection and transport, the
stator consists of the following main components:
Q
Q
Q
Stator frame
End shields
Bushing compartment
The stator frame with flexible core suspension

components, core, and stator winding is the heaviest
component of the entire generator. A rigid frame is
required due to the forces and torques arising during
operation. In addition, the use of hydrogen for the
generator cooling requires the frame to be pressureresistant up to an internal pressure of approximately 10
bar (130 psi g).
The welded stator frame consists of the cylindrical
frame housing, two flanged rings and axial and radial
ribs. Housing and ribs within the range of the phase
connectors of the stator winding are made of nonmagnetic steel to prevent eddy current losses, while the
remaining frame parts are fabricated from structural
steel.
1
1
3
Stator End shield

Frame housing
Two lateral supports for flexible core suspension in

the frame are located directly adjacent to the points
where the frame is supported on the foundation. Due to
the rigid design of the supports and foot portion, the
forces due to weight and short-circuits will not result in
any over-stressing of the frame.
Manifolds are arranged inside the stator frame at the
bottom and top for filling the generator with CO2 and H2
. The connections of the manifolds are located side by
side in the lower part of the frame housing.
Additional openings in the housing, which are sealed
gastight by pressure-resistant covers, afford access to
the core clamping flanges of the flexible core suspension
system and permit the lower portion of the core to be
inspected. Access to the end winding compartments is
possible through manholes in the end shields.
In the lower part of the frame at the exciter end an
opening is provided for bringing out the winding ends.
The generator terminal box is flanged to this opening.
2 Bushing compartment
4 Stator foot
Fig:1 Stator frame

1
The arrangement and dimensionally of the ribs are
determined by the cooling gas passages and the required
mechanical strength and stiffness. Diminishing is also
dictated by vibrational considerations, resulting partly in
greater wall thickness then required, from the point of
view of mechanical strength. The natural frequency of
the frame does not correspond to any exciting frequency.
BHEL,Haridwar
1
2
3
4
Frame housing
Clamp
Supporting ring
Dovetail bar
Fig.2
Stator Frame Interior

2.1-2100-10550/1
0209 E
Turbogenerators
Description
Stator End shields
The ends of the stator frame are closed by pressure

containing end shields. The end shields feature a high
stiffness and accommodate the generator bearings, shaft
seals and hydrogen coolers. The end shields are
horizontally split to allow for assembly.
The end shields contain the generator bearings. This
results in a minimum distance between bearings and
permits the overall axial length of the TE end shields to be
utilized for accommodation of the hydrogen cooler sections.
Cooler wells are provided in the end shield on both sides
of the bearing compartment for this purpose. One manhole
in both the upper and lower half end shield provided.
Inside the bearing compartment the bearing saddle is
mounted and insulated from the lower half end shield. The
bearing saddle supports the spherical bearing sleeve and
insulates it from ground to prevent flow of shaft currents.
The bearing oil is supplied to the bearing via a pipe
permanently installed in the end shield and is then passed
on to the lubricating gap via ducts in the lower bearing
sleeve. The bearing drain oil is collected in the bearing
compartment and discharged from the lower half of
the end shields via a pipe.
The bearing compartment is seated on the air side

with labyrinth rings. On the hydrogen side the bearing
compartment is closed by the shaft seal and labyrinth
rings. The oil for the shaft seal is admitted via
integrally welded pipes. The seal oil drained towards
the air side is drained together with the bearing oil.
The seal oil drained towards the hydrogen side is first
collected in a gas and oil tight chamber below the
bearing compartment for defoaming and then passed
via a siphon to the seal oil tank of the hydrogen side
seal oil circuit.
The static and dynamic bearing forces are directly
transmitted to the foundation via lateral feet attached
to the lower half end shield. The feet can be detached
from the end shield, since the end shields must be
lowered into the foundation opening for rotor insertion.
Fig.1
Fig. 2
TE Stator End Shield
BHEL,Haridwar
EE Stator End Shield
2.1-2150-10550/1
0209 E
Turbogenerators
Generator Terminal Box
Description
The phase and neutral leads of the three-phase

stator windings are brought out of the generator
through six bushings located in the generator
terminal box at the exciter end of the generator.
The terminal box is a welded construction of non-
1
1
2
3
Flange for terminal box

Phase connector
Connection to bushing
Fig.1
Phase Connector
BHEL,Haridwar
magnetic steel plate. This material reduces stray

losses due to eddy currents.
Welded ribs are provided for the rigidity of the
terminal box. Six manholes in the terminal box provide
access to the bushings during assembly and
overhauling.
1
1
2
3
Generator terminal box

Manhole
Flange for bushing
Fig.2
Terminal Box Interior
2.1-2170-10550/1
0209 E
Turbogenerators
Description
Hydraulic Testing of Stator Frame
The empty stator frame with attached end shields

and terminal box is subjected to hydraulic test at 10
bar to ensure that it will be capable of withstanding
maximum explosion pressures. The water pressure
is increased in steps with pressure being reduced to
atmospheric pressure after each step, to allow for
measurement of any permanent deformation.
This test also checks for leakage at the weld seams.
In addition, the welded structure is subjected to an
air pressure test to check its gas tightness.
Fig.1
Fig.2
2
Hydraulic Testing of Stator Frame
Sealing of bolted flange joints
Sealing the Bolted Flange Joints
The bolted flange joints which must be gas tight

(e.g., end shields, terminal box, manhole covers) are
BHEL,Haridwar
Hydraulic Testing and Anchoring

of Stator Frame
sealed with elastically deformed O-ring packings.

Each O-ring packing is inserted into a groove of
rectangular cross-section and compressed by the
flanges. The elastic deformation of the O-ring packing
provides for a sufficient sealing force.
3
Anchoring and Aligning the Stator Frame and

End Shields to the Foundation
The stator frame is anchored to the foundation with

anchor bolts in conjunction with aligning elements and
sole plates set in grout on the foundation.
Fig.3
Feet at Stator Frame
The levelling screws are screwed into the support

foot of the frame and permit a rapid and exact
a l i g n m e n t o f t h e s t a t o r. To e n s u r e a u n i f o r m
transmission of forces these are arranged
symmetrically about the anchor bolts. The spherical
portions of the levelling screws ensure complete
contact and thus a rigid connection between stator
and foundation.
The stator end shields are aligned on the machine
sole plates with shims.
Different thermal expansion of the stator and the
foundation result in differential movements between
the frame and machine sole plates. The stator is
therefore fixed in position in a manner allowing for
expansion while retaining alignment. Fixed keys
located at the feet in the middle of the stator frame
secure the frame axially in a central position.
2.1-2190-10550/1
0209 E
1
2
3
Stator foot
Anchor bolt
Sole plate
4 Levelling screw
5 Conical seat
6 Spherical washer
Alignign element
BHEL,Haridwar
8 End shield foot
7 Hydraulic jack
For erectioin only
10. Foundation skid
9 Shims
Central positioning
of stator
Turbogenerators
Anchoring of Generator On Foundation
Description
2.1-2191-10550/1
0209E
Turbogenerators
Description
In order to minimize the hysteresis and eddy current

losses of the rotating magnetic flux which interacts with
the core, the entire core is built up of thin laminations.
Each lamination layer is made up from a number of
individual segments.
Stator Core
of non-magnetic steel and are insulated from the core

and the pressure plates to prevent the claiming bolts
from short-circuiting the laminations and allowing the flow
of eddy currents.
1
2
3
4
5
6
Fig.1
Segment with Spacers
The segments are punched in one operation from

0.5 mm (0.02 in.) thick electrical sheet-street
laminations having a high silicon content, carefully
debarred and then coated with insulating varnish on
both sides. The stator frame is turned on end while the
core is stacked with lamination segments in individual
layers. The segments are staggered from layer to layer
so that a core of high mechanical strength and uniform
permeability to magnetic flux is obtained. On the outer
circumference the segments are stacked on insulated
dovetail bars which hold them in position. One dovetail
bar is not insulated to provide for grounding of the
laminated core. Stacking guides inserted into the
winding slots during stacking provide smooth slot walls.
To obtain the maximum compression and eliminate
undue setling during operation, the laminations are
hydraulically compressed and heated during the
stacking procedure when certain heights of stack are
reached. The complete stack is kept under pressure
and located in the frame by means of clamping bolts
and pressure plates.
The clamping bolts running through the core made
BHEL,Haridwar
1
2
3
4
5
6
Clamping finger
Stator Slow
Pressure Plate
Stator core tooth
Clamping bolt
Shield
Fig.2
Stator Core After Compression
The pressure is transmitted from the pressure plates

to the core by clamping fingers. The clamping extend up
to the ends of the teeth, thus ensuring a firm compression
in the area of the teeth. The stepped arrangement of the
laminations at the core ends provides for an efficient
support of the tooth portion and, in addition, contributes
to a reduction of eddy current losses and local heating
in this area. The clamping fingers are made of nonmagnetic steel to avoid eddy current losses.
For protection against the effects of the stray flux in
the coil ends, the pressure plates and core end portions
are shielded by gas-cooled rings of insulation-bonded
electrical sheet-steel.
To remove the heat, space segments, placed at
intervals along the bore length, divide the core into
sections to provide radial passages for cooling gas flow.
In the core end portions, the cooling ducts are wider and
spaced more closely to account for the higher losses
and to ensure more intensive cooling of the narrow core
sections.
2.1-2200-10550/1
0209 E
Turbogenerators
Mounting of Stator Core in Stator

Frame
Description
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
Stator frame
Flat spring
Cage
Flux shied
Insulated through bolt

Pressure plate
Clamping finger
Core
BHEL,Haridwar
2.1-2201-10550/1
0209 E
Turbogenerators
Spring Support of Stator Core
Description
The revolving magnetic field exerts a pull on the

core, resulting in a revolving and nearly elliptical
d e f o r m a t i o n o f t h e c o r e w h i c h s e ts u p a s ta t o r
vibration at twice the system frequency. To reduce the
transmission of these dynamic vibrations to the
foundation, the generator core is spring mounted in
the stator frame. The core is supported in several sets
of rings. Each ring set consists of two supporting rings
and two core clamping rings. The structural members
to which the insulated dovetail bars are bolted are
uniformly positioned around to supporting ring interior
to support the core and to take up the torque acting
on the core.
For firm coupling of the ring sets to the core, the
supporting ring is solidly pressed against the core by
the clamping ring. The clamping ring consists of two

p a r t s w h i c h a r e h e l d t o g e t h e r b y t w o c l a m ps .
Tightening the clamps reduces the gap between the
ring segments so that the supporting ring is linked to
the frame by three flat springs. 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 spring 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 shortcircuit 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.
1
2
3
BHEL,Haridwar
Clamp
Stator frame
Rib
4
5
6
Flat spring
Cage
Insert sleeve
2.1-2220-10550/1
0209 E
Turbogenerators
Stator Winding
Description
1. General, Connection
The three-phase stator winding is a fractional-pitch twolayer type consisting of individual bars. Each stator slot
accommodates two bars.
properties and resistance to magnetically induced forces.

The bars afford maximum operating reliability, since each
coil consists of only main insulation identical.
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.
p=pole pitch
Fig.1 Lap type Winding
The slot bottom bar and top bars are displaced from
each other by one winding pitch and connected at their ends
to from coil groups.
The coil groups are connected together with phase
connectors inside the stator frame shown in the connection
diagram.
This arrangement and the shape of the bars at the ends
result in a cone shaped winding having particularly
favourable characteristics both in respect of its electrical
BHEL,Haridwar
At the Roebel crossover points the insulation is

reinforced with insulating strip inserts.
To ensure that the strands are firmly bonded together
are to give dimensional stability in the slot portion, the bars
are cured in an electrically heated press. Prior to applying
the bar insulation, The bar ends are bent with a special care
to ensure a uniform spacing of the bars over the entire length
of the end turns after installation.
Contacts sleeves for electrical connection of the bars
and the water boxes with cooling water connections are
brazed to the bar ends.
In the course of manufacture, the bars are subjected to
numerous electrical and leakage tests for quality control.
2.1-2300-10550/1
0209 E
Turbogenerators
Connection Diagram of Stator Winding
Description
BHEL,Haridwar
2.1-2301-10550/1
0209 E
Turbogenerators
Stator Slot
Description
2
3
4
5
6
7
8
10
11
12
13
14
15
BHEL,Haridwar
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Stator core
Slot wedge
Top strip
Top ripple spring
Side strip
Semiconducting wrapper
Vertical separating strip
Top bar
Center filler
Bottom bar
Solid strand
Hollow strand
Insulation
Semiconducting side ripple spring
Equallising strip
2.1-2303-10550/1
0209E
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.
BHEL,Haridwar
2.1-2305-10550/1
0209 E
Turbogenerators
Micalastic High Voltage Insulation
Description
High-quality mica, selected epoxy resins and a

matching vacuum pressure impregnation (VPI)
process are the characteristic features of the
Micalastic insulation for large turbogenerators. A
consistent development has led to a high-quality
insulation system, the reliability of which is ensured
by continuous quality control.Method of Insulation
and Impregnation
For insulation with Micalastic, the conductor
strands as well as the ventilating ducts are arranged
together to form a compact assembly and set to the
required shape. This assembly is then baked with
BHEL,Haridwar
epoxy resin to give it the mechanical strength required

for further processing.
Following this, several layers of mica tape are
applied continuously, half-overlapped, upto the end
portions of the bar. The mica tape consists of a thin
high-strength backing material to which the mica is
bonded by synthetic resin. The number of layers, i.e.,
the thickness of insulation, is determined by the
voltage of the machine. The taped bars are then dried
under vacuum and impregnated with epoxy resin
which, by reason of its low viscosity penetrates the
insulation thoroughly and eliminates all voids. After
2.1-2320-10550/1
0209 E
Fig. 2 Impregnating and Curing Mould for 20 stator Bars in Front of Impregnating Tank
tan
30
10 3
20
10
5
0.2
0.4
0.6
0.8
1.0
1.2
1.4
Rated Voltage
Fig.3 Dielectric Dissipation Factor of a Stator Bar with
Micalastic Insulation for 21 KV as a Function of the
Voltage
in %
impegnatioin under vacuum, the bars are subjected

to pressure, with nitrogen being used as pressurizing
medium (VPI process).
For direct cooled windings, the individual
impregnated bars are brought to the required
dimensions in processing moulds and cured in an
oven at high temperature. With indirectly cooled
windings, up to 20 stator bars are placed in molds
with by insulation for impregnation and curing. Fig.2
shows a mold loaded with bars ready for impregnation
prior to insertion into the impregnating plant.
To minimize corona discharges between the
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 highvoltage tests.
The bars are now ready for insertion into the slots.
In case of indirectly or direct gas-cooled stator bars,
the connecting bus bars and phase connectors are
also provided with an insulation bonded with a
thermosetting synthetic resin. Dependent on their
geometrical configuration and dimensions, the
c o n n e c t i o n s a r e p r o v i d e d w i t h m i c a ta p e s a n d
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 is
measured as a function of the voltage. The dielectric
dissipation factor/test voltage curve of a typical stator
2.1-2320-10550/2
0209 E
Fig. 4 Cumulative frequency of Maximum increase in

Dielectric Dissipation Factor of Bars in a 21 KV
winding with Micalastic insulation
Turbogenerators
Description
bar with Micalastic insulation is shown in Fig. 3.

Fig.4 shows the fluctuations due to manufacturing of
the maximum increase in the dielectric dissipation
factor up to rated voltage for the bars of a 21 kV
winding. The method of impregnation, which is exactly
matched to the insulation, and the use of a special
impregnating resin enable the maximum increase in
dielectric dissipation factor to be reduced considerably
below the limits specified in section 33 of VDE 0530.
During insertion of the stator bars, high-voltage
tests of one minute duration are performed as follows
:
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
insulation system developed for high-voltage
turbogenerators. The insulation is applied from end
to ened on the stator gbars providing effedtive
peotection against over voltages arising during normal
operation and against the high stresses that may
occur at the slot ends when high test voltages are
applied. In this manner is is possible to isulate
windings for voltages of over 30 kV efficiently and
reliably.
Micalastic has a long electerical life as
determined on hunndreds of experimental bars and
substantiated on numerous full-size bars (Fig. 5).
Fig.5 Dielectric Dissipation Factor of 27 kV Micalastic

Insulation as a Function of the Temperature
BHEL,Haridwar
Mcalastic is a good conductor of heat by reason

of the high mica content and the void free synthetic
resin. Efficient heat transfer is particularly important
in machines that require a thick insulation because
of the high voltages, especially if these machines are
not designed with direct conductor cooling.
Micalastic is highly resistant to high temperatures
and temperature chages. The composition of the
insulation and synthetic resin impregnation permits
the machine to be operated continuously under
conditions corresponding to those for insulation class
F.
Fig.6 Dielectric Dissipation Factor of 27 kV Micalastic

Insulation as a Function of the Temperature
Micalastic insulation shows only an insignificant

increase in the dielectric dissipation factor with
inceasing temperature.(Fig.6)
The elasticity of Micalastic enables it to
accomodate thermo-mechanical stesses. Studies on
models have provided information on the on the
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.
Micalastic does not burn. The flammability is so
low that even on arcing it does not continue to burn
once the arc is extinguished. Fire extinguishing
2.1-2320-10550/3
0209 E
systems, such as CO 2 systems, are therefore not

necessaryfor machines insulated with Micalastic.
Micalastic provides protection against moisture
due to its impregnation with synthetic resin which seal
the winding completely.
Micalastic is highly resistant to chemical action.
Corrosive gases, vapours, lubrication oil and weak
acids or alkalies, to which the windings of air-cooled
machines may be exposed under unfavourable
conditions, do not attack the insulation; the
impersonating resin behaves neutrally towards
chemicals.
2.1-2320-10550/4
0209 E
Micalastic retains its outstanding properties, even

after years of operation. Evidence of its unchanging
quality has been provided by repeated test carried
out on machines over an operating period of several
years.
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.
Turbogenerators
Construction of High Voltage Insulation
Description
Item No.
1
2
3
4
5
6
7
Component
Strand insulation
Strand bonding
Crossover insulation
Profiled strip
Internal potential grading wrapper
Insulation
Outer corona protection
Insulant, semiconductive material

Braided glass fiber insulation
Epoxy resin
Micanite
Profiled micanite
Semiconductive wrapping
Mica tape, vacuum impergnated with epoxy resin
Semiconductive varnish
Note: The number of conductors shown does not necessarily correspond to the number of conductors of the generator .
BHEL,Haridwar
2.1-2321-10550/1
0209E
Turbogenerators
Stator Winding
Corona Protection
Description
To prevent potential differences and possible corona

discharges between the insulation and the slot wall, the
slot sections of the bars are provided will an outer
corona protection. This protection consist of a wearresistant, highly flexible coating of conductive alkyd
varnish containing graphite.
1
1
2
3
4
5
6
7
and prevents the formation of corona discharge during

operation and during performance of high voltage tests.
A final wrapping of glass fabric tapes impregnated

with epoxy resin serves as surface protection.
Stator bar (slot end)

High-voltage insulation
Outer corona protection
Transition coating
End corona protection
Glass tape-epoxy protective layer
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
BHEL,Haridwar
Fig.2
Application
Protection
of
Graded
End
Corona
2.1-2330-10550/1
0209E
Turbogenerators
Coil and End Winding Support System
Description
The stator windings are placed in rectangular slots

which are uniformly distributed around the
circumference of the stator core. The location of the
bars in the slots is illustrated in a separate drawing [1].
The bars are protected by a cemented graphitize
paper wrapper over the slot portion of the bar. The bars
fit tightly in the slots. Manufacturing tolerances are
compensated with semi-conducting filler strips along
the bar sides which ensure good contact between the
outer corona protection and the slot wall.
Radial positioning of the bar is done with slot
wedges. Below the longitudinally divided slot wedges
a top ripple spring of high-strength, fiber glass fabric is
arranged between the filler and slide strip which presses
the bar against the slot bottom with a specific
preloading. An equalizing strip is inserted at the slot
bottom to compensate any unevenness in the bar shape
and slot bottom surface during bar insertion. The strip
is cured after insertion of the bars. These measures
prevent vibrations. The specified preloading is checked
at each slot wedge.
With the windings placed in the slots, the bar ends
form a cone-shaped end winding. A small cone taper is
1
1
2
Slot wedge
End turn covering
Fig.1
used to keep the stray losses at a minimum. The design

and construction of the end windings are illustrated in a
separate drawing [2].
Any gaps in the end winding due to the design or
manufacturing are filled with curable plastic fillers,
ensuring solid support of the cone-shaped top and
bottom layers.
The two bar layers are braced with clamping bolts of
high-strength fibre glass fabric against a rigid, tapered
supporting ring of insulating material. Tight seating is
ensured by plastic filters on both sides of the bars which
are cured on completion of winding assembly.
Each end winding thus forms compact, selfsupporting arches of high rigidity which prevents bar
vibrations during operation and can withstand shortcircuit forces.
In addition, the end turn covering provides good
protection against external damage. The supporting rings
rest on supporting brackets which are capable of moving
in the axial direction. This allows for a differential
movement between the end winding and the core as a
result of different thermal expansions.
Stator with Complete Stator Winding
1
1
2
End turn covering

Clamping bolt
Fig.2
Covering and Locating the End Winding

[1]. 2.1-2303 Stator slot
[2]. 2.1- 2341 Stator End Winding
BHEL,Haridwar
2.1-2340-10550/1
0209 E
Turbogenerators
Stator End Winding
Description
2
3
14
13
12
Teflon hose
2
3
4
5
6
7
Water manifold
Stator frame
Core
Clamping
Pressure plate for core
Insulated through bolt
BHEL,Haridwar
11
10
8
9
10
11
12
13
14
Flux Shield
Support ring
Clamping bolt
Bottom bar
Top bar
Pressure plate for stator bars
Water box
2.1-2341-10550/1
0209 E
Turbogenerators
Electrical Connection of Bars

Water Supply and Phase Connectors
Description
Electrical Connection of Bars
The electrical connection between the top and bottom

bars is by a bolted contact surface.
At their ends the strands are brazed into a connecting
sleeve, the strand rows being separated from each other
by spaces. The contact surfaces of the connecting
sleeves for the top and bottom bars are pressed against
each other
boxes. The cooling water is then discharged from the

generator via the hoses and the ring header.
During manufacturing of the stator bars, various checks
are performed to ensure water tightness and unobstructed
water passages.
The flow check ensures that no reduction in the cross
sectional area of the strand ducts has occurred, and that
all strands are passed by identical water flows. After
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
Fig.1
Electrical Bar Connections and Water
Supply
by non-magnetic clamping bolts. Special care is taken
to obtain flat and parallel contact surfaces. In order to
prevent an any reduction in contact pressure or any
plastic deformations due to excessive contact pressure,
Belleville washers are arranged on the clamping bolts
which ensure a uniform and constant contact pressure.
2
Water Supply
The water connection at the stator bar is separate

from the electrical connection. As a result no electrical
forces can act on the water connection.
While the solid strands of the stator bars terminate
at the connecting sleeve, the hollow strands are brazed
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
BHEL,Haridwar
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
ends coupled to the phase connectors are provided with
connecting fittings which are joined to the cylindrical
contact surface with Belleville washers on the bolts to
maintain a uniform and constant contact pressure.
The phase connectors are provided with a Micalastic
insulation. In addition, a grounded outer corona protection
consisting of a semiconducting coating is applied over the
entire length. At the beginnings and ends of the phase
connectors several layers of semi-conductive and corona
protection is applied in varying lengths.
The phase connectors are mounted on end winding
supporting ring over supporting brackets. Neighbouring
phase connectors are separated with spacers and tied
securely in position. This ensures a high short-circuit
strength and differential movements between phase
connectors and end windings are thus precluded.
Fig.2
Phase Connector Ends

2.1-2350-10550/1
0209 E
Turbogenerators
Electrical Bar Connection

and Water Supply
Description
10
11
12
14
15
1
2
3
4
5
Teflon Hose
Crimping sleeve
Cap nut
Pipe connection
Water box
6
7
8
9
10
Clamping bolt
Connecting sleeve
Clamping plate with through bore
Intermediate member
Clamping plate with threaded bore
*
BHEL,Haridwar
11
12
13
14
15
Bottom bar
Top bar
Belleville washer
Spring washer
O-ring
Contact surface
2.1-2351-10550/1
0209 E
Turbogenerators
Terminal Bushings
Description
1
Arrangement of Terminal Bushings
The beginnings and ends of the three phase windings

are brought out from the stator frame through terminal
bushings which provide for high-voltage insulation and
seal against hydrogen leakage.
The bushings are bolted to the bottom plate of the
generator terminal box by the mounting flanges.
The generator terminal box located beneath the stator
frame at the exciter end is made from non-magnetic steel
to avoid eddy-current losses resulting temperature rises.
Bushing-type generator current transformers, for
metering and relaying are mounted on the bushings
outside the generator terminal box. The customer's bus
is connected to the air side connection flange of the
bushings via terminal connectors.
4
2
Construction of Bushings
The cylindrical bushing conductor consists of highconductivity copper with a central bore for direct primary
water cooling.
The insulator is wound directly over the conductor. It
consists of impregnated capacitor paper with conducting
fillers for equalization of the electrical direct-axis and
quadrature-axis fields.
The shrunk-on mounting sleeve consists of a gastight
casting of nonmagnetic steel with a mounting flange and
a sleeve-type extension extruding over entire height of
the current transformers.
The cylindrical connection ends of the terminal
bushing conductors are silver-plated and designed to
accommodate bottle two-part cast terminal connectors.
Connection to the beginning and end each phase
inside the terminal box and to the external bus in by
means of flexible connectors. To maintain a uniform and
constant contact pressure Belleville washers are used
for all bolted connections.
Covers with brazed sockets for connection to the
water supply are flanged to the ends of the terminal
BHEL,Haridwar
1
2
3
4
5
Phase connector
Teflon hose
Flexible connector
Manhole
Terminal bushing
Fig.1
Flexible Connection Between Bushing and

Phase Connector
2.1-2370-10550/1
0209 E
Turbogenerators
Description
PW Connection for Terminal

Bushings and Phase Connectors
Primary water inlet
3
4
Conventional
Neutral connection
1
2
3
4
5
Phase connector
H.V. terminal box
Flexible connector
PTFE insulating hose
Water-cooled bushing
Note: If required, the H.V. terminal box may be turned through 180 deg. Mounting position of phase connectors and
neutral connection may be changed as well.
BHEL,Haridwar
2.1-2371-10550/1
0209 E
Turbogenerators
Cooling of Terminal Bushing
Description
Primary water
inlet
Primary water
outlet
BHEL,Haridwar
2.1-2372-10550/1
0209 E
Turbogenerators
Description
General
The separate water cooling circuits are used for

the stator windings and phase connectors and the
bushings.
All water connections between ungrounded parts
and the distribution manifolds and water manifolds of
the cooling circuits are insulated with teflon hoses.
The water connections are equipped with O-rings of
Viton and Belliville washers to prevent loosening of
the connection. The fittings are made from
nonmagnetic stainless steel.
Components for Water Cooling

of Stator Windings
via the terminal bushings on the opposite side.

The parallel-connected cooling circuit are checked
for uniform water flows by a flow measurement system
covering all three phase.
The cooling primary water flows through the stator
bars, which are hydraulically connected in parallel,
from the exciter and to the turbine end of the
generator. This ensures a minimum temperature rise
of the stator bars, a minimum water velocity, and a
m i n i m u m h e a d l o s s . M o r e o v e r, t h e t h e r m a l
expansions of the stator bars are completely uniform.
3
Phase Connector Cooling Circuit
Winding Cooling Circuit
The end windings are enclosed by an annular

water manifold to which all stator bars are connected
through hoses. The water manifold is mounted on the
holding plates of the end winding support ring and
connected to the primary water supply pipe. This
permits the insulation resistance of the water-filled
stator winding to be measured. The water manifold is
grounded during operation. For measurement of the
i n s u l a t i o n r e s i s ta n c e , e . g . d u r i n g i n s p e c t i o n s ,
grounding is removed by opening the circuit outside
the stator frame.
The hoses, one side of which is connected to
ground, consists of a metallic section to which the
measuring potential is applied for measurement of the
insulation resistance of the water-filled stator winding.
The cooling water is admitted to three terminal
bushings via a distribution water manifold flows
through the attached phase connectors and is then
passed to the distribution water manifold for outlet
BHEL,Haridwar
Phase connectors and terminal bushing supplied

with cooling water through pipes arranged outside the
generator at the terminal bushing and generator
terminal box and connected to the cooling water inlets
and outlet of the cooling circuit through teflon hoses.
The flexible expansion joints and the hydraulically
series-connected phase connector sections are
connected by teflon hoses.
The hoses, one side of which is connected to
ground, consist of a metallic section to which the
measuring potential is applied for measurement of the
insulation resistance of the water-filled stator winding.
The cooling water is admitted to three terminal
bushings via a distribution water manifold flows
through the attached phase connectors and is then
passed to the distribution water manifold for water
outlet via the terminal bushings on the opposite side.
The parallel-connected cooling circuit are checked
for uniform water flows by a flow measurement system
covering all three phase.
2.1-2380-10550/1
0209 E
Turbogenerators
Grounding of the Stator Cooling

Water Manifold
Description
Primary water
outlet
Primary water
inlet
3
8
4
1
2
3
4
5
6
7
8
Primary water inlet / outlet

Compensator
Insulation
Stator frame
Water manifold
Insulated ground connection
Water manifold ground connection
Stator frame ground connection
BHEL,Haridwar
2.1-2389-10550/1
0209 E
Turbogenerators
Rotor Shaft
Description
The high mechanical stresses resulting from the
centrifugal forces and short-circuit torques call for highquality heat-treated steel. Therefore, the rotor shaft is
forged from a vacuum cast steel ingot. Comprehensive
tests ensure adherence to the specified mechanical and
magnetic properties as well as a homogeneous forging.
The root shaft consists of an electrically active
portion the so-called rotor body, and the two shaft
journals. Integrally forged flange couplings to connect
the rotor to the turbine and exciter are located outboard
of the bearings. Approximately two-thirds of the rotor
body circumference is provided with longitudinal slots
which hold the field winding. Slot pitch is selected so
1
1
2
3
Shaft journal
Rotor slot
Pole
Fig.1
2
4
5
6
that two solid poles are displaced by 180 0.

Due to the non-uniform slot distribution on the
circumference, different moments of inertia are obtained
in the main axis of the rotor. This in turn causes
oscillating shaft deflections at twice the system
frequency. To reduce these vibrations, the deflection in
the direction of the pole axis and the neutral axis are
compensated by transverse slotting of the pole.
The solid poles are also provided with additional
longitudinal slots to hold the copper bars of the damper
winding. The rotor wedges act as a damper winding in
the area of the winding slots.
Transverse slot in pole

Retaining ring seat
Rotor tooth
Rotor Shaft
Note:Shaft and slots may vary from actual design.
BHEL,Haridwar
2.1-3000-10550/1
0209 E
Turbogenerators
Cooling of Rotor Winding
Description
Each turn is subdivided into eight parallel cooling

zones. One cooling zone includes the slots from the
centre to the end of the rotor body, while another
covers half the end winding.
The cooling gas for the slot portion is admitted
into the hollow conductors through milled openings
directly before the end of the rotor body and flows
1
1 End winding
2 Gas inlet (cooling zone: slot portion)
3 Gas inlet (cooling zone: end winding)
4 Rotor tooth
Fig.1
Gas Inlets at End Winding
through the hollow conductors to the centre of the
rotor body. The hot gas is then discharged into the
air gap between the rotor body and the stator core
through radial openings in the conductors and the
rotor slot wedges. The cooling gas passages are
a r r a n g e d a t d i ff e r e n t l e v e l s i n t h e c o n d u c t o r
assembly so that each hollow conductor has its own
BHEL,Haridwar
cooling gas outlet.

The cooling gas for the end windings is admitted
into the hollow conductors at the ends of the rotor
body. It flows through the conductors approximately
up to the pole centre for being directed into a
collecting compartment and is then discharged into
the air gap via slots.
1
2
3
4
5
6
7
1
2
3
4
5
Rotor winding
Gas outlet in orator slot wedge
Top strip
Rotor tooth
Rotor slot wedge
Damper bar
Rotor body
Fig.2
Gas Outlets in Slot Portion
At the end winding, one hollow conductor passage

of each bar is completely closed by a brazed copper
filler section. The enlargement of the conductor
cross-section results in both a reduction of losses
and increased conductor rigidity.
2.1-3100-10550/1
0209 E
Turbogenerators
Cooling Scheme of Rotor Winding
BHEL,Haridwar
Cooling zone: End winding

Cooling zone : Slot portion
8 Parallel cooling zones per

turn
Description
2.1-3101-10550/1
0209 E
Turbogenerators
Rotor Winding
Description
1.
Rotor Winding
1.1
Construction
The field winding consists of several coils
inserted into the longitudinal slots of the rotor body.
The coils are wound around the poles so that one
north and one south magnetic pole are obtained.
The hollow conductors have a trapezoidal crosssection and are provided with two cooling ducts of
approximately semi-circular cross-section All
conductors have identical copper and cooling duct
cross-sections.
The individual conductors are bent to obtain half
turns. After insertion into the rotor slots, these turns
are combined to form full turns, the series-connected
turns of one slot constituting one coil. The individual
coils of the rotor winding are electricity seriesconnected.
copper-nickel-silicon alloy featuring high strength and

good electrical conductivity, and are used as damper
winding bar. The slot wedges extend below the shrink
seats of the retaining rings. The rings act as shortcircuit rings to induced currents in the damper
windings.
2.2
End Winding Bracing

The spaces between the individual coils in the
end winding are filled with insulating members which
prevent coil movement. Fig. 1 shows a typical rotor
end winding with the fillers inserted.
1
2
3 4
5
1.2
Conductor Material
The conductors are made of copper with a silver
content of approximately 0.1%. As compared to
electrolytic copper, silver-alloyed copper features high
strength properties at higher temperatures so that coil
deformations due to thermal stresses are eliminated.
1.3
Insulation
The insulation between the individual turns is
made of layers of glass fibre laminate. The coils are
insulated from the rotor body with L-shaped strips of
glass fibre laminate with Nomex filler.
To obtain the required creepage paths between
the coil and the frame, thick top strips of glass fibre
laminate are inserted below the slot wedges.
2.
Location of Parts in the Rotor Winding
2.1
Rotor Slot Wedges

To protect the winding against the effects of the
centrifugal force, the winding is secured in the slots
with wedges. The slot wedges are made from a
BHEL,Haridwar
1
2
3
4
5
Rotor shaft
Rotor slot wedge
Filler
Gas outlet
Rotor end winding
Fig. 1 Rotor End Winding With Filler
2.1-3300-10550/1
0209 E
Turbogenerators
Rotor Slot
Description
2
3
1
2
3
4
5
Rotor slot wedge

Top strip
Hollow conductor
Cooling gas duct
Winding insulation
6
7
8
9
Slot liner
Radial cooling gas outlet
Cooling gas bore
Rotor shaft
Note: The number of conductors shown does not necessarily correspond to the number of conductors of the generator described.
BHEL,Haridwar
2.1-3301-10550/1
0209 E
BHEL,Haridwar
Note:
1
2
3
4
Rotor body
Snap ring
Retaining rnig
Rotor winding
5
6
7
8
End winding insulation

Filler
End ring
Balancing slot
The number of conductors shown does not necessarily correspond to number of conductors of the generator described.
Turbogenerators
Rotor End Winding
Description
2.1-3310-10550/1
0209 E
Turbogenerators
Rotor Retaining Ring
Description
The rotor retaining rings contain the centrifugal
forces due to the end windings. One end of each ring
is shrunk on the rotor body, while the other end of the
ring overhangs the end windings without contacting
t h e s h a f t . T h i s e n s u r e s a n u n o b s t r u c t e d s h a ft
deflection at the end windings.
The shrunk on end ring at the free end of the
retaining ring serves to reinforce the retaining ring
and secures the end winding in the axial direction at
the same time.
A snap ring is provided for additional protection
BHEL,Haridwar
against axial displacement of the retaining ring.

To reduce the stray losses and retain strength, the
rings are made of non-magnetic, cold-worked
material.
Comprehensive tests, such as ultrasonic
examination and liquid penetrant examination, ensure
adherence to the specified mechanical properties.
The retaining ring shrink-fit areas act as shortcircuit rings to induce currents in the damper system.
To ensure low contact resistance, the shrink seats of
the retaining rings are coated with nickel, aluminium
and silver by a three-step flame spraying process.
2.1-3350-10550/1
0209 E
Turbogenerators
Rotor Field Connections
Description
The field connections provide the electrical,
connection between the rotor winding and the exciter
and consists of:
Q
Q
Q
Field current lead at end winding

Radial bolts
Field current lead in shaft bore
1. Field Current lead at End Winding

The field current lead at the end winding consists
of hollow rectangular conductors. The hollow
conductors are inserted into shaft slots and insulated.
That are secured against the effects of centrifugal
force by steel wedges. One end of each field current
lead is brazed to the rotor winding and the other end
is screwed to a radial bolt. Cooling hydrogen is
admitted into the hollow conductors via radial bolts.
The hot gas is discharged into the air gap together
with the gas used to cool the end winding.
BHEL,Haridwar
2. Radial Bolts
The field current leads located in the shaft bore are
connected to the conductors inserted in the shaft slots
through radial bolts which are secured in position with
slot wedges. Contact pressure is maintained with a
tension bolt and an expanding cone in each radial bolt.
Contact pressures increase due to centrifugal force
during operation. All contact surfaces are silver-plated
to attain a low contact resistance. The radial bolt is made
from forged electrolytic copper.
3. Field Current Lead in Shaft Bore
The leads are run in the axial direction from the radial
bolt to the exciter coupling. These consist of two semicircular conductors insulated from each other and from
the shaft by a tube. The field current leads are connected
to the exciter leads at the coupling with multicontact
plug-in contact which allow for unobstructed thermal
expansion of the field current leads.
2.1-3370-10550/1
0209 E
Turbogenerators
Electrical and Mechanical

Connection of EE Coupling
Description
1
10
11
12
1
2
3
4
5
6
Generator rotor
Coupling bolt
Shear bush
H 2 seal between half couplings
Multicontact plug-in socket strip
Multicontact plug-in bolt
BHEL,Haridwar
7
8
9
10
11
12
Exciter rotor
Insulation
Insulation
Field current lead in exciter rotor shaft
Insulation
Field current lead in generator rotor shaft
2.1-3373-10550/1
0209 E
Turbogenerators
Rotor Fan
Description
conjunction with the gas expelled from the discharge
ports along the rotor.
The moving blades of the fan are inserted into Tshaped grooves in the fan hubs. The fan hubs are
shrink-fitted to the shaft journal spider.
The generator cooling gas is circulated by one

axial-flow fan located on the turbine-end shaft
journal. To augment the cooling of the rotor winding,
t h e p r e s s u r e e s ta b l i s h e d b y t h e f a n w o r k s i n
1
1
2
3
Rotor shaft journal

Balancing weight
Gas inlet to rotor winding
4
4
5
6
Fan Hub
Fan blade
Rotor retaining ring (Covered)
Note: Depending on generator size the rotor fan may be of three or five stages.
BHEL,Haridwar
2.1-3600-10550/1
0209 E
Turbogenerators
Hydrogen Cooler
Description
The hydrogen cooler is a surface-type heat
removed from the hydrogen is dissipated through the
cooling water. The water flows through the finned
tubes while the hydrogen around them.
The vertical arrangement enables the heat
exchanger to be installed without having to increase
the overall axial length of of the generator or the
cross-section area of the stator frame.
The Cooler comprises a pair of separate cooling
elements each of which consists of two tube bundies,
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 cooling water to and
from the cooler are connected to inlet and outlet
channels which are situated above the
coolerelements. The tube bundies 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 cooler well and to prevent uncooled
hydrogen from flowing oast the cooler.
Each cooler consists of the tube bundle, the upper
and lower tube-sheets, the return water channel and
the inlet/outlet water channel. The tubes have copper
fins to obtain a larger heat transfer surface, the fins
being joined to the tubes by tinning. The ends of the
tubes are expanded into the upper and lower tubesheets.
The two side walls of structural steel base the
cooler and direct the hydrogen flow. They are solidly
bolted to the upper tube-sheet. While the attachment
to the lower tubesheet permits them to move freely
to allow for expansion of the tube bundle.
Flexible seal strips bolted to the side walls seal
the gap between the cooler and the cooler well in
the cooler assembly, thus preventing uncooled
hydrogen from flowing past the cooler.
The upper tubesheet is larger than the cooler well
opening and is used to fix the cooler. Gastight sealing
of this tubesheet is done by a packing.
The return water channel is bolted to the upper
tubesheet over a flat gasket. This arrangement
permits the return water channel to be detached for
BHEL,Haridwar
cleaning, even when the generator is in operation and

filled with hydrogen.
The lower tubesheet is freely movable and capable
of following the differential movement between stator
f r a m e a n d c o o l e r d u e t o t h e d i ff e r e n t t h e r m a l
expansion resulting from the different materials and
temperature.
Attached to the lower tubesheet is the inlet/outlet
water channel with its cooling water inlet and outlet
pipes.
A seal cap is bolted over the inlet/outlet water
Fig.1
Hydrogen Cooler Removed
2.1-4000-10550/1
0209 E
Turbogenerators
Hydrogen Cooler
Description
4
5
1
2
3
Return water channel

End shield
Finned tube bundle
BHEL,Haridwar
4
5
6
Cooling water connection

Protective chamber
Hydrogen seal
2.1-4001-10550/1
0209 E
Generator Bearings
Turbogenerators
Description
The tangential locator is supported on the bearing

saddleover a piece of insulating material.
The inner surface of the cast bearing sleeve body
is provided with spiral dovetail grooves which firmly hold
the babbitt liner to the bearing sleeve body. The lower
bearing sleeve has a groove to admit the bearing oil to
the bearing surface. The upper sleeve has a wide
overflow groove through which the oil is distributed over
the shaft journal and fed to the lubricating gap. The oil is
drained laterally from the lubricating gap, caught by
baffles and returned to the turbine oil tank.
All generator bearings are provided with a hydraulic
shaft lift oil system to reduce bearing friction during
startup. High pressure oil is forced between the bearing
surface and the shaft journal, lifting the rotor shaft to
allow the formation of a lubricating oil film.
The bearing temperature is monitored with one
double element thermocouple located approximately in
the plane of maximum oil film pressure. The
thermocouples are screwed in position on both sides of
the lower bearing sleeve from outside with the detectors
extending to the babbitt liner.
The rotor shaft is supported in sleeve bearings

having forced-oil lubrication. The bearings are located
in the stator end shields. The oil required for bearing
lubrication and cooling is obtained from the turbine oil
supply system and supplied to the lubricating gap via
pipes permanently installed inside the lower half of the
stator end shield and via grooves in the bearing saddle
and lower bearing sleeve.
The lower bearing sleeve rests on the bearing
saddle via three brackets with spherical support seat for
self-alignment of the bearing. The bearing saddle is
insulated from the stator end shield and the bearing
brackets are insulated from the bearing sleeve to prevent
the flow of shaft currents and to provide for double
insulation of the generator bearing from ground. A radial
locator serves to locate the bearing in the vertical
direction and is bolted to the upper half of the stator end
shield. The locator is adjusted to maintain the required
clearance between the bearing sleeve and the insulation
of the radial locator.
A tangential locator is located at the bearing sleeve
joint to prevent the bearing from turning in the saddle.
2
1
2
3
Stator End shield

Shaft Seal
Lower Bearing sleeve
Fig.1 Generator Bearing
BHEL, Haridwar
4
4
5
6
7
Pressurised oil inlet for Hydraulic shaft lift oil system

OIl Baffle
Bearing oil inlet
Outer labyrinth ring
2.1-5000-10550/1
0209E
Turbogenerators
Description
Generator Bearing (Insulation)
14
13
12
11
10
9
8
7
6
4
3
2
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
End shield, lower half

Bearing oil drain
Bearing insulation
Bearing saddle
Connections for jacking oil
Rotor shaft
Bearing oil wiper
Outer labyrinth ring
Bearing sleeve
Tangential locator
Radial locator
Bearing cover
End shield Upper half
Shaft seal
BHEL, Haridwar
2.1-5001-10550/1
0209E
Turbogenerators
Measuring of Bearing Temperature
Description
Direction of
Shaft rotation
1
2
3
4
End Shield
Thermocouple lead
Thermocouple
Bearing Sleeve
BHEL, Haridwar
2.1-5003-10550/1
0209 E
Turbogenerators
Generator Bearing Insulation
Description
4
7
Insulation
1
2
3
4
5
6
7
BHEL, Haridwar
End shield or Bearing bracket

Half Bearing ring
Bearing sleeve
Bearing oil wiper
Bearing oil drain
Bearing oil inlet
Tangential locator
2.1-5005-10550/1
0209 E
Turbogenerators
Shaft Seal
Description
Air side
Hydrogen
side
The rotor shaft ends are brought out of the

gastight enclosure through double-flow shaft seals.
With this type of shaft seal, the escape of
hydrogen between the rotating shaft and the housing
is prevented by maintaining a continuous film of oil
between the shaft and a non-rotating floating seal
ring. To accomplish this, seal oil from two separate
circuits, i.e. the air side and the hydrogen side seal
oil circuit, is fed to the seal ring at a pressure slightly
higher than the hydrogen pressure. In addition,
higher pressure air side oil is supplied to the shaft
seal for thrust load compensation of the seal ring.
1
2
1
2
Fig.1
Seal ring housing

Seal ring
Air side seal oil
Ring relief oil
Interchange of Oil in Annular Groove of Shaft

Seal
The double-flow shaft seal is characterized by its

s h o r t a x i a l l e n g t h , i ts i n d e p e n d e n c e f r o m t h e
respective axial and radial position of the shaft, and
low hydrogen losses due to absorption by the seal
oil.
The two halves of the babbited seal ring float on
the shaft journal with a small clearance and are
guided in the axial direction by a seal ring housing
resistant to distortion and bending. The seal ring is
BHEL, Haridwar
relatively free to move in the radial direction, but is

restrained from rotating by use of a pin. The seal ring
housing, bolted to the end shield, is insulated to
prevent the flow of shaft currents. The oil is supplied
to the shaft seal at three different pressures (air side
seal oil pressures, hydrogen side seal oil pressures
and higher pressure oil for ring relief) over pipes and
the mounting flange of the seal ring housing. The air
side and hydrogen side seal oil is admitted into the
air side and hydrogen side annular grooves,
respectively, of the seal ring via passage in the seal
ring housing and seal ring. A continuous film of oil is
maintained between the shaft and the seal ring. The
clearance between shaft and seal ring is such that
friction losses are minimized and an oil film of
s u f f i c i e n t t h i c k n e s s i s m a i n ta i n e d w i t h o u t
unnecessarily large oil flow. Temperature rise of the
seal oil is therefore small which contributes to reliable
sealing. The babbit lining of the seal ring ensure high
reliability even in the event of boundary friction.
The air side seal oil pump delivers the oil at a
pressure maintained at >1.4 bar above the generator
hydrogen gas pressure at the shaft seal by means of
a differential pressure valve ("A" valve)
On the hydrogen side, the hydrogen-saturated seal
oil is circulated in a closed circuit. A pressure
equalizing valve maintains the oil pressure on the
hydrogen side slightly below that on the air side, thus
keeping the interchange of oil between the air and
hydrogen sides to a very small value.
Air side seal oil for ring relief is fed to the annular
groove in the air side seal ring carrier and forced
between the seal ring and the seal ring housing. In
this way the oil and gas pressure acting on the seal
ring are balanced, and the friction between the seal
and seal ring housing is reduced. The seal ring is thus
free to adjust its radial position, which is important
during the starting and shutdown period. The seal ring
will adjust its position according to the shaft position
as dictated by the oil film thickness and the vibratory
condition.
The seal ring need to allow axial displacement of
the generator shaft, which is primarily caused by
turbine expansion. This permits the shaft to slide
through the seal ring without impairing the sealing
effect.
2.1-6000-10550/1
0209 E
Turbogenerators
Shaft Seal
General
H2 side
Air side
1
2
3
4
7
8
10
Section G-H
Section C-D
11
19
12 13
14 15
16
17
18
20
Section E-F
Section A-B
1
2
3
4
5
6
7
End shield
Packing
Insulation
Seal ring chamber
Seal oil inlet bore
Pressure oil groove
Seal oil groove
8 Inner labyrinth ring

9 Seal strip
10 Rotor shaft
11 Oil wiper ring (H 2 side)
12 Seal ring carrier
13 Seal oil groove (H 2 side)
14 Seal oil groove (H 2 side)
15
16
17
18
19
20
Seal oil groove (Air side)

Babbit
Seal ring
Oil wiper ring (Air side)
Seal oil inlet bore (air side)
Pin
Air
Hydrogen
Air side seal oil
H2 side seal oil
Pressure oil for seal ring relief
BHEL,Haridwar
2.1-6001-10550/1
0209E
Turbogenerators
Seal Oil System
Description
Shaft seals supplied with pressurized seal oil are
provided to prevent hydrogen losses at the shaft and
the ingress of air into the hydrogen-cooled generator.
Details of the shaft seal are given in a separate
description in this manual.
As long as the seal oil pressure in the annular gap
exceeds the gas pressure in the generator, no hydrogen
will escape from the generator housing. The shaft seal
is supplied with seal oil by a separate system consisting
of a hydrogen side seal oil circuit and an air side seal
oil circuit. The oil in the seal oil system is the same as
that used in the turbine-generator journal shown.
1
Air Side Seal Oil Circuit
During normal operation, the air side seal oil pump

(AC) draws the seal oil from the seal oil storage tank
and feeds it to the shaft seals via coolers and filters.
The seal oil supplied to the shaft seals which drains
towards the air side through the annular gaps between
the shaft and seal rings is returned to the seal oil storage
tank.
For the air side seal oil circuit, three seal oil pumps
are provided with one of the three pumps always in
operation. In the event of a failure of the pump in service
due to a mechanical or electrical failure, the second

pump automatically takes over. If both pumps fail, the
seal oil supply is taken over by the stand-by pump
without any interruption.
2
Hydrogen Side Seal Oil Circuit
During normal operation, the hydrogen side pump

draws the seal oil from the seal oil storage tank and
feeds it to the shaft seal via coolers and filters. The
seal oil supplied to the shaft seals which drains
towards the hydrogen side through the annular gaps
between the shaft and the seal rings is first collected
in the generator pre-chambers and then returned to
the seal oil tank.
By dividing the seal oil system into two separate
circuits, the hydrogen losses at the seals are kept to
a minimum. Since the hydrogen side seal oil comes
into contact with only the hydrogen gas, it is saturated
with hydrogen and contains no air. Vacuum treatment
of the seal oil and the resulting continuous hydrogen
losses are thus avoided. The air side seal oil, which
is only in contact with air, becomes saturated with air.
By separating the two seal oil circuits, entry of air to
the hydrogen compartment is kept to a minimum
1 Seal ring
Air side seal oil circuit

2
3
4
5
6

Seal oil pump
DPR-A valve
Oil cooler
Seal oil filter
Hydrogen side seal oil circuit

7
8
9
10
11
12
13
Generator prechamber
Pressure equalising valve
Seal oil tank
Seal oil filter
DPR-C Valve
Oil cooler
Seal oil pump
Air side seal oil
Pressure oil for Seal oil ring relief
Hydrogen
Fig-1: Seal oil diagram (Simplified)
BHEL, Haridwar
2.1-7100-10550/1
0209 E
thereby maintaining good hydrogen purity.

One seal oil pump is used for oil circulation in the
hydrogen side oil circuit. In the event of a failure of
this pump, the seal oil to the hydrogen side annular
derived from the air side oil supply circuit.
W h e n o p e r a t i n g i s t h i s m a n n e r, a s l o w
deterioration of the hydrogen purity in the generator
will take place, since the oil flowing towards the
hydrogen side will introduce air, which will come out
of the oil in the hydrogen atmosphere due to the
change in pressures. In case of prolonged operation,
it may eventually become necessary to improve the
hydrogen purity by gas scavenging.
3
Seal Oil Pressure Regulation
The air side and the hydrogen side seal oil circuits
are, however, in contact in the annular gaps between
the shaft seal. The seal oil pressures at the shaft seal
are set so that the air side seal oil pressure is slightly
higher than the hydrogen side seal oil pressure.
Accordingly, a very small quantity of oil flows from
the air side to the hydrogen side in the annular gap
resulting in a gradual increase in the amount of oil in
the hydrogen side oil circuit. A float valve in seal oil
tank returns the excess oil to the seal oil storage tank.
The interchange of oil between the two circuit is so
small that the aforementioned advantages of two
separate circuit are not impaired.
Oil pressures which exceed the generator gas
pressure are required to ensure proper sealing of the
generator. With the seal oil pumps in operation, the
seal oil pressure is controlled by differential pressure
valves "A" ("A" valve). The first "A" valve controls the
seal oil pressure after two equal-priority ac air side
seal oil pumps. The pressure after the stand-by seal
oil pump is separately controlled by the second "A"
valve. Depending on the valve setting and the impulse
oil pressure prevailing (seal oil pressure and hydrogen
casing pressure), a larger or smaller amount of oil is
returned to the suction pipe so that the required seal
oil pressures is established at the shaft seals.
The function of the "A" valves is illustrated in the
attached diagram. Since the gas pressure and the
impulse oil pressure act in opposite directions, the
valve stem is moved upwards or downwards when
these pressure become unbalanced. The valve cone
is arranged so that the valve closes further for a
downward movement of the valve stem (occurs at
rising gas pressure or falling seal oil pressure). This
oil flow throttling results in a rise of the air side seal
oil pressure at the shaft seals. Setting of the desired
differential pressure (set valve) to be maintained by
the valve is done by a corresponding pre-loading of
the main bellows. The pre-loading is adjusted with a
compression spring, the upper end of which is rigidly
connected to the valve yoke, while its lower end is
linked to the valve stem by means of an adjusting nut.

A s m a y b e s e e n o n t h e a t ta c h e d d i a g r a m ,
differential pressure valve "C" ("C" valve) serves to
control the seal oil pressure in the hydrogen side seal
oil circuit and operates on the same principle, with
the only difference being that the air side seal oil
pressures are used as impulse.
The constant differential pressure between the air
side and the hydrogen side oil is controlled by
separate pressure equalizing control valves for each
shaft seal. The function of the pressure equalizing
control valve is illustrated in the attached diagram.
Due to the fact that the air side and hydrogen side
seal oil pressures act in opposite directions, the valve
stem is moved upwards or downwards when these
pressures are unbalanced. The valve opens further
with a downward movement of the valve stem (occurs
at rising air side seal oil pressure), resulting in a raise
of the hydrogen side seal oil pressure. Setting of the
desired differential pressure to be maintained by the
valve is done by a corresponding pre-loading of the
control piston.
4
Seal Oil Drains
The oil drains from the air side of the shaft seals
discharges to the generator bearing space and is
returned to the turbine oil tank via the seal oil storage
tank together with the bearing oil.
The oil drained from the hydrogen side of the shaft
seals is discharged into the generator pre-chambers.
The pre-chambers reduce the oil flow which permits
the escape of entrapped gas bubbles and de-foaming
of the oil. Down-stream of the pre-chambers, the oil
flows are combined and returned into the seal oil tank.
Float valves keep the oil level in the tank at a
predetermined level. If an excessive amount of oil is
supplied to the seal oil tank, a float valve allows some
oil to return to the seal oil storage tank.
The small amount of hydrogen escaping from the
generator together with the oil does not present a
danger to the generator surrounding since the oil
drained on the hydrogen side is returned to the turbine
oil tank only via the seal oil storage tank where the
majority of the entrapped hydrogen is removed. The
seal oil storage tank is connected to the bearing
vapour-exhausters which also vent the generator prechambers.
5
Seal Ring Relief
To ensure free movement of the seal ring, the shaft

seals are provide with pressure oil for ring relief. The
oil supply for ring relief is obtained from the air side
oil circuit. The required pressure setting for each shaft
seal is accomplished separately.
2.1-7100-10550/2
0209 E
Turbogenerators
Differential Pressure Valve A
Description
**
5
Hydrogen
Seal oil
**
6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
*
**
Connection for gas signal pipe

Connection for oil signal pipe
Oil inlet
Valve head
Main Bellow
Upper sealing bellows
Valve stem
Compression spring
Adjusting nut
Lock nut
Yoke
Lower sealing bellows
Valve Housing
Valve cone
Oil inlet
Vent connection
Screw plug
8
9
10
11
12
13
14
3
BHEL, Haridwar
15
2.1-7101-10550/1
0209 E
Turbogenerators
Differential Pressure Valve C
Description
*
6
9
10
11
12
13
14
15
BHEL, Haridwar
3
4
5
6
7
8
9
10
11
12
13
14
15
Connection for air side seal

oil signal
Connection for hydrogen side
seal oil signal
Hydrogen side seal oil inlet
Valve head
Main Bellow
Upper sealing bellows
Valve stem
Compression spring
Adjusting nut
Lock nut
Yoke
Lower sealing bellows
Valve Housing
Valve cone
Hydrogen side seal oil inlet
*
**
Vent connection
Screw plug
2.1-7103-10550/1
0209 E
Turbogenerators
Pressure Equalizing Control Valve
Description
2
3
4
5
6
17
16
15
14
13
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Connection for air side signal pressure

Cap
Lock nut
Threaded spindle
Compression spring
Piston housing
Oil outlet
Compression spring
Threaded spindle
Lock nut
Cap
Valve cone
Oil inlet
Valve housing
Connection for Hydrogen side signal pressure
Valve cone stem
Control piston
7
12
10
11
BHEL, Haridwar
2.1-7104-10550/1
0209E
Turbogenerators
List of Valves for Seal oil System
Description
SL
VALVE
NO. DESIG
TYPE OF VALVE
MAV 72
AA513
NEEDLE VALVE
15
2.5
CS
SC
SHUT OFF VALVE IN U LOOP DRAIN
PIPE LINE
MKW01
AA503
GATE VALVE
80
2.5
CS
FL
SHUT OFF TO SEAL OIL PUMPS
PIPE LINE
MKW01
AA504
NEEDLE VALVE
15
2.5
CS
SC
SHUT OFF VALVE FOR SOST DRAIN
PIPE LINE
MKW03
AA001
FLOAT VALVE
50
1.6
CS
FL
FLOAT VALVE FOR SOST DRAIN
SEAL OIL UNIT
MKW03
AA002
FLOAT VALVE
50
1.6
CS
FL
FLOAT VALVE FOR SOT SUPPLY FROM

AIR SIDE CIRCUIT
SEAL OIL UNIT
MKW03
AA 501
GATE VALVE
50
4.0
CS
FL
SHUT OFF VALVE IN DRAIN LINE OF

S O T CIRCUIT
SEAL OIL UNIT
MKW03
AA502
GATE VALVE
50
4.0
CS
FL
SHUT OFF VALVE FOR SEAL OIL SUP

PLY TO SOT
SEAL OIL UNIT
MKW03
AA503
NEEDLE VALVE
15
2.5
CS
SC
DRAIN VALVE FOR H2 SIDE SEAL OI

L DRAIN LOOP
PIPE LINE
MKW03
AA504
GLOBE VALVE
50
4.0
CS
FL
SHUT OFF VALVE IN DRAIN BYPASS A

T SOT
SEAL OIL UNIT
10
MKW03
AA505
GLOBE VALVE
20
2.5
CS
FL
SHUTOFF VALVE FOR OIL LEVEL IND

ICATOR FOR S O TANK
SEAL OIL UNIT
11
MKW03
AA506
GLOBE VALVE
20
2.5
CS
FL
SHUT OFF VALVE FRO OIL LEVEL IND

ICATOR ,BOTTOM
SEAL OIL UNIT
12
MKW11
AA001
RELIEF VALVE
20
2.5
CS
FL
RELIEF VLV FOR AC SOP-1(AIR SIDE

)
SOP UNIT
13
MKW11
AA002
DPR VALVE
25
1.6
CS
FL
FOR MAINTAINING CONSTANT PRESS D

IFFERENCE
SEAL OIL UNIT
14
MKW11
AA507
GLOBE VALVE
8
2.5
CS
BW
SEAL OIL IMPULSE OF DPRV
SEAL OIL UNIT
15
MKW11
AA003
CHECK VALVE
50
4.0
CS
FL
CHECK VALVE AFTER AC SOP-1 AIR S

IDE
SEAL OIL UNIT
16
MKW11
AA508
GATE VALVE
50
4.0
CS
FL
SHUT OFF VALVE IN BYEPASS LINE
SEAL OIL UNIT
17
MKW11
AA501
GATE VALVE
80
4.0
CS
FL
INLET TO SOP-1 AIR SIDE
SEAL OIL UNIT
18
MKW11
AA505
GATE VALVE
50
4.0
CS
FL
SHUT OFF VALVE AFTER DPRV
SEAL OIL UNIT
19
MKW11
AA506
GLOBE VALVE
10
2.5
CS
BW
SHUT OFF VALVE IN OIL IMPULSE LI

NE OF DPRV
SEAL OIL UNIT
20
MKW11
AA004
SHUT OFF VALVE
50
2.5
CS
FL
NR SHUT OFF VALVE AFTER AIR SID

E SOP-1&2
SEAL OIL UNIT
21
MKW11
AA504
GATE VALVE
50
4.0
CS
FL
SHUT OFF VALVE BEFORE DPRV
SEAL OIL UNIT
22
MKW13
AA001
RELIEF VALVE
20
2.5
CS
FL
BLOW OFF OF OIL FOR SOP(H2 SIDE)
SEAL OIL UNIT
23
MKW13
AA002
DPR VALVE
25
1.6
CS
FL
FOR MAINTAINING CP DIFFERENCE
SEAL OIL UNIT
BHEL, Haridwar
NB mm
NP MPA
BODY mat
END conn
FUNCTION
LOCATIOIN
2.1-7112-10550/1
0209E
SL
VALVE
NO. DESIG
TYPE OF VALVE
24
MKW13
AA003
CHECK VALVE
50
4.0
CS
FL
CHECK VALVE AFTER H2 SIDE SOP
SEAL OIL UNIT
25
MKW13
AA501
GATE VALVE
50
4.0
CS
FL
SHUT OFF VALVE BEFORE H2 SIDE SE

ALOIL PUMP
SEAL OIL UNIT
26
MKW13
AA503
GATE VALVE
50
4.0
CS
FL
SHUT OFF VALVE FOR SEAL OIL BEF

ORE H2 SIDE COOLERS
SEAL OIL UNIT
27
MKW13
AA505
GLOBE VALVE
50
4.0
CS
FL
SHUT OFF VALVE IN AIR SIDE IMPUL

SE LINE
SEAL OIL UNIT
28
MKW13
AA511
GLOBE VALVE
50
4.0
CS
FL
SHUT OFF VALVE IN H2 SIDE SEAL O

IL DRAIN LINE
SEAL OIL UNIT
29
MKW13
AA507
GLOBE VALVE
10
2.5
CS
BW
EQUALISING VALVE IN BYE PASS OF

IMPULSE LINE
SEAL OIL UNIT
30
MKW13
AA508
NEEDLE VALVE
8
2.5
CS
BW
SEAL OIL VENT VALVE AT DPRV AIR

SIDE
SEAL OIL UNIT
31
MKW13
AA509
GLOBE VALVE
8
2.5
CS
BW
SEAL OIL VENT VLV AT DPRV H2 SID

E
SEAL OIL UNIT
32
MKW13
AA510
GATE VALVE
25
4.0
CS
FL
SHUT OFF VLV IN H2 SIDE DPRV BY

PASS LINE TO SOT
SEAL OIL UNIT
33
MKW13
AA506
GLOBE VALVE
10
2.5
CS
BW
SHUT OFF VALVE IN H2 SIDE IMPUL

SELINE
SEAL OIL UNIT
34
MKW21
AA001
RELIEF VALVE
20
0.0
CS
FL
RELIEF VLV FOR AC SOP-2 (AIR SIDE

)
SOP UNIT
35
MKW21
AA002
CHECK VALVE
50
4.0
CS
FL
CHECK VLV AFTER AIR SIDE SOP-2
36
MKW21
AA501
GATE VALVE
80
4.0
CS
FL
INLET TO SOP-2(AIR SIDE)
37
MKW21
AA503
GATE VALVE
50
4.0
CS
FL
AIR SIDE & H2 SIDE OIL INTERCONN
SEAL OIL UNIT
38
MKW23
AA503
GLOBE VALVE
8
25.0
CS
SC
H2 IMPULSE TO DPRV
SEAL OIL UNIT
39
MKW23
AA504
GLOBE VALVE
8
25.0
CS
SC
H2 IMPULSE TO DPRV
SEAL OIL UNIT
40
MKW31
AA001
RELIEF VALVE
20
2.5
CS
FL
RELIEF VLV FOR SOP-3 (AIR SIDE)
41
MKW31
AA506
GLOBE VALVE
10
2.5
CS
BW
SHUT OFF VLV IN OIL IMPULSE LINE

OFDPRV
SEAL OIL UNIT
42
MKW31
AA002
DPR VALVE
25
1.6
CS
FL
FOR MAINTAINING CP DIFFERENCE
SEAL OIL UNIT
43
MKW31
AA507
GLOBE VALVE
8
2.5
CS
BW
SEAL OIL IMPULSE VENT OF DPRV
SEAL OIL UNIT
44
MKW31
AA004
NR SHUT OFF VALVE
50
2.5
CS
FL
NON RETURN SHUT OFF VLV AFTER AI

R SIDE SEAL OIL PUMP
SEAL OIL UNIT
45
MKW31
AA504
GATE VALVE
50
4.0
CS
FL
SHUT OFF VLV BEFORE DPRV
SEAL OIL UNIT
46
MKW31
AA505
GATE VALVE
50
4.0
CS
FL
SHUT OFF VLV AFTER DPRV
SEAL OIL UNIT
47
MKW31
AA003
CHECK VALVE
50
4.0
CS
FL
CHECK VLV AFTER SOP-3(AIR SIDE)
SEAL OIL UNIT
48
MKW31
AA501
GATE VALVE
80
4.0
CS
FL
INLET TO SOP-3(AIR SIDE)
SEAL OIL UNIT
2.1-7112-10550/2
0209E
NB mm
NP MPA
BODY mat
END conn
FUNCTION
LOCATIOIN
SEAL OIL UNIT

SOP UNIT
SOP UNIT
Turbogenerators
Description
SL
VALVE
NO. DESIG
TYPE OF VALVE
49
MKW51
AA501
DOUBLE CHG OVER

VLV
50
1.6
CS
FL
3-WAY CHANGE OVER VLV AT SEAL OI

L COOLER (AIR SIDE)
SEAL OIL UNIT
50
MKW51
AA502
DOUBLE CHG OVER

VLV
50
1.6
CS
FL
3-WAY CHANGE OVER VLV AT SEAL OI

L COOLER (AIR SIDE)
SEAL OIL UNIT
51
MKW51
AA503
GLOBE VALVE
8
2.5
CS
BW
FILLER VLV FOR AIR SIDE S.O.COOL

ER
SEAL OIL UNIT
52
MKW51
AA504
GLOBE VALVE
8
2.5
CS
BW
S.O.DRAIN VLV AT AIR SIDE COOLER

-2
SEAL OIL UNIT
53
MKW51
AA505
GLOBE VALVE
8
2.5
CS
BW
S.O.DRAIN VLV AT AIR SIDE COOLER

-1
SEAL OIL UNIT
54
MKW51
AA506
GLOBE VALVE
8
2.5
CS
BW
COOLING WATER DRAIN VLV AT COOLE

R-2 AIR SIDE
SEAL OIL UNIT
55
MKW51
AA512
DOUBLE CHG OVER

VLV
50
1.6
CS
FL
CHANGE OVER VALVE FOR SEAL

OIL FILTER-1 (AIR SIDE)
SEAL OIL UNIT

WITH FILTER
56
MKW51
AA513
DOUBLE CHG OVER

VLV
50
1.6
CS
FL
CHANGE OVER VALVE FOR SEAL

OIL FILTER-2 (AIR SIDE)
SEAL OIL UNIT

WITH FILTER
57
MKW51
AA508
GLOBE VALVE
8
2.5
CS
BW
COOLING WATER VENT VLV AT COOLE

R-2 (AIR SIDE)
SEAL OIL UNIT
58
MKW51
AA510
GLOBE VALVE
8
2.5
CS
BW
SEAL OIL VENT VLV INLET AT COOL

ER-2 (AIR SIDE)
SEAL OIL UNIT
59
MKW51
AA511
GLOBE VALVE
8
2.5
CS
BW
SEAL OIL VENT VLV FROM COOLER-1

(AIR SIDE)
SEAL OIL UNIT
60
MKW51
AA507
GLOBE VALVE
8
2.5
CS
BW

R-1 (AIR SIDE)
SEAL OIL UNIT
61
MKW51
AA509
GLOBE VALVE
8
2.5
CS
BW

R-1 (AIR SIDE)
SEAL OIL UNIT
62
MKW53
AA501
DOUBLE CHG OVER

VLV
50
1.6
CS
FL
CHANGE OVER VALVE AT SEAL OIL CO

OLER (H2 SIDE)
SEAL OIL UNIT
63
MKW53
AA502
DOUBLE CHG OVER

VLV
50
1.6
CS
FL
CHANGE OVER VALVE AT SEAL OIL CO

OLER (H2 SIDE)
SEAL OIL UNIT
64
MKW53
AA503
GLOBE VALVE
8
2.5
CS
BW
FILLER VLV FOR H2 SIDE S.O.COOLE

R
SEAL OIL UNIT
65
MKW53
AA504
GLOBE VALVE
8
2.5
CS
BW
SEAL OIL DRAIN VALVE AT H2 SIDE

COOLER-2
SEAL OIL UNIT
66
MKW53
AA505
GLOBE VALVE
8
2.5
CS
BW
SEAL OIL DRAIN VALVE AT H2 SIDE

COOLER-1
SEAL OIL UNIT
67
MKW53
AA506
NEEDLE VALVE
8
2.5
CS
BW

R-2 (H2 SIDE)
SEAL OIL UNIT
68
MKW53
AA513
DOUBLE CHG OVER

VLV
50
1.6
CS
FL
CHANGE OVER VLV FOR SEAL OIL FI

LTER-2 (H2 SIDE)
SEAL OIL UNIT

WITH FILTER
69
MKW53
AA507
GLOBE VALVE
8
2.5
CS
BW

R-1(H2 SIDE)
SEAL OIL UNIT
70
MKW53
AA509
GLOBE VALVE
8
2.5
CS
BW
COOLING WATER VENT VLV AT COOLER

-1(H2 SIDE)
SEAL OIL UNIT
71
MKW53
AA510
GLOBE VALVE
8
2.5
CS
BW
SEAL OIL VENT VALVE AT COOLER-2

(H2SIDE)
SEAL OIL UNIT
BHEL, Haridwar
NB mm
NP MPA
BODY mat
END conn
FUNCTION
LOCATIOIN
2.1-7112-10550/3
0209E
SL
VALVE
NO. DESIG
TYPE OF VALVE
72
MKW53
AA511
GLOBE VALVE
8
2.5
CS
BW
SEAL OIL VENT VALVE AT COOLER-1

(H2SIDE)
SEAL OIL UNIT
73
MKW53
AA512
DOUBLE CHG OVER

VLV
50
1.6
CS
FL
CHANGE OVER VLV AT SEAL OIL FIL

ETR-1(H2 SIDE)
SEAL OIL UNIT
74
MKW53
AA508
GLOBE VALVE
8
2.5
CS
BW

R-2(AIR SIDE)
SEAL OIL UNIT
75
MKW71
AA511
3-WAY VALVE
50
1.6
CS
FL
3-WAY VLV TE(AIR SIDE)
SOV RACK
76
MKW71
AA512
GATE VALVE
50
4.0
CS
FL
SHUT OFF VLV FOR SEAL OIL,TE (AI

R SIDE)
SOV RACK
77
MKW71
AA513
GLOBE VALVE
10
2.5
CS
BW
SHUT OFF VLV IN SEAL OIL IMPULSE

LINE,TE (AIR SIDE)
SOV RACK
78
MKW71
AA514
GLOBE VALVE
8
2.5
CS
BW
VENT FOR EQUALISING VLV TE (AIR

SIDE)
SOV RACK
79
MKW71
AA521
3-WAY VALVE
50
1.6
CS
FL
3-WAY VLV,EE (AIR SIDE)
SOV RACK
80
MKW71
AA522
GATE VALVE
50
4.0
CS
FL
SHUT OFF VLV FOR SEAL OIL,EE (AI

R SIDE)
SOV RACK
81
MKW71
AA523
GLOBE VALVE
10
2.5
CS
BW
SHUT OFF VLV IN SEAL OIL IMPULSE

LINE,EE (AIR SIDE)
SOV RACK
82
MKW71
AA524
GLOBE VALVE
8
2.5
CS
BW
VENT FOR EQUALISING VLV EE (AIR

SIDE)
SOV RACK
83
MKW71
AA551
NEEDLE VALVE
15
2.5
CS
SC
FIRST SHT OFF VLV FOR PR.MSRMENT

BEF.AIR SIDE MNFLD
PIPE LINE
84
MKW71
AA552
NEEDLE VALVE
15
2.5
CS
SC
FIRST SHUT OFF VLV FOR AIR SIDE

SO PR MSRMENT,TE
PIPE LINE
85
MKW71
AA553
NEEDLE VALVE
15
2.5
CS
SC
FIRST SHUT OFF VLV FOR AIR SIDE

S O PR MSREMENT,EE
PIPE LINE
86
MKW73
AA011
EQUALISING VALVE
50
2.5
CS
FL
EQUALISING VLV FOR S.O.PRESSURE

TE(H2 SIDE)
SOV RACK
87
MKW73
AA021
EQUALISING VALVE
50
2.5
CS
FL
EQUALISING VLV FOR S.O.PRESSURE

EE(H2 SIDE)
SOV RACK
88
MKW73
AA511
3-WAY VALVE
50
1.6
CS
FL
3-WAY VLV TE (H2 SIDE)
SOV RACK
89
MKW73
AA512
GATE VALVE
50
4.0
CS
FL
SHUT OFF VLV FOR SEAL OIL IMPULS

E LINE, TE (H2 SIDE)
SOV RACK
90
MKW73
AA513
GLOBE VALVE
10
2.5
CS
BW
SHUT OFF VLV FOR SEAL OIL IMPULS

E LINE, TE (H2 SIDE)
SOV RACK
91
MKW73
AA514
GLOBE VALVE
8
2.5
CS
BW
VENT FOR EQUALISING VALVE TE (H2

SIDE)
SOV RACK
92
MKW73
AA521
3-WAY VALVE
50
1.6
CS
FL
3-WAY VLV,EE (H2 SIDE)
SOV RACK
93
MKW73
AA522
GATE VALVE
50
4.0
CS
FL
SHUT OFF VLV FOR SEAL OIL EE (H

2 SIDE)
SOV RACK
94
MKW73
AA523
GLOBE VALVE
10
2.5
CS
BW
SHUTOFF VALVE IN SEAL OIL IMPULS

E LINE,EE (H2 SIDE)
SOV RACK
95
MKW73
AA524
GLOBE VALVE
8
2.5
CS
BW
VENT FOR EQUALISING VALVE EE (H2

SIDE)
SOV RACK
96
MKW76
AA511
GATE VALVE
25
1.6
CS
FL
MULTIWAY SHUT OFF VALVE FOR R.R.

FLOW METERS (TE)
SOV RACK
2.1-7112-10550/4
0209E
NB mm
NP MPA
BODY mat
END conn
FUNCTION
LOCATIOIN
Turbogenerators
Description
SL
VALVE
NO. DESIG
TYPE OF VALVE
NB mm
NP MPA
BODY mat
END conn
FUNCTION
LOCATIOIN
97
MKW76
AA512
GATE VALVE
25
4.0
CS
FL
SHUT OFF VALVE AFTER R.R.FLOW ME

TER(TE)
SOV RACK
98
MKW76
AA513
REGULATING
25
4.0
CS
FL
REGULATING VALVE FOR RING RELIEF

OIL,TE
SOV RACK
99
MKW76
AA521
GATE VALVE
25
1.6
CS
FL
MULTIWAY SHUT OFF VALVE FOR R.R.

FLOW METERS (EE)
PIPE LINE
100 MKW76
AA522
GATE VALVE
25
4.0
CS
FL
SHUT OFF VALVE AFTER R.R.FLOW ME

TER(EE)
PIPE LINE
101 MKW76
AA523
REGULATING VALVE
25
4.0
CS
FL
REGULATING VALVE FOR RING RELIEF

OIL,TE
PIPE LINE
102 PGB51
AA501
3-WAY VALVE
65
1.6
CS
FL
3-WAY VLV FOR COOLING WATER INLE

T (H2 SIDE)
SEAL OIL UNIT
103 PGB52
AA501
REGULATING VALVE
65
1.6
CS
FL
REGULATING VALVE AFTER SEAL OIL

COOLER-1, H2 SIDE
SEAL OIL UNIT
104 PGB52
AA502
REGULATING VALVE
65
1.6
CS
FL

COOLER-2,H2 SIDE
SEAL OIL UNIT
105 PGB61
AA501
3-WAY VALVE
65
1.6
CS
FL
3-WAY VLV FOR COOLING WATER INLE

T (AIR SIDE)
SEAL OIL UNIT
106 PGB62
AA501
REGULATING VALVE
65
1.6
CS
FL

COOLER-1,AIR SIDE
SEAL OIL UNIT
107 PGB62
AA502
REGULATING VALVE
65
1.6
CS
FL

COOLER-2,AIR SIDE
SEAL OIL UNIT
Legend
FL
SC
CS
CR
GM
= Flanged
= Screwed
= Carbon Steel
= Cromium Steel
= Gun Metal
RT = Room Temperature
BHEL, Haridwar
2.1-7112-10550/5
0209E
Turbogenerators
Bearing Vopour Exhauster
Description
6
The bearing vapour exhauster establishes a

vacuum in the generator bearing compartments
which prevents the escape of oil from the bearing
compartments along the shaft. In addition, the
bearing vapour exhausted draws off any hydrogen
gas which may be admitted into the bearing
compartments in the event of a shaft seal failure.
The bearing vapour 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.
1
4
Drive motor
Regressing device
Suction branch
Delivery branch
Fig.1
Bearing Vapour Exhauster
BHEL, Haridwar
1
2
3
4
1
2
3
4
5
6
7
21
Packing washer
Seal collar
Motor shaft
Motor flange
Regressing device
Exhauster housing
Fan Impeller
Fig.2
Bearing Vapour Exhauster

2.1-7120-10550/1
0209 E
Turbogenerators
Seal Oil Pumps
Description
1
General
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 internalising, 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.
The idler screw are hydraulically driven due to
suitable screw dimensions. The thread flanks transmit
only the torque resulting from fluid friction, which ensures
very quiet running.
The screw pumps are driven by electric motors
through a coupling. The motor speed and rating are
matched to the expected delivery flow and heads.
Oil lubricated radial seals at the rotor shaft ends

prevent the hydrogen gas from escaping from the
generator to the atmosphere.
Seal oil pumps are used to supply the seal oil to the
shaft seals in a closed circuit.
2
Construction and Mode of Operation
The seal oil pumps are three-screw pumps. One

double-thread driving rotor and two driven idler screw
dare closely meshed and run with a close clearance in
the casing insert. The pump casing accommodates the
casing insert and is closed off by covers at the drive
end and nondriver 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
1
2
3
4
Idler screw
Driving rotor
Dummy pastor
Shaft seal (sliding ring gland)
Fig.1
Screw Pump With Relief Valve
BHEL, Haridwar
2.1-7123-10550/1
0209 E
Turbogenerators
Seal Oil Cooler and Seal Oil Filter
Description
1
Seal Oil Coolers

The two full-capacity seal oil coolers are designed
as plate heat exchangers. One of the two coolers is
in operation while the other is in standby mode, and
changeover can be performed without affecting
system operation. The oil side of the standby cooler
must be filled. [1]
2
1
2
3
4
5
Seal Oil Filters
The seal oil filters are arranged directly after the

seal oil coolers. The filters have a fine mesh screen
which serves to prevent damage to the shaft seals by
foreign particles entrained in the oil. By connecting
two separate filters in series, one of the two filters
can always be maintained in operation, supplying
filtered oil to the shaft seals. The change-over valve
assembly at the filters allows one filter to be out of
service for cleaning without interruption of the oil flow.
6
7
8
1
2
3
4
Valve assembly
Position indicator
Pressure equalizing valve
Differential pressure indicator
Fig.1
BHEL, Haridwar
5
6
7
8
Transfer valve assembly

Valve lever
Filter housing
Oil outlet flange
Seal Oil Filter
2.1-7130-10550/1
0209 E
Turbogenerators
Seal Oil Cooler
Description
1. Upper tubesheet
2. Support plate
3. Return water channel
4. Partition ring
5. Inspection port
6. Tube bundle
7. Cooler shell
BHEL, Haridwar
8. Cooling water connection

9. Cooler base
10. Water channel
11. Lower tubesheet
12. Oil outlet
13. Oil inlet
2.1-7131-10550/1
0209 E
Turbogenerators
Seal Oil Filter
Description
1
2
1
2
3
4
5
6
7
BHEL, Haridwar
Position indicator
Eyebolt
Filter valve
Strainer
Filter housing
Support
Vent plug
10 11
12
8
9
10
11
12
13
Drain plug
Changeover valve assembly
Oil outlet flange
Valve lever
Oil inlet flange
Signal line for differential
pressure
2.1-7132-10550/1
0209 E
Turbogenerators
Differential Pressure Meter System
Description
1. General
The pressures of the hydrogen side and air side
seal oil circuits are applied to differential pressure
measurement devices. A complete system for
measurement of the seal oil differential pressures
consists of the following components.
Q
Q
Q
Differential pressure transmission lines

Equalizing valve assembly
Differential pressure gauges
The seal oil pressures are transmitted to the

diaphragms of the pressure gauges via the
BHEL, Haridwar
transmission lines and equalizing valve assembly.

Vents are provided at the pressure gauges.
2. D i f f e r e n t i a l P r e s s u r e M e t e r s f o r D i r e c t
Indication
The two input pressures to be compared act on
the diaphragms on both sides, With the force set up
by the differential pressure producing a deflection of
t h e e l a s t i c b o d y. T h e r e s u l t i n g m o v e m e n t i s
transmitted to the pointer mechanism for direct
indication of the differential pressure. The point has
a deflection of 270 degrees.
2.1-7150-10550/1
0209E
Turbogenerators
Gas System
Description
1.
Q
Q
Q
Q
Q
General
The gas system consists of the following components:
CO2 bottle rack
H2 bottle rack
N2 bottle rack
Gas dryer
Gas valve rack
The design of the gas system complies with the safety

regulations according to VDE 0530. Part 3 and with the
German pressure vessel code.
2.
Hydrogen Supply
The hydrogen for the generator is supplied from a

hydrogen bottle rack. The hydrogen should have a minimum
purity of 99.7%.
2.1 H2 Bottle Rack
The H2 bottles are connected to the manifold on the
bottle rack. Valves on the bottles and valves on the manifold
allow replacement of individual bottles during operation.
The hydrogen is stored in the steel bottles at a very high
pressure. The hydrogen gas available in the manifold at
bottle pressure is passed to two parallel-connected
pressure reducers for expansion to the required
intermediate pressure and is then passed to pressure
reducers on the gas valve rack for expansion to the
pressure required for generator operation. Relief valves
on the low-pressure sides of all pressure reducers are
connected to an outlet pipe system through which any
excess hydrogen is passed to the atmosphere. All pressure
reducers are of identical design. Single-stage construction
of the pressure reducers ensures a constant pressure,
even under low or no flow conditions, and allows large
volume flow quantities of hydrogen to be reduced in
pressure during the hydrogen filling procedure.
3.
Carbon Dioxide Supply
As a precaution against explosive mixtures, air must

never be directly replaced with hydrogen during generator
filling not the hydrogen replaced directly with air during the
emptying procedure. In both cases, the generator must be
scavenged or purged with an inert gas, carbon dioxide
(CO2) being used for this purpose.
3.1 CO2 Bottle Rack
The carbon dioxide is supplied in steel bottles in the
BHEL, Haridwar
liquid state. The bottles should be provided with risers to

ensure complete emptying. The arrangement of the CO 2
bottle rack corresponds to that of the H2 bottle rack. The
liquid CO 2, which is stored under pressure, is fed to the
gas valve rack via a shutoff valve.
3.2 CO2 Vaporiser
At the gas valve rack the liquid CO2 is evaporated and
expanded in a CO2 vapouriser. The heat for vaporization is
supplied to the vapouriser electrically. A temperature control
is provided so that freezing of the flash evaporator is
prevented, and the CO2 is admitted into the generator at
the proper temperature. One safety valve each on the highpressure and low-pressure sides protects the pipe system
against inadmissible high pressure.
4
Compressed air Supply
To remove the CO2 from the generator, a compressed

air supply with compressed air filter is connected to the
general air system of the power plant.
Under all operating conditions, except for CO 2
purging, the compressed air hose between the filter and
the generator pipe system should be disconnected. This
visible break is to ensure that no air can be admitted into a
hydrogen-filled generator.
5.
Gas Valve Rack and Gas Monitoring Equipment
5.1 Gas Valve Rack

To aid in operation of the gas system, the gas valve
rack is furnished with a mini diagram on the face of the
panel.
The valves used in the gas system have rubber/metalsealed valve seats to ensure gas tightness.
5.2 Casing Pressure Measurement
For measuring and checking the gas pressure in the
generator, the gas rack is provided with a pressure
transmitter and pressure gauges for local measurement.
For safety, the pressure transmitter is of an explosion proof
design.
5.3 Electrical Purity meter System
The transmitter for the CO2 / H2 purity meter system on
the gas valve rack is also of an explosion proof design.
The meter system operates on the thermal conductivity
method. The meter system measures the H2 content of the
gas in the generator as well as the composition of gas
mixtures (CO2 / air and H2 / CO2) during filling and emptying
2.1-7200-10550/1
0209E
of the generator.
5.4 Mechanical Purity Meter System
The second purity meter system is a mechanical type
and uses the physical relationships between the hydrogen
pressure, the speed of the generator fan, and the specific
gravity of the medium. This meter system, therefore,
functions only at rated speed.
5.5 Gas Analysis
In addition, facilities are provided for gas sampling for
chemical analysis of the gas in the generator.
6.
Removing the air above the water level in the

primary water tank during initial operation of the
primary water system.
Removing the oxygen dissolved in the primary water
during filling of the primary water system.
Removing the hydrogen gas above the water level
in the primary water tank during shutdown of the
primary water system
Removing the hydrogen gas dissolved in the primary
water during shutdown of the primary water
system.
Gas Dryer
A small amount of the hydrogen circulating in the

generator for cooling is passed through a gas drier. The
gas inlet and gas outlet pipes of the gas dryer are connected
at points of the generator with different static
heads(differential fan pressure), so that the gas is forced
through the dryer by the differential pressure only.
7.
nitrogen supply is required for:
Nitrogen (N2 ) Supply

On a water-cooled turbine generator an additional
2.1-7200-10550/2
0209E
The N 2 purge during initial operation ensures a

complete removal of the oxygen from the primary water
circuit, thus eliminating the risk of corrosion attack.
The N 2 purge during shutdown prevents the
formation of an explosive hydrogen-air mixture During
operation hydrogen may enter into the primary water
tank by diffusion at the insulating hoses.
The nitrogen available from a bottle is passed to a
pressure reducer for expansion and admitted into the
primary water tank via the N 2 supply line.
Turbogenerators
List of Valves for Gas System
Description
SL
VALVE
NO. DESIG
TYPE OF VALVE
NB mm
NP MPA
BODY mat
END conn
FUNCTION
LOCATIOIN
MKG 11
AA 001
PR.REDUCER
8
0.0
CS
SC
H2 PR.REDUCER(STAGE-1)
H2 DISTRIBUTER
MKG 11
AA 501
GLOBE VALVE
8
25.0
CS
SC
SHUTOFF AT H2 CYLINDER
H2 CYLINDER
MKG 11
AA 531
MANIFOLD VLV
8
25.0
CR
SC
H2 DISTRIBUTER MANIFOLD
H2 DISTRIBUTER
MKG 11
AA 561
GLOBE VALVE
8
25.0
CR
SC
SHUT OFF AT INLET TO

G 11/ AA 001
MKG 12
AA 001
PR.REDUCER
8
25.0
CS
SC
H2 PR.REDUCER(STAGE-1)
MKG 12
AA 501
GLOBE VALVE
8
25.0
CR
SC

KG12/ AA 001
MKG 15
AA 501
GLOBE VALVE
25
2.5
CR
SC
SHUT OFF AT OUTLET FROM MKG 11/

AA001
MKG 15
AA 502
GLOBE VALVE
25
2.5
CS
SC

KG19/ AA 001
MKG 15
AA 504
GLOBE VALVE
25
2.5
CS
SC
FOR CONNECTING H2 DISTRIBUTER TO

GAS UNIT
10
MKG 16
AA 501
GLOBE VALVE
25
2.5
CR
SC

AA001
H2 DISTRIB
11
MKG 17
AA 504
GLOBE VALVE
25
2.5
CS
SC
FOR CONNECTING GAS UNIT TO STATI

ONH2 PLANT
GAS UNIT
12
MKG 17
AA 505
GLOBE VALVE
25
2.5
CS
SC
SHUT OFF AT INLET TO MKG 19/ AA

002
GAS UNIT
13
MKG 19
AA 001
PR.REDUCER
25
2.5
CS
SC
H2 PR.REDUCER (STAGE-2)
GAS UNIT
14
MKG 19
AA 002
PR.REDUCER
25
2.5
CS
SC
H2.PR.REDUCER (STAGE-2)
H2 UNIT
15
MKG 19
AA 501
GLOBE VALVE
50
2.5
CS
FL

AA001
GAS UNIT
16
MKG 19
AA 502
GLOBE VALVE
50
2.5
CS
FL

AA002
GAS UNIT
17
MKG 25
AA 501
GLOBE VALVE
25
2.5
CS
SC
SHUT OFF AT INLET TO AF
GAS UNIT
18
MKG 25
AA 502
GLOBE VALVE
50
2.5
CS
FL
EXHAUST
GAS UNIT
19
MKG 25
AA 507
3-WAY VALVE
12
1.6
CR
SC
FOR CALIBRATION OF GAS ANALYSER
GAS UNIT
20
MKG 25
AA 509
GLOBE VALVE
25
2.5
CS
SC
SHUT OFF AT OUTLET TO AF
GAS UNIT
21
MKG 25
AA 511
GLOBE VALVE
8
25.0
CR
SC
SHUT OFF AT INLET TO GAS ANALYSE

R CABINET
GAS UNIT
22
MKG 25
AA 512
GLOBE VALVE
8
25.0
CR
SC
FOR TAKING SAMPLE OF GAS FOR PUR

ITY ANALYSIS
GAS UNIT
23
MKG 25
AA 518
THREE WAY VLV
50
1.6
CR
FL
SHUT OFF CO2 SUPPLY TO EXHAUST F

ROMTG
GAS UNIT
BHEL, Haridwar
MK
H2 DISTRIBUTER
H2 DISTRIBUTER
H2 DISTRIBUTER
H2 DISTRIB
GAS UNIT
GAS UNIT
2.1-7212-10550/1
0209E
SL
VALVE
NO. DESIG
TYPE OF VALVE
NB mm
NP MPA
BODY mat
END conn
FUNCTION
LOCATIOIN
24
MKG25
AA021
GLOBE VALVE
8
25.0
CR
SC
VALVE AT INLET TO GAS ANALYSER C

ABINET
PIPELINE
25
MKG25
AA022
GLOBE VALVE
8
25.0
CR
SC
VALVE AT INLET OF GAC FROM GENER

ATOR
PIPELINE
25
MKG 25
AA 519
3-WAY VALVE
50
1.6
CS
FL
SHUT OFF TO H2 SUPPLY TO GENERAT

OR
GAS UNIT
26
MKG31
AA001
PR REGULATOR
8
15.0
CS
SC
N2 PRESSURE REGULATION
N2 DISTRIBTR
27
MKG 31
AA 501
GLOBE VALVE
CS
SC
SHUTOFF VALVE AT N2 CYLINDER
N2 CYLINDER
28
MKG 31
AA 502
GLOBE VALVE
8
25.0
CR
SC
N2 DISTRIBUTER MANIFOLD
N2 DISTRIBTR
29
MKG 31
AA 503
GATE VALVE
8
25.0
CR
SC
INLET TO PRESSURE REGULATOR
N2 DISTRIBTR
30
MKG 35
AA 501
GLOBE VALVE
8
25.0
CR
SC
OUTLET OF PRESSURE REGULATOR
N2 DISTRIBTR
31
MKG 05
AA 501
GLOBE VALVE
8
25.0
CS
SC
SHUTOFF AT INLET TO GAC FROM GEN

ERATOR
32
MKG 51
AA 001
SAFETY RELIEF VLV
6
17.5
CS
SC
TO RELEASE EXCESS CO2 PR. AT INL

TO CO2 VAP.
CO2 VAPOURSR
33
MKG 51
AA 501
GLOBE VALVE
CS
SC
SHUTOFF AT CO2 CYLINDER
CO2 CYLINDER
34
MKG 51
AA 531
MANIFOLD VALVE
8
25.0
CR
SC
CO2 DISTRIBUTER MANIFOLD VALVES
CO2 DISTRIBTR
35
MKG 51
AA 561
GLOBE VALVE
10
25.5
CR
SC
SHUT OFF AT INLET TO CO2 VAPORI

SER
CO2 VAPOURSR
36
MKG 59
AA 001
SAFETY RELIEF VLV
32
0.6
CS
FL
TO RELEASE EXCESS CO2 PR. ATCO2

VAP. OUTL
CO2 DISTRIBTR
37
MKG59
AA507
GLOBE VALVE
50
CR
SC
OUTLET CO2 PRESSURE REGULATOR
PIPELINE
38
MKG 69
AA 502
GAS VALVE
50
1.6
CS
FL
SHUT OFF AT INLET TO REF. GAS DR

IER-1
PIPE LINE
39
MKG 69
AA 503
GAS VALVE
50
1.6
CS
FL
SHUT OFF AT OUTLET TO REF.GAS DR

IER-1
PIPE LINE
40
MKG 69
AA 509
GAS VALVE
50
1.6
CS
FL
SHUT OFF AT INLET TO REF. GAS DR

IER-2
PIPE LINE
41
MKG 69
AA 510
GAS VALVE
50
1.6
CS
FL
SHUT OFF AT OUTLET TO REF.GAS D

RIER-2
PIPE LINE
42
MKG 69
AA 505
GAS VALVE
50
1.6
CS
FL
SHUT OFF AT INLET TO OIL TRAP IN

GAS DRIER INL.
PIPE LINE
43
MKG 69
AA 508
GAS VALVE
15
1.6
CS
SC
SHUT OFF IN OIL TRAP DRAIN
PIPE LINE
44
MKG 69
AA 506
GLOBE VALVE
8
1.6
CS
SC
INLET OF DEW POINT METER FROM

GAS DRIER OUTLET
PIPE LINE
45
MKG 69
AA 507
GLOBE VALVE
8
1.6
CS
SC
INLET OF DEW POINT METER FROM

CASING GAS
PIPE LINE
46
MKG69
AA 504
MKG69
AA511
GAS VALVE
50
1.6
50
1.6
CS
FL
CS
FL
SHUTOFF AT OUTLET OF GAS

RECIRCULATING BLOWER
SHUTOFF AT INLET OF GAS
PIPE LINE
50
1.6
CS
FL
SHUTOFF IN BYPASS TO GAS

47
48
MKG69
AA505
2.1-7212-10550/2
0209E
GAS VALVE
GAS VALVE
PIPE LINE
PIPE LINE
PIPE LINE
Turbogenerators
CO 2 Vaporiser
Description
1
General
CO 2 is used to displace air from the generator
before hydrogen filling and to displace hydrogen from
the generator before filling the generator with air.
Since the CO 2 is available in the liquid state, it
must be expanded into a gas before use. The CO 2 is
expanded in a CO 2 vaporiser located on the gas valve
rack.To prevent icing of the vaporiser it is electrically
heated.
2
Design features and mode of operation
The CO 2 vaporiser consists of a tubular housing

closed by flanges at both ends. One flange carries
electrical heating elements which are connected to
terminals in the terminal box mounted external to the
flange. The opposite flange contains the inlet and
12
Fig.1
11
1
2
3
4
5
6
outlet to the cooled copper pipe of the evaporator.

The horizontally arranged housing is
filled with heat transmitting liquid to ensure a better
heat transfer to the copper pipe coil and thus to the
CO 2 flowing through the pipe coil.
The heat transfer liquid is filled into the CO 2
vaporiser through the expansion vessel mounted on
top of the housing. For protection against excessive
pressures in the CO 2 line, one relief valve is arranged
before and after the CO 2 flash evaporator.
The orifice at the CO 2 out let of the expansion
vessel provides for an expansion of the CO 2 obtained
from the bottles to a pressure of 25 to 7 psig. Heating
of the CO 2 in the copper pipe coil is sufficient to
prevent icing of the expansion device at the prevailing
flow velocities.
Vent for heat transmitting liquid

Copper pipe coil
Insulation
Expansion vessel
Relief valve before CO 2 vaporiser
Shutoff valve before CO 2 vaporiser
10
9
7
8
9
10
11
12
CO2 inlet
CO2 outlet
Housing
Heating element
Drain for heat transfer liquid
Terminal box
CO 2 Vaporiser
BHEL, Haridwar
2.1-7230-10550/1
0209 E
Turbogenerators
Gas Dryer (RefrigerationType)
Description
For hydrogen gas drying, 2 nos. Refrigeration gas driers
are available. Either of these two can be selected for the
gas drying operation, by suitably operating the following
valves, to bring in circuit either drier-1 or drier-2:
MKG69 AA501
MKG69 AA504
At inlet of Refrigeration gas drier-1

At outlet of Refrigeration gas drier-1
MKG69 AA 506
MKG69 AA507
At inlet of Refrigeration gas drier-2

At outlet of Refrigeration gas drier-2
The Refrigeration gas drier is to be operated for a total

period of 8 hours in 24 hours duration. This can be
suitably selected on the timer available on the drier.
BHEL, Haridwar
After the operation of the Refrigeration drier, the

condensate gets collected in the condensate chamber,
which can be observed through the glass window.
Drain the condensate chamber once every 24 hours.
For draining, first open the upper valve and let the
condensate flow from the condensate chamber and
collect in the pipe. Then close this upper valve and
open the lower valve to drain the condensate. This is
done to ensure that no hydrogen leakage takes place
from the generator system.
For further details, refer O&M manual for the
Refrigeration gas drier
2.1-7270-10550/1
0209 E
Turbogenerators
Description
free, mechanically clean
-distilled water
-fully de-mineralised water from boiler feed water
treatment plant
-condensate
Since the primary water comes into direct contact
with the high-voltage stator winding, it must have an
electrical conductivity below a value of 2 mho/cm. The
water in the primary water circuit is therefore treated in a
water treatment system. Fully de-mineralised water from
the boiler feed water treatment plant and condensate may
only be used if no chemicals, such as ammonia,
hydrazine, phosphate, etc. were added to the water or
condensate.
General
The losses occurring in the stator windings,
terminal bushings and phase connectors are
dissipated through direct water cooling. Since the
cooling water is the primary coolant to dissipate the
losses, it is designated as primary water.
The primary water system basically consists of the
following components:
-Primary water supply unit
-Primary water coolers
-Primary water valve rack
-Primary water tank
The primary water supply unit combines the
following components for primary water supply to the
generator:
Primary water pumps
Primary water filters
Conductivity transmitter
Water treatment system
Flow, pressure and temperature transmitters.
2
Primary Water Circuit

Fig. 1 shows a simplified schematic of the primary
water system. Note that the diagram shows that the
external portion of the system may be operated through
a bypass line, with no primary water flowing through the
water-cooled generator components.
The primary water is circulated by one of the two
pumps on the primary water supply unit. Both primary
water pumps are of full-capacity type. The electric control
Primary Water Quality

The primary water system may be filled with oxygen-
12
9
11
8
12
1
2
3
4
5
6
7
8
9
10
4
5
11
12
Primary water tank

Pressure regulator
Waste gas to atmosphere
Pump
Cooler
Filter
Bypass line
Cooling water for stator
winding
Ion exchanger
Cooling water for main
bushings
and phase connector
Teflon hose
Cooling water
manifold
11
Fig.1
10
Simplified schematic of the primary water system
BHEL, Haridwar
Primary water circuit-General

Coolant flow: Stator winding
Coolant flow: Main bushings
and phase connectors
Water treatment
Waste gas
2.1-7300-10550/1
02090 E
circuit of the pumps is arranged so that either pump may

be selected for normal service.
The primary water is drawn from the primary water
tank and passes to a primary water manifold (inlet) via
coolers and filters and from there to the stator bars via
teflon hoses. The primary water leaving the stator
winding is passed through similar teflon hoses to another
primary water manifold (outlet) and is then returned to
the primary water tank. A separate flow path from a point
before the stator winding inlet cools the bushings and
phase connectors.
4
Primary Water Tank

The primary water tank is mounted on the stator
frame on anti-vibration pads and is covered by the
generator lagging. The purpose of primary water tank is
to remove the hydrogen in the primary water after it
2.1-7300-10550/2
0209 E
leaves the stator winding. The hydrogen occurs in the

primary water due to diffusion through the teflon hoses
which connect the stator winding to inlet and outlet
manifolds.
Since the primary water tank is the lowest pressure
point in the system, has a relatively high water
temperature, a large water surface and sufficient
retention time, intensive de-gassing of the primary water
is ensured. The hydrogen gas in the primary water tank
is vented to atmosphere via the primary water valve rack
and a pressure regulator. The pressure regulator can be
adjusted to set the gas pressure in the primary water
tank.
The water level in the primary water tank can be read
at a water level gauge. Additionally, a capacitance type
measuring system is provide for activating an alarm at
minimum and maximum water level.
Turbogenerators
Description
SL
VALVE
NO. DESIG
TYPE OF VALVE
NB mm
NP MPA
BODY mat
END conn
FUNCTION
LOCATIOIN
MKF 12
AA 001
N- R VALVE
100
1.6
SS
FL
NON RETURN AT OUTLET OF STATOR

WATER PUMP-1
P&F UNIT
MKF 12
AA 501
GLOBE VALVE
100
2.5
SS
FL
INLET TO STATOR WATER PUMP-1 MKF

12/AP001
P&F UNIT
MKF 12
AA502
NEEDLE VALVE
10
2.5
SS
SC
DRAIN VALVE BEFORE PUMP-1
P&F UNIT
MKF 12
AA 504
GLOBE VALVE
100
2.5
SS
FL
OUTLET OF STATOR WATER PUMP-1
P&F UNIT
MKF 22
AA001
N- R VALVE
100
1.6
SS
FL
NON RETURN AT OUTLET OF STATOR

WATER PUMP-1
P&F UNIT
MKF 22
AA 501
GLOBE VALVE
100
2.5
SS
FL
INLET TO STATOR WATER PUMP-1 MKF

12/AP001
P&F UNIT
MKF 22
AA502
NEEDLE VALVE
10
2.5
SS
SC
DRAIN VALVE BEFORE PUMP-2
P&F UNIT
MKF 22
AA 504
GLOBE VALVE
100
2.5
SS
FL
OUTLET OF STATOR WATER PUMP-1
P&F UNIT
MKF 36
AA 488
DOZING VALVE
25
1.6
SS
FL
FEED VALVE AFTER DOSING PUMP
ALK. UNIT
10 MKF 36
AA 495
GLOBE VALVE
25
1.6
SS
FL
SHUTOFF VALVE FOR ALKALISER UNIT
PIPE LINE
11 MKF 36
AA 497
NEEDLE VALVE
15
2.5
SS
SC
VENT VALVE AT ALKALISER UNIT
PIPE LINE
12 MKF 52
AA501
GLOBE VALVE
100
2.5
SS
FL
PRIMARY WATER SHUT OFF VALVE BEF

ORE COOLER-1
PIPE LINE
13 MKF 52
AA502
GLOBE VALVE
100
2.5
SS
FL
PRIMARY WATER SHUT OFF VALVE BEF

ORE COOLER-2
PIPE LINE
14 MKF 52
AA511
GLOBE VALVE
100
2.5
SS
FL
PRIMARY WATER SHUT OFF VALVE AFT

ER COOLER-1
PIPE LINE
15 MKF 52
AA512
GLOBE VALVE
100
2.5
SS
FL
PRIMARY WATER SHUT OFF VALVE AFT

ER COOLER-2
PIPE LINE
16 MKF 52
AA521
NEEDLE VALVE
15
2.5
SS
SC
PRIMARY WATER DRAIN VALVE FOR CO

OLER-1
PIPE LINE
17 MKF 52
AA 522
NEEDLE VALVE
15
2.5
SS
SC
PRIMARY WATER DRAIN VALVE FOR CO

OLER-2
PIPE LINE
18 MKF 52
AA 531
NEEDLE VALVE
10
2.5
SS
SC
PRIMARY WATER VENT VALVE FOR COO

LER-1
PIPE LINE
19 MKF 52
AA 532
NEEDLE VALVE
10
2.5
SS
SC
PRIMARY WATER VENT VALVE FOR COO

LER-2
PIPE LINE
20 MKF 52
AA 541
NEEDLE VALVE
15
2.5
SS
SC
PRIMARY WATER VENT VALVE BEFORE

COOLERS
PIPE LINE
21 MKF 52
AA544
NEEDLE VALVE
15
2.5
SS
SC
PRIMARY WATER DRAIN VALVE (MANIF

OLD)
PIPE LINE
22 MKF 52
AA 545
NEEDLE VALVE
10
2.5
SS
SC
PRIMARY WATER VENT VALVE (MANIFO

LD)
PIPE LINE
23 MKF 52
AA 551
NEEDLE VALVE
15
2.5
SS
SC
COOLING WATER DRAIN VALVE AT COO

LER-1
PIPE LINE
BHEL, Haridwar
2.1-7312-10550/1
0209E
SL
VALVE
NO. DESIG
TYPE OF VALVE
NB mm
NP MPA
BODY mat
END conn
FUNCTION
LOCATIOIN
24 MKF 52
AA 552
NEEDLE VALVE
15
25.0
SS
SC
COOLING WATER DRAIN VALVE AT COO

LER-2
PIPE LINE
25 MKF 52
AA 561
NEEDLE VALVE
10
2.5
SS
SC
COOLING WATER VENT VALVE AT COOL

ER-1
PIPE LINE
26 MKF 52
AA 562
NEEDLE VALVE
10
2.5
SS
SC
COOLING WATER VENT VALVE AT COOL

ER-2
PIPE LINE
27 MKF 52
AA 578
NEEDLE VALVE
15
2.5
SS
SC
VENT VALVE AFTER PW COOLERS
PIPE LINE
28 MKF 52
AA 580
GLOBE VALVE
100
2.5
SS
FL
INLET TO WATER FILTER-1
P&F UNIT
29 MKF 52
AA 581
NEEDLE VALVE
15
2.5
SS
SC
DRAIN VALVE AT FILTER-1
P&F UNIT
30 MKF 52
AA 582
NEEDLE VALVE
10
2.5
SS
SC
VENT VALVE AT FILTER-1
P&F UNIT
31 MKF 52
AA 583
GLOBE VALVE
100
2.5
SS
FL
OUTLET FROM WATER FILTER-1
P&F UNIT
32 MKF 52
AA 590
GLOBE VALVE
100
2.5
SS
FL
INLET TO WATER FILTER-2
P&F UNIT
33 MKF 52
AA 591
NEEDLE VALVE
15
2.5
SS
SC
DRAIN VALVE AT FILTER-2
P&F UNIT
34 MKF 52
AA 592
NEEDLE VALVE
10
2.5
SS
SC
VENT VALVE AT FILTER-2
P&F UNIT
35 MKF 52
AA 593
GLOBE VALVE
100
2.5
SS
FL
OUTLET FROM WATER FILTER-2
P&F UNIT
36 MKF 60
AA 001
RELIEF VALVE
25
2.5
SS
FL
RELIEF VALVE IN MAKE UP LINE
P&F UNIT
37 MKF 60
AA 003
N- R VALVE
25
1.6
SS
FL
CHECK VALVE IN MAKE UP LINE
P&F UNIT
38 MKF 60
AA 501
REG. VALVE
25
2.5
SS
FL
MAKE UP INLET VALVE
PIPE LINE
39 MKF 60
AA 201
GLOBE VALVE
25
2.5
SS
FL
MAKE UP DRAIN VALVE
PIPE LINE
40 MKF 60
AA 502
REG. VALVE
25
2.5
SS
FL
CONTROL VALVE FOR WATER TREATMEN

T SYSTEM
P&F UNIT
41 MKF 60
AA 503
NEEDLE VALVE
10
2.5
SS
SC
VENT VALVE BEFORE ION-EXCHANGER
P&F UNIT
42 MKF 60
AA 506
GLOBE VALVE
25
2.5
SS
FL
SHUT OFF VALVE IN MAKE UP LINE
P&F UNIT
43 MKF 60
AA 509
GLOBE VALVE
25
2.5
SS
FL
SHUT OFF VALVE AFTER ION-EXCHANG

ER
P&F UNIT
44 MKF 60
AA 510
NEEDLE VALVE
10
2.5
SS
SC
DRAIN VALVE AFTER ION-EXCHANGER
P&F UNIT
45 MKF 60
AA 511
NEEDLE VALVE
10
2.5
SS
SC
DRAIN VALVE AT FINE FILTER
P&F UNIT
46 MKF 60
AA 512
NEEDLE VALVE
10
2.5
SS
SC
VENT VALVE AT FINE FILTER
P&F UNIT
47 MKF 60
AA 513
GLOBE VALVE
25
2.5
SS
FL
SHUT OFF VALVE AFTER FINE FILTER
P&F UNIT
48 MKF 60
AA 517
NEEDLE VALVE
10
2.5
SS
SC
DRAIN VALVE FOR WATER TREATMENT

SYSTEM
P&F UNIT
2.1-7312-10550/2
0209E
Turbogenerators
Description
SL
VALVE
NO. DESIG
TYPE OF VALVE
NB mm
NP MPA
BODY mat
END conn
FUNCTION
LOCATIOIN
49 MKF 60
AA 519
GLOBE VALVE
25
2.5
SS
FL
SHUT OFF VALVE AFTER WATER TREAT

MENT SYSTEM
P&F UNIT
50 MKF 60
AA 520
GLOBE VALVE
25
2.5
SS
FL
BY PASS VALVE IN MAKE UP LINE
P&F UNIT
51 MKF 60
AA 522
NEEDLE VALVE
10
2.5
SS
SC
DRAIN PRIMARY WATER MAKE UP LINE
P&F UNIT
52 MKF 80
AA 121
GLOBE VALVE
100
2.5
SS
FL
SHUT OFF AT INLET TO GEN.
P.W.TANK
53 MKF 80
AA 503
GLOBE VALVE
100
2.5
SS
FL
SHUT OFF IN MAIN CIRCUIT DISCHAR

GELINE
P.W.TANK
54 MKF 80
AA 504
GLOBE VALVE
100
2.5
SS
FL
SHUT OFF VALVE FOR GEN. BY PASS
P.W.TANK
55 MKF 01
AA 321
WATER VALVE
20
1.6
SS
FL
SHUT OFF VALVE BEFORE WATER LEVE

L GAUGE,TOP
P.W.TANK
56 MKF 01
AA 311
WATER VALVE
20
1.6
SS
FL
SHUT OFF VALVE BEFORE WATER LEVE

L GAUGE,BOTTOM
P.W.TANK
57 MKF 01
AA 326
WATER VALVE
20
1.6
SS
FL
SHUT OFF VALVE BEFORE LEVEL TRAN

SMITTER,TOP
P.W.TANK
58 MKF 01
AA 316
WATER VALVE
20
1.6
SS
FL
SHUT OFF VALVE BEFORE LEVEL TRAN

SMITTER,BOTTOM
P.W.TANK
59 MKF 01
AA 210
GLOBE VALVE
10
2.5
SS
SC
DRAIN VALVE AT LEVEL TRANSMITTER
P.W.TANK
60 MKF 01
AA 251
WATER VALVE
20
1.6
SS
FL
VENT VALVE AT LEVEL TRANSMITTER
P.W.TANK
61 MKF 01
AA 306
WATER VALVE
20
1.6
SS
FL
SHUT OFF VALVE FOR INLET TO

LEVEL TRANSMITTER
P.W.TANK
62 MKF 01
AA 301
WATER VALVE
20
1.6
SS
FL
SHUT OFF FOR OUTLET FROM LEVEL

TRANSMITTER
P.W.TANK
63 MKF 81
AA 502
REG. VALVE
20
1.6
SS
FL
FOR NITROGEN FILLING
P.W.TANK
64 MKF 82
AA 001
GLOBE VALVE
100
1.6
SS
FL
SHUT OFF VALVE IN PRIMARY WATER

OUTLET OF STATOR WDG
P.W.TANK
65 MKF 82
AA 501
REG. VALVE
100
1.6
SS
FL
REGULATING VALVE BEFORE STATOR

WINDING
PIPE LINE
66 MKF 82
AA 504
NEEDLE VALVE
15
2.5
SS
SC
SHUT OFF VALVE BEFORE FLOW TRANS

MITTER AT STATOR OUT
PIPE LINE
67 MKF 82
AA 502
NEEDLE VALVE
10
2.5
SS
SC
DRAIN VALVE BEFORE MKF82/AA501
PIPE LINE
68 MKF 82
AA 505
NEEDLE VALVE
15
2.5
SS
SC
SHUT OFF VALVE AFTER FLOW TRANSM

ITTER AT STATOR OUT
PIPE LINE
69 MKF 82
AA 507
NEEDLE VALVE
15
2.5
SS
SC

ITTER AT STATOR OUT
PIPE LINE
70 MKF 82
AA 508
NEEDLE VALVE
15
2.5
SS
SC
SHUT OFF VALVE FOR PRESS. MEAS

BEFORE STATOR WDG
PIPE LINE
71 MKF 82
AA 509
NEEDLE VALVE
15
2.5
SS
SC

PIPE LINE
BHEL, Haridwar
2.1-7312-10550/3
0209E
SL
VALVE
NO. DESIG
TYPE OF VALVE
NB mm
NP MPA
BODY mat
END conn
FUNCTION
LOCATIOIN
72 MKF 82
AA 510
NEEDLE VALVE
15
2.5
SS
SC
SHUTR OFF VALVE AFTER FLOW TRANS

73 MKF 82
AA 512
NEEDLE VALVE
10
2.5
SS
SC
ISOLATION VALVE FOR D.P.GAUGE
GEN.
74 MKF 82
AA 513
NEEDLE VALVE
10
2.5
SS
SC
ISOLATION VALVE FOR D.P.GAUGE
GEN.
75 MKF 83
AA 501
REG. VALVE
40
1.6
SS
FL
REGULATING VALVE BEFORE BUSHING
PIPE LINE
76 MKF 83
AA 502
GLOBE VALVE
40
1.6
SS
FL
SHUT OFF VALVE AFTER BUSHING
PIPE LINE
77 MKF 83
AA 503
NEEDLE VALVE
15
2.5
SS
SC

MITTER MKF83/CF001A
PIPE LINE
78 MKF 83
AA 504
NEEDLE VALVE
15
2.5
SS
SC

ITTER MKF83/CF001A
PIPE LINE
79 MKF 83
AA 505
NEEDLE VALVE
15
2.5
SS
SC

MITTER MKF83/CF011A
PIPE LINE
80 MKF 83
AA 506
NEEDLE VALVE
15
2.5
SS
SC

ITTER MKF83/011A
PIPE LINE
81 MKF 83
AA 507
NEEDLE VALVE
15
2.5
SS
SC

MITTER MKF83/CF021A
PIPE LINE
82 MKF 83
AA 508
NEEDLE VALVE
15
2.5
SS
SC

ITTER MKF83/CF021A
PIPE LINE
83 MKF 83
AA 513
NEEDLE VALVE
15
2.5
SS
SC

MITTER MKF83/CF001B
PIPE LINE
84 MKF 83
AA 514
NEEDLE VALVE
15
2.5
SS
SC

ITTER MKF83/CF001B
PIPE LINE
85 MKF 83
AA 515
NEEDLE VALVE
15
2.5
SS
SC

MITTER MKF83/CF011B
PIPE LINE
86 MKF 83
AA 516
NEEDLE VALVE
15
2.5
SS
SC

ITTER MKF83/CF011B
PIPE LINE
87 MKF 83
AA 517
NEEDLE VALVE
15
2.5
SS
SC

MITTER MKF83/CF021B
PIPE LINE
88 MKF 83
AA 518
NEEDLE VALVE
15
2.5
SS
SC

ITTER MKF83/CF021B
PIPE LINE
89 PGB 71
AA 501
GATE VALVE
250
1.6
CS
FL
COOLING WATER INLET OF COOLER-1
PIPE LINE
90 PGB 71
AA 502
GATE VALVE
250
1.6
CS
FL
COLING WATER INLET OF COOLER-2
PIPE LINE
91 PGB 72
AA 501
GATE VALVE
250
1.6
CS
FL
COOLING WATER OUTLET OF COOLER-1
PIPE LINE
92 PGB 72
AA 502
GATE VALVE
250
1.6
CS
FL
COOLING WATER OUTLET OF COOLER-2
PIPE LINE
93 MKF83
AA519
NEEDLE VALVE
15
2.5
SS
SC

MITTER MKF83/CF001A
PIPE LINE
94 MKF 83
AA 520
NEEDLE VALVE
15
2.5
SS
SC

ITTER MKF83/CF001A
PIPE LINE
95 MKF83
AA521
NEEDLE VALVE
15
2.5
SS
SC

MITTER MKF83/CF011B
PIPE LINE
96 MKF83
AA522
NEEDLE VALVE
15
2.5
SS
SC

ITTER MKF83/011A
PIPE LINE
2.1-7312-10550/4
0209E
PIPE LINE
Turbogenerators
Description
SL
VALVE
NO. DESIG
TYPE OF VALVE
NB mm
NP MPA
BODY mat
END conn
FUNCTION
LOCATIOIN
97 MKF83
AA523
NEEDLE VALVE
15
2.5
SS
SC

MITTER MKF83/CF021B
PIPE LINE
98 MKF83
AA524
NEEDLE VALVE
15
2.5
SS
SC

ITTER MKF83/CF021A
PIPE LINE
99 MKF 82
AA 514
NEEDLE VALVE
10
2.5
SS
SC
ISOLATION VALVE FOR WDG. INLET

PR.TRANSMITTER
PIPE LINE
Legend
FL
SC
CS
CR
GM
= Flanged
= Screwed
= Carbon Steel
= Cromium Steel
= Gun Metal
BHEL, Haridwar
2.1-7312-10550/5
0209E
Turbogenerators
Primary Water Pumps
Description
Design Features of Primary Water Pumps
The primary water for cooling the stator winding,
phase connectors and terminal bushings is circulated in a
closed system. To insure uninterrupted generator
operation, two full-capacity primary water pump sets
are provided. Either pump can be in service with other
acting as the stand-by. The standby pump is ready for
service and is automatically started without interrupting
the primary water circulation if the operating pump fails.
The primary water pumps are of a single-stage
centrifugal type with spiral casing and overhung impeller.
The pump suction is arranged axially, while the
BHEL, Haridwar
discharge is directed radially upwards. The spiral casing

is flanged to the bearing housing. The pump impeller is
provided with relief holes close to the hub so that no axial
thrust is carried by the bearings. The point where the pump
shaft passes through the pump casing is sealed by means
of a water-cooler sliding-ring gland. The cooling water is
supplied to the sliding-ring gland through a bypass line
from the pump discharge. The pump shaft is supported in
oil-lubricated anti-friction bearings. The oil level in the
bearing housing can be checked at an oil sight glass. The
pump is connected to the three-phase AC motor by a flexible
coupling covered by a coupling guard.
2.1-7320-10550/1
0209E
Turbogenerators
Primary Water Cooler
Description
The primary water cooler is of a straight tube type.
One tubesheet is stationary, while the other tubesheet
is a floating type. The floating tubesheet is sealed by
O-Ring.
Q
Tube bundle is free to move in response to

temperature change.
Q
The water channel at glands can be removed
without draining the primary water.
The tube bundle consists of round tubes expanded

into the tubesheets. Baffles installed on the tube
bundle result in a transverse flow of cooling water
across the tubes. This achieves a more efficient heat
BHEL, Haridwar
exchange and protects the tubes from vibrations and

bending.
The cooler shell is stainless steel with welded
flanges for connection to the flanges on the water
channels. The pipe nozzles for the primary water inlet
and outlet are welded to the shell. Each cooler shell
has vent and drain connection.
To vent and drain the tube side of the primary water
coolers, the water channels are equipped with vent
and drain connections.
Tube bundle, cooler shell and water channels are
bolted together. The larger tubesheet is mounted
between the shell flange and the water channel.
The primary water cooler sections are
interconnected on their primary water sides via valves.
2.1-7330-10550/1
0209E
Turbogenerators
Primary Water Treatment System
Description
The water treatment system serves to maintain a
low electrical conductivity of the primary water. The water
treatment system is connected in parallel to main circuit
and contains a mixed-bed ion exchanger with series
connected fine filter, an integrating flow meter and a
conductivity transmitter.
1.
Mixed-Bed Ion Exchanger
The mixed-bed ion exchanger consists of a tank

filled with anion and cation exchanger tank prevent the
escape of the resins into the piping system. A fine filter
after the ion exchanger retains any resin particles. An
alarm is initiated when the filter is contaminated.
The water flow passing through the ion exchanger
is measured by means of an integrating flow meter after
the filter. After the ion exchanger part of the flow is
passed through a conductivity transmitter for checking
the resin activity.
2.
Ion Exchanger Resins
The ion exchangers consist of chemically and highly

active synthetic resins.
The base substances of the exchanger resins are
polymers. The polymer in the cation exchanger contains
highly acid groups, while the polymer in the anion
exchanger is composed of highly basic groups.
BHEL, Haridwar
The exchanger resins are thus capable of accepting

ions from the primary water while simultaneously
releasing equivalent amounts of other ions (hydrogen
ions from the cation exchanger and hydroxyl ions from
the exchanger) to the primary water. This process takes
place through the ion exchanger.
The combination of highly acid cation exchangers
and highly basic cation exchangers forms a multitude of
small demineralization units, resulting in a high-purity
deionate.
The capacity of the mixed- bed of the ion exchanger
is limited by the number of ion it can exchange. This
capacity is primarily determined by the type of exchanger
used, but also depends on the quantity of reactivating
agent, the rate of flow and the water temperature.
When the resins are exhausted, they must be
replaced by new resins.
After removal from the primary water treatment
system, the resins can be reactivated.
3. Adding Make-up Water to the Primary Water
Circuit
Any loss of primary water in the total circuit can be
compensated for by introducing make-up water upstream
of the mixed-bed ion exchanger. The quantity of make up water is totaled at a volumetric water meter and is
indicative of the tightness of the primary water system.
2.1-7340-10550/1
0209 E
Turbogenerators
Description
1
General
Even with the use of oxygen-poor water, copper

corrosion in the primary water circuit of water-cooled
windings cannot be completely avoided; in isolated
cases the corrosion products reduce the crosssectional flow area of the water distribution system.
Besides, the formation of conductive deposits can
occur in the rotating water inlet and outlet hoses of
water-cooled rotor windings.
The severity of the corrosion attack can be largely
reduced by alkalizing the oxygen-poor water. Also, the
system becomes less susceptible to disturbances
resulting from air in-leakage.
Operating the generator with alkaline water at pH
8 to 9 improves its reliability land availability.
Operation at alkaline pH is ensured by a selfregulating alkalizer unit for feeding dilute sodium
hydroxide solution (NaOH).
2
Mode of Operation
Dilute sodium hydroxide solution is injected into

the low-conductivity primary water circuit where it
remains as dissolved, dissociated sodium hydroxide
solution. OH ion concentration determines the pH
value.
The ion exchanger in the water treatment system,
i.e. mixed bed filters with H + cation exchangers and
OH anion exchangers, remains in service
continuously. It removes all copper, iron, chlorine,
Alkalizer Unit
for Primary Water Circuit
carbon dioxide ions, etc. from the water, However, it

also removes the Na + ions from the sodium hydroxide
solution. This elimination of sodium, which is
proportional both to the volumetric flow rate through
the ion exchanger and the NaOH concentration, must
be compensated by continuous feeding of dilute
sodium hydroxide solution.
The alkalizer unit is arranged in the treatment
circuit Sodium hydroxide solution is injected into the
treatment circuit where it is mixed with the water in
the treatment circuit and raises its conductivity. The
water has the highest purity at the feed point
downstream of the ion exchangers. The conductivity
of the mixed water is only determined by the
concentration of the sodium hydroxide solution and
provides a reference quantity for the pH valve. The
relationship between pH and conductivity under ideal
conditions is illustrated in Fig.1
Following the admission on alkaline water, the
conductivity in the treatment circuit is monitored.
Conductivity must be maintained constant as required
for obtaining the specified alkalinity. Conductivity in
primary water circuit likewise approaches a constant
value after several hours.
3
The hydraulic circuit of the alkalizer units is

illustrated in Fig.2
The diaphragm pump extracts the NaOH solution
1
2
3
Fig. 1 Conductivity as a function of pH in water at 18oC
BHEL, Haridwar
Hydraulic Circuit
Diaphragm pump
NaOH tank
Feed valve
(check valve)
Fig.2
4
5
6
7
Level detector
Soda lime filter in tank vent
Vent
Treatment circuit
Schematic Diagram of Alkalizer Unit

2.1-7341-10550/1
0209 E
from the NaOH tank and delivers it to the treatment circuit

via a spring-loaded feed valve. The treatment circuit and
especially the fine filter down steam of the treatment
circuit homogenize the concentration of the solution
injected into the circuit by shot feeding. The volume flow
meter in the treatment circuit stops the diaphragm pump
via a limit switch when the volumetric flow rate drops
below a predetermined limit value. A vent on the
diaphragm pump enables starting without back pressure
5
4
3
2
1.
2.
3.
4.
5.
NaOH tank
NaOH tank cap
Diaphragm pump
NaOH tank vent with lime filter
Feed valve (check valve)
Fig. 3 Alkalyser Unit
2.1-7341-10550/2
0209 E
and venting of the unit for activation. Low NaOH level in

the tank is sensed with a level detector to activate an
alarm. A soda lime filter in the tank vent binds the carbon
dioxide contained in the inlet air and prevents the
formation of carbonates in the NaOH solution.
The tank has a capacity to store the sodium hydroxide
solution required for a service period of several months.
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
circuit under no-flow or empty conditions. The feed rate
of the diaphragm pump is controlled by changing the
stroking rate dependent on the conductivity in the
treatment circuit using a controller and stroking rate
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
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.
Via potential-isolated contacts the following alarm
conditions can be signalled to the control room either as
single alarm or as group alarm:
Q
low conductivity in leakage water circuit
Q
low conductivity in primary water circuit
Q
low NaOH level in tank
Q
loss of supply voltage.
Turbogenerators
Primary Water Filters
Description
1
Main Filter
The primary water system includes a strainer-type

main filter with magnet bars. The filter screen of the
strainer has a mesh size of 75 mm (3 mils) and is
supported by a perforated sheet-metal cylinder. The
magnet bars consist of a magnet carrier and a number
of permanent magnets. The high-grade permanent
magnets have an unlimited useful service life. The
magnet bars are arranged so that a strong magnetic
field is set up between them. The primary water must
pass through this magnetic field so that all iron particles
come within the range of the magnetic bars, and are
thus attracted and retained. The magnet bar are
protected by stainless steel sleeves. On contamination
of the strainer-type filter, which is indicated by an alarm
initiated at excessive differential pressure, the filter
should be cleaned.
BHEL, Haridwar
Fine Filter
A fine filed with one-way filter element giving a degree

of filtration of 5 mm (0.2 mils) is installed after the mixedbed ion exchanger in the primary water treatment system.
The filter element consists of cellulose fibres bonded
with synthetic resin to achieve stability. The fibres are
distributed in the element in such a way that their porosity
is highest on the outer circumference of the element and
decreases continuously towards the filer interior.
Therefore, filtration takes place in depth, and the solid
matter is held in the entire volume of the element. The
coarser particles are removed at the highly porous outer
surface, while the smaller particles are arrested in the
element body at varying depth, depending on their size.
On contamination of the filter, which is indicated by an
alarm initiated at excessive differential pressure, the filter
element should be removed and replaced with new one.
2.1-7343-10550/1
0209 E
Turbogenerators
Primary Water Main Filter
Description
1
2
3
4
5
Primary
water
inlet
Primary
water
outlet
10
13
1
2
3
4
5
6
12
11
Connection for vent pipe

Filter cover
O-ring
Compression spring
Clamping bolt (adjustablea0
Connections for differential
pressure indicator
7 Supporting cylinder (inner)
8 Filter screen
9 Supporting cylinder (outer)
10 Filter housing
11 Connection for drain pipe
12 Tension bolt
13 Magnet bar
Note: Internal details shown here are typical and may vary
from actual supply.
BHEL, Haridwar
2.1-7344-10550/1
0209 E
Turbogenerators
Primary Water Fine Filter
Description
1
2
3
4
5
6
Primary
water outlet
4
7
8
1
2
3
4
5
Connection for vent pipe

Differential pressure indicator
Filter cover
O-ring
Impulse pipe for differential
pressure indicator
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
10
11
Primary
water inlet
Note: Internal details shown here are typical and may vary
from actual supply.
BHEL, Haridwar
12
2.1-7345-10550/1
0209 E
Turbogenerators
Description
Primary water
outlet
Protective Screens at Primary Water Inlet

and Outlet
Primary water
inlet
Detail-X
Section A-B
Detail-Y
BHEL, Haridwar
2.1-7349-10550/1
0209 E
Turbogenerators
Coolant Temperature Control
Description
Due to load variations during operation and the resulting
thermal expansions and contractions, the generator is
subjected to stresses.
In order to reduce these stresses, the hydrogen cooling
circuit and the primary water cooling are each provided with
a temperature control system to control the cooling gas and
primary water temperatures so that the active generator
components are maintained at the proper temperature level.
The requirements for the temperature control systems are
described below :
cold
hot
mean =
Cold gas temperature or cold primary water

temperature
Hot gas temperature or hot primary water
temperature
Mean temperature of hot and cold gas or of
hot and cold primary water
- cold with generator carrying full load.
hot
The temperature rise at full load is the temperature

difference between the hot and cold hydrogen gas as given
in the hydrogen cooler design data or between the hot and
cold primary water as given in the design data of the primary
water cooler.
After start-up and run-up to rated speed, the cooling water
supply to the hydrogen coolers should be opened only when
the temperature of the hydrogen gas has reached the preset
cold gas reference. The temperature difference between cold
gas and hot gas is determined by the no-load losses.
The cooling water supply to the primary water coolers
should be opened only when the generator is carrying load,

since only then current-dependent heat losses will have to
be dissipated.
The temperature control systems are cold coolant
temperature control schemes with variable set point as a
function of the stator current. Set point adjustment is selectable
between I and I2 or with an exponent between one and two.
With rising stator current, the set point is reduced, so that the
mean value (mean) of hot and cold coolant temperatures
assumes a nearly constant value, as shown in Fig. 1.
The difference between the setting values of the two set
points corresponds to half the temperature rise of the
hydrogen cooling gas at no-load, with 5-10 K (9-180F) to be
taken as a guiding value.
In order to maintain a low temperature level in the
generator, the reference should be set at the lowest possible
value, ensuring that the cold coolant temperature will not drop
below the minimum level of 100C (500F) even when the
generator is carrying the full load.
Parallel shifting of the curves shown in Fig. 1 is possible
by adjustment of the cold gas reference. The temperature of
cold primary water must, however, always be higher than cold
hydrogen cooling gas over the entire load range of the
generator in order to avoid any condensation of moisture
contained in the gas on the generator components carrying
primary water.
The control valve must be absolutely tight when in the
closed position to ensure that the cooling gas temperature
will not drop while the generator is being shut down.
t
(0F)
Room
temperature
Generator load l/lN (%)

Fig. 1 Coolant temperature as a Function of Generator load
BHEL, Haridwar
2.1-8010-10550/1
0209 E
Turbogenerators
Safety Equipment
Description
for Hydrogen Operation
The use of hydrogen as coolant in the generator

calls for special safety equipment to ensure that
hazardous operating conditions which might endanger
personnel or the plant will not occur.
The safety and protective measures provided for
the generator are described in detail in this section.
The required measuring and alarm equipment is
discussed elsewhere in this manual [1].
During normal operation, leaks may develop which
result in a continuous escape of hydrogen. Long time
experience has shown that no operational restrictions
are required as long as the hydrogen losses do not
3
exceed 12 m (s.t.p.) during any 24 hour period. The
surroundings of the generator and the hydrogen
supply system should not be endangered if
engineering principles were followed in plant design
and provision is made for ample ventilation of these
areas so that the formation of localized hydrogen
pockets or explosive hydrogen-air mixtures is
precluded.
Particular precautions are taken with respect to a
failure of the seal oil system. A special vapor
exhauster creates a slight vacuum in the generator
bearing compartments to prevent the escape of oil
vapor from the bearing compartments along the shaft.
Any hydrogen collecting in the bearing compartment
will be drawn off by the exhauster and vented.
Operation of the exhauster is monitored by a flow
transmitter with limit switch. If the exhauster fails, the
second exhauster on standby is automatically started.
To prevent the hydrogen which enters the bearing
compartment from escaping via the oil drain pipes,
the drain oil is returned to the turbine oil tank via the
seal oil storage tank and a loop seal. This loop seal
is permanently filled with oil to prevent the escape of
gas. The loop is designed to withstand momentary
pressure surges.
The bearing oil circuit and the seal oil circuit are
separated from each other.

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 ta n k
(hydrogen side circuit) passes into the seal oil storage
tank. After remaining in this tank for a predetermined
time, the degassed oil is admitted to the turbine oil
tank together with the bearing oil via a loop seal.
The measures outlined above have the following
effects:
Q
The bearing compartments and the oil drain pipes

are ventilated continuously so that no explosive
hazard will arise during normal operation.
During normal operation, practically no hydrogen
will enter the turbine lube oil tank via the loop seal
together with the seal oil drained from the shaft
seals, since the hydrogen is already extracted in
the seal oil storage tank.
The isolating action of the loop seal prevents the
hydrogen escaping due to small leakages from
flowing into the turbine through the only partly filled
oil drain pipe.
The seal oil storage tank is continuously vented

via the vapor exhauster provided for the bearing
compartments. The exhauster creates a slight vacuum
in the seal oil storage tank so that the oil saturated
with hydrogen is degassed. After remaining in this tank
for a predetermined time, the degassed oil is admitted
to the turbine oil tank together with the bearing oil via
a loop seal.
This continuous ventilation of the seal oil storage
t a n k p r e v e n ts t h e f o r m a t i o n o f a n y e x p l o s i v e
hydrogen-air-mixture.
To avoid any danger to the unit to the hydrogen
supply, only two hydrogen bottles should be opened
if the bottle supply is used.
Also refer to the following section

[1] 2.1-8400
BHEL, Haridwar
Measuring devices and supervisory equipment
2.1-8310-10550/1
0209 E
Turbogenerators
List of Valves for Waste Gas System
Description
SL
VALVE
NO. DESIG
TYPE OF VALVE
NB mm
NP MPA
BODY mat
END conn
FUNCTION
LOCATIOIN
MKQ31
AA501
DIAPHRAGM VALVE
80
2.5
GM
FL
SHUT OFF AT INLET OF VAP.EXHAUST

ER-1
PIPE LINE
MKQ32
AA501
DIAPHRAGM VALVE
80
2.5
GM
FL
SHUT OFF AT INLET OF VAP.EXHAUST

ER-1
PIPE LINE
MKQ31
AA001
NON-RETURN
80
2.5
CS
FL
SHUT OFF AT OUTLET OF VAP.EXHAUS

TER-2
PIPE LINE
MKQ32
AA001
NON-RETURN
80
2.5
CS
FL
SHUT OFF AT OUTLET OF VAP.EXHAUS

TER-2
PIPE LINE
MKF91
AA003
SAFETY VALVE
6
2.5
CS
SC
SHUT OFF AT PW TANK EXHAUST
PIPE LINE
MKF91
AA506
GLOBE VALVE
20
2.5
CS
SC
PW TANK GAS EXHAUST
PIPE LINE
MKF91
AA513
GLOBE VALVE
20
2.5
CS
SC
PW TANK GAS EXHAUST
PIPE LINE
MKF91
AA505
GLOBE VALVE
20
2.5
CS
SC
PW TANK GAS EXHAUST
PIPE LINE
Legend
FL
SC
CS
CR
GM
= Flanged
= Screwed
= Carbon Steel
= Cromium Steel
= Gun Metal
BHEL, Haridwar
2.1-8312-10550/1
0209E
Turbogenerators
Generator Waste Fluid System
Description
The Waste fluid system serves for controlled
discharge of fluid to be drained from the
seal oil system

generator liquid level detection system
waste gas system
as a result of venting or minor leaks.

In addition, the fluids to be drained for carrying
out repair or maintenance work in the above areas
are discharged to the waste fluid system.

Any waste fluid collected is discharged to the
waste fluid system either directly or via collecting
vessels that are integrated in the respective systems.
In the waste fluid system, the fluid is collected in
a pipe section of large nominal size. This pipe section
is fitted with a shutoff valve for fluid draining and a
level detector for activating a high level alarm. The
fluid drained should be transferred to the waste oil
tank of the power station for controlled waste disposal.
Fig. 1 Generator Waste Fluid System
BHEL, Haridwar
2.1-8315-10550/1
0209E
Turbogenerators
Generator Mechanical Equipment
Description
Protection
Tripping Criteria
Turbogenerators require comprehensive safety and

supervisory devices to prevent damage and long forced
outages.
The protective equipment detects dangerous
operation conditions at an early stage and prevents them
from developing into damaging conditions. The
protection relieves the operating personnel from making
the necessary fast decisions.
The following criteria are sensed by the generator
mechanical equipment protection and processed by the
generator protection circuits:
1.1 High Cold Gas Temperature in Generator
1.2 Liquid in Generator Terminal Box
terminal bushing and phase connectors. Secondary

cooling water flows through the hydrogen coolers located
in the stator end shields. Generator operation will only
be endangered by these coolants in the event of large
leakages. As a result of the high hydrogen pressure.
Little water will emerge from a small leak. Hydrogen will,
however, enter into the water circuit. The hydrogen loss
can be derived from the hydrogen consumption of the
generator.
Operation of the generator will be seriously
endangered in the event of a major ingress of water which
will collect in the generator terminal box. Due to the
restricted volume of the compartment the liquid can rise
quickly, resulting in a terminal short-circuit or ground
fault. In order to prevent such a failure, two level
detectors are connected to the 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

1.4 High Seal Oil Inlet Temperatures
1.5 High Primary Water Inlet Temperature
1.6 Low Primary Water Flow Rate at Sector Outlet
1.7 Low Primary Water Flow Rate at Bushing Outlets
Each of these criteria activates a turbine trip. The
generator is disconnected from the system and deexcited through the two-channel reverse power relay.
2
Protection Circuits
2.3 Exciter Unit Protection Against Overheating

The protection circuit covering criterion 1.3 prevents
overheating of the exciter in case of insufficient cooling
(failure of exciter coolers).
2.4 Shaft Seal protection Against High Seal Oil Inlet
Temperature
High seal oil inlet temperature endangers proper
sealing performance of the shaft seals. High seal oil
temperature, as may, for instance, be experienced on
failure of the seal oil coolers, results in a reduction of oil
viscosity. The gas may penetrate the seal oil film at the
shaft seal contact face and allow the hydrogen to enter
the bearing compartment.
2.1 Generators Protection Against Overheating by

High Cold Gas Temperature
The protection circuit covering criterion 1.1 prevents
insufficient cooling and thus overheating of the hydrogencooled components in case of high cooling gas
temperature.
2.5 Protecting of Water-Cooled Components Against

Overheating
The protection circuit covering criteria 1.5 prevents
insufficient cooling and thus overheating of the watercooled components in case of high primary water inlet
temperature.
2.2 G enerator Protection Against Internal Ground

Fault or Terminal Short-Circuit
The generator may be damaged by leaks in
components through which primary or secondary cooling
water or seal oil flows inside the generator.
Primary water flows through the stator winding,
2.6/2.7 Protection of Water-Cooled Components

Against Insufficient primary Water Supply
The protection circuits covering criteria 1.6 to 1.7
prevent overheating and damage to the stator winding,
phase connectors and bushing in case of insufficient
primary water supply.
BHEL, Haridwar
2.1-8320-10550/1
0209 E
Turbogenerators
Tripping Scheme for Generator
Description
Mechanical Equipment Protection
TT
GCB
FB
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
GCB
FB
A
=
=
=
=
Turbine trip
Generator Circuit breaker
Field breaker
Alarm
Alarm is initiated when the electrical generator protection system is tripped. Individual alarms for each criterion are provided.
BHEL, Haridwar
2.1-8321-10550/1
0209 E
Turbogenerators
Description
Generator Mechanical Equipemtn Protection

Two-out-of-Two Protection Circuit
With Functional Test
Plant
enable
CSA11 = non coincidence module

CSF11 = functional test module
CSV11 = logic module
CSZ11 = pulse generator
BHEL, Haridwar
GS = limit value monitor

K1 = relay
MU = transducer
2.1-8323-10550/1
0209 E
Turbogenerators
Generator Electrical Protection
Description
Generators are high-quality machines for securing
the best possible continuity of power supply. In
addition to a suitable technical design and responsible
mode of operation, provision must therefore be made
for automatic protection facilities. This protection must
ensure a fast and selective detection of any faults in
order to minimize their dangerous effects.
The protective equipment must be designed so
that any serious fault will result in an immediate
disconnection and de-excitation of the generator.
Faults which do not cause any direct damage must
be brought to the attention of the operating staff,
enabling them to operate the unit outside the critical
range or to take precautionary measures for shutdown.
Generators may be endangered by short-circuits,
ground faults, overvoltages, under-excitation and
excessive thermal stresses.
The following protective equipment is
recommended:
Rapid fault detection is required for the following

reasons:
Q
An interruption of the field circuit with arcing
releases high amounts of energy in the form of
heat which may cause severe burning.
Q
A one-line-to-ground fault may develop to a double
ground fault, resulting in dangerous magnetic
unbalances, especially on four-pole generators.
To minimize the consequential damage, it is
recommended to provide two pole and four-pole
generators with a protection circuit featuring a delayed
response. In the core of four-pole generators, the rotor
ground fault protection must always operate of avoid
the hazard of sudden, extremely high vibrations due
to magnetic unbalances.
Relay time:
approximately 1 s
Differential protection
Breakdown of insulation between different stator
phase windings results in an internal short-circuit. The
fault is detected by a differential relay which initiates
immediate isolation and de-excitation of the generator.
In order to obtain a high sensitivity, the protected area
should include the generator only.
Operating value: 0.2-0.4/ N
Relay time:
< 60 ms
In certain cases, the generator may also be
included in the differential protection for the main
transformer and station service feeder. Generator
faults are then detected by two differential protection
devices.
2
Stator Ground Fault Protection

B r e a k d o w n o f i n s u l a t i o n b e t w e e n t h e s ta t o r
winding and frame results in a stator ground fault. If
possible, the stator ground fault protection should
cover the complete winding, including the neutral point
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
immediate isolation and de-excitation of the generator.
Relay time:
<1 s
The load resistance of a found transformer and

any required boost to raise the neutral point potential
should be selected so that ground current due to a
fault will amount to less than 15 A.
3
Under-excitation Protection
Failure of the voltage regulator, mal-operation of
the generator or transformer control system and
generator operation in a system with capacitive load
may result in a reduction of the excitation required to
e n s u r e s y s t e m s ta b i l i t y b e l o w a p r e d e t e r m i n e d
minimum value. Short-circuits or interruptions in the
field circuit result in a complete loss of field and thus
in instability of the generator. This causes higher
temperature rises in the rotor and core end portions,
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.
A momentary excursion beyond the steady-state
stability limit must not necessarily result in a loss of
stability. Therefore it is advisable to design the underexcitation protection so that a warning will be given
when the steady-state stability limit is reached. The
generator will be shut down after a few seconds only.
The protection must operate instantaneously if a
loss of field occurs when the steady-state stability limit
is reached.
If the loss of field cannot be detected directly (e.g.
exciters with rotating diodes), it is recommended to
introduce a second stator criterion covering the range
of the permeance values 1/ xd and 1/ x d and to provide
for instantaneous tripping when this criterion is
exceeded.
5
Over current Protection

System faults may result in inadmissible thermal
stressing of the generator. For this reason, an over
current protection should be provided which operates
Rotor Ground Fault Protection
BHEL, Haridwar
2.1-8330-10550/1
0209 E
on failure of the system protection.

A definite-time delay over current relay may be used
for this purpose, however, its relay time should longer
than that of the system protection.
Operating value: 1.3/N
Relay time:
6-8 s maximum
To avoid long relay times, it is recommended to equip
large generators with an inverse-time-delay (impedance
relay. This relay is energized by over current and
operates with long or short-time setting, dependent on
the location of the short-circuit.
If connected to the generator neutral point, the overcurrent protection serves as backup protection for the
differential protection.
6
Load Unbalance Protection

Generators operating in an interconnected system
are normally subjected to small load unbalances only.
However, all one and two line-to-ground faults occurring
in the system, phase breakages or circuit breaker failures
are in fact load unbalances which may result in unduly
high thermal stressing of the rotor.
It is recommended to provide a two-stage load
unbalance protection. When the continuously permissible
load unbalance is reached, an alarm is given, whereas
a time-dependent isolation from the system occurs when
this value is exceeded.
In case of large units, it is recommended to provide
a protection with unbalanced load/time characteristic.
Operating value and relay time should be matched to
the load unbalanced/time characteristic applicable to the
particular generator.
7
Rise-in-voltage Protection
Rejection of partial or complete system loads causes
a voltage rise, followed by an increase in the prime mover
speed. This may result in the generator and the
apparatus connected to it being endangered by unduly
high voltages. Mal-operation during manual voltage
regulation of the generator may also result in
inadmissible voltage stressing of these devices. Due to
the sudden voltage variations resulting from switching
operations, it is advisable, at least in the case of large
units, to provide a two-stage rise-in voltage protection,
i.e.:
Q
with high (1.45 UN ) o p e r a t i n g v a l u e a n d

instantaneous tripping;
with low (1.2 UN) operating value and delayed
tripping.
Under-Frequency Protection
Major disturbances in an interconnected system may
result in operation of the generator at under-frequency.
At rated voltage, the generator can be continuously
operated at rated k VA up to 95% of rated frequency.
To avoid excessive magnetic and thermal stressing,
it is recommended to provide an under-frequency
protection.
2.1-8330-10550/2
0209 E
Since the frequency deviation due to a system

disturbance is normally accompanied by a voltage
deviation, the protection should be designed on the basis
of the permissible load characteristic of the generator
on frequency and voltage deviations.
9
Reverse Power Protection

A rise in system frequency for any reason whatsoever
result in closing of the control valves, and the turbine is
driven by the motoring generator. Since the turbine is
then no longer supplied with cooling steam, the unit must
be disconnected from the system. The relay must be
provided with a time delay of approximately 20s to
prevent undesired response to system swings (long time
setting).
Specific faults in the turbine-generator interior initiate
emergency tripping. The steam supply to the turbine is
interrupted. A reliable criterion of perfectly tight closure
of the emergency stop valves is the flow of power from
the system back into the generator.
Disconnection of the unit from the system by the
generator circuit breaker with a time delay of 4s is only
permissible after the reverse power has been drawn by
the generator (short-time setting).
Operating value: about 50-80% of reverse power
Relay time:
longtime setting: approximately 20 s
short-time setting: approximately 4s
10 Overvoltage Protection
The use of surge inverters on the high-voltage side
of the unit transformer is considered sufficient for
protecting the generator against atmospheric over
voltage and switching surges in the system.
With a view to a possible flashover from the highvoltage winding to the low-voltage winding in the unit
transformer, it is, however, advisable to provide surge
diverters for the generator too, which should be
connected between the phases and ground.
Normally, the surge diverters are installed in the direct
vicinity of the unit transformer. It is assumed that
switching surges due to a load isolator or circuit breaker
connected between the generator and transformer will
not endanger the generator.
Care should be taken to provide explosion-proof
surge diverters or suitable constructional measures in
order to avoid danger to persons or nearby components.
Design principle:
Reseal voltage: approximately 1.2-1.4 UN
(allowing for power-frequency
overvoltage on load rejection)
Power-frequency
spark-over voltage:
approximately 2 UN
(<test voltage for stator winding,
e.g. VDE 0530,
U P = 2 UN + 1 kV)
Impulse spark-over
voltage
<4 U N
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.
BHEL, Haridwar
2.1-8331-10550/1
0209 E
Turbogenerators
Rotor Grounding System
Description
Grounding brushes are fitted to the turbine-end stator end shield to remove the static charges of the shafts.
The brush holders are arranged with 90 0 displacement, 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
2. Brush holder
BHEL, Haridwar
3. Rotor shaft
4. Turbine bearing
2.1-8350-10550/1
0209 E
Turbogenerators
Arrangement of Brush Holders for
Description
Rotor Grounding System
6
8
1
2
3
4
Brush holder
Grounding brush (Design A)
Grounding brush (Design B)
Brush spindle
BHEL, Haridwar
5
6
7
8
Insulation
Roror shaft
Labyrinth ring
End shield
2.1-8351-10550/1
0209 E
Turbogenerators
Operation
The supervisory equipment consists of alarms and
measuring devices. The measuring devices give a
visual indication of the system parameters, the alarm
devices initiate visual or audible signals in the event
of a controlled quantity falling below or exceeding the
predetermined limit values. In many cases, the
BHEL, Haridwar
Measuring Devices and Supervisory

Equipment
Introduction
measuring and alarm devices are combined to form
one supervisory.
Closely associated with the supervisory equipment
are regulating systems, automatic controls and
protective devices which provide for a reduction of
the manual supervisory work.
2.1-8400-10550/1
0209 E
Turbogenerators
Operation
1
Temperature Tranducers
Resistance Temperature Detectors
and Thermocouples
Resistance Temperature Detectors (RTDs)
RTDs 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 RTDs 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+ T)
where
R0 = reference resistance at 00C
= 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.
Fig. 1: Resistance Characteristics of Platinum RTDs 100

The standard reference resistance of the platinum
resistance element is 100 ohms. The temperature
coefficient amounts to =3.8510-3 degC-1 this being the
mean value for the range 0 -100 0C.
1.1 Circuit Connections
The two-wire connections so far commonly used involves
errors in case of leads. Long leads are exposed to different
temperatures, and the lead resistances then reach values in
the order of the resistance of the RTD element.
1.1.1 Three wire Connections
If a third lead is connected to the element in addition to
the two element leads, automatic compensation for lead
wire resistance including its changes can be achieved by
resistance of the two leads forming the pair to the element
are always the same.
1.1.2 Four-Wire Connection
If the two element leads are not alike or if the threewire method of compensation would be too costly a fourwire circuit should be used. Fig.2 shows the circuit diagram
of the four-wire method.
BHEL, Haridwar
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).
2
Thermocouples
Thermocouples are used for temperature

measurements on generator, e.g. to measure the generator
and exciter bearing temperatures. Thermocouples are
mainly employed where small time constants require fast
temperature indication.
2.1 Principle
Temperature measurement with thermocouples is
carried out as follows:
Two conductors of dissimilar materials, i.e. the
positive and the negative conductor (thermoelectric
elements) are joined at one end (hot junction) so as to
produce an electromotive force (emf), i.e. a
thermoelectric emf (in mV). The magnitude of the emf is
dependent upon the temperature difference between the
temperature to be measured and that of the other two
ends of the conductors.
To use the thermoelectric emf for temperature
measurement, the free ends of the conductors are exposed
to a constant temperature (cold junction temperature) and
connected to a milli-voltmeter calibrated in 0C.
2.1-8410-10550/1
0209 E
Thermocouple
Cu - NiCu
Fe - NiCu
Ni Cr - Ni
Pt Rh - Pt
Ni Cr- Constantan
1 Hot junction
2 Thermocouple
3 Compensating lead
Temperature limits
oC
-200
-200
0
0
0
4
5
6
7
+600
+900
+1200
+1600
+1000
Max. continuous
oC
400
700
1000
1300
400
Cold junction correction

Connecting cables
Milli volt meter
Compensating resister
Fig. 3: Thermocouples
Parameter
~4.3 mV/100 deg C
~5.3 mV/100 deg C
~4.1 mV/100 deg C
~0.6 mV/100 deg C
~6.3 mV/100 deg C
Colour codes
Neg. pole
Pos.pole
Red
Red
Red
Red
Red
Brown
Blue
Green
White
Purple
Indicator
Moving
coil
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.
To do this, add the thermoelectric emf due to the cold
junction temperature to the measured thermoelectric emf
and read measuring point temperature to obtain the total
thermoelectric emf .
Thermoelectric voltage Utherm in mV
60
50
40
30
20
NiCr-Const.
Cu-CuNi
Fe-CuNi
NiCr-Ni
10
PtRh-Pt
0
Fig.4: Voltage-temperature function for standardised

thermocouples
2.2 Compensating Leads

The compensating leads serve to extend the
thermocouple up to the cold junction. When exposed to
a temperature up to 200 0C they produce the same
thermoelectric emf as the associated thermocouple. See
DIN 43710 for calibration data and limits of error of
compensating leads.
The compensating leads used for the different
thermocouples are identified by colors:
Cu-CuNi brown
Fe-CuNi blue
NiCr-Ni
green
PtRh-Pt white
NiCr-Constantan red
The insulating sleeve of the positive lead is provided
withe a red mark in addition to the color code.
2.3 Cold Junction
For measuring a temperature by means of a
2.1-8410-10550/2
0209 E
1 Compensator
2 Genenerator
3 Double pole double throw switch
Fig.: 5 Circuit arrangement for connection of several
thermocouples
The cold junction can, however, also be implemented

by using a Pt100 RTD for determination of the actual
temperature. The temperature is referred to the
calibration figure for 0 o C by electronic means. The
electronic cold junction also avoids the temperature error
due to the junction between the compensating leads and
the copper leads.
To obtain a simpler circuit, the large number of
thermocouples used on the generator can be connected
to a double pole measuring point selector switch enabling
the respective thermocouple to be connected to a
compensator for measurement.
Supervision of Generator
Turbogenerators
Operation
The most essential measuring and supervisory
devices at the generator serve for:
-temperature monitoring
-detection of liquid in generator interior.
1
Temperature Monitoring
1.1 Stator Slot Monitoring

The slot temperatures are measured with resistance
temperature detectors (RTDS). This platinum measuring
wire is embedded in a molded plastic body which
provides for insulation and pressure relief.
The RTDS are embedded directly in the stator slots
between the bottom and top bars at points where the
highest temperature are expected.
The RTDS are characterized by a constant
temperature vs. resistance characteristic, high
mechanical strength and insensitivity to electrical and
magnetic fields.
1
2
3
4
1
2
3
4
5
Top bar
Resistance temperature detector
Separator
Bottom bar
Stator core
Stator Liquid Detection

Liquid (cooling water from hydrogen coolers, primary
water or seal oil) entering the generator housing is
sensed by level detectors assembled in gas tight housing
located on the seal oil valve rack. See Figs.2 and 3.
Fig. 2 Level detector

When pipes from several low-level points of the generator
are connected to a common level detector, sight glasses
are provided in the inlet pipe to identify the source of the
liquid.
The generator terminal box has two leakage detection
pipes acting on the generator protectors. The two pipes
extend serval inches above the bottom of the generator
terminal box and are interconnected so that both
detectors will respond if the box should be in an inclined
position.
These detectors are utilized as tripping criteria for
the generator mechanical equipment protection, whereas
all other detectors initiate only alarms.
1
Fig. 1 Stator slot resistance temperature detector
1.2 Cold and Hot Gas Temperatures

The temperature of the hot and cold gases are
measured by RTDS upstream and downstream of the
hydrogen coolers, and the limit values are sensed
downsteam of the coolers for use with the hydrogen
temperature control system.
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
turbine-end water manifold of the stator winding is
measured withe manifold of the stator winding is
measured with resistance temperature detectors. The
temperature detectors are mounted in the water manifold
in thermowell exposed to the primary water.
BHEL, Haridwar
4
1
2
3
4
Shutoff valve before level detector

Level detector
Sight glass
Shut off valve after level detector
Fig. 3
Combined arrangement of Level detectors in

Seal oil valve rack
2.1-8420-10550/1
0209 E
SL.
NO.
1
2
Turbogenerators
List of Valves
Operation
For Generator system
VLV
DESG
TYPE OF VALVE
MKA 24 Globe Valve

AA 511
MKA 24 Globe Valve
AA 521
NOM.
NOM BODY END FUNCTION
BORE PRESS MATL CONN
50
2.5
CS
FL
50
2.5
CS
FL
By-Pass of Valve
MKA 24/AA 501
By-Pass of Valve
MKA 24/AA 501
LOCATION
REMARKS
Sela Oil Valve
Rack
Sela Oil Valve
Rack
MKA 24
AA 502
Globe Valve
15
25.0
CS
SC
Outlet of Sight Glass

MKA 24/BR 506
Sela Oil Valve
Rack
MKA 24
AA 501
Globe Valve
50
2.5
CS
SC
Inlet of Sight Glass

MKA 24/BR 506
Sela Oil Valve
Rack
MKA 23
AA 512
Globe Valve
15
25.0
CS
SC

MKA 23/BR 516
Sela Oil Valve
Rack
MKA 23
AA 511
Globe Valve
50
2.5
CS
FL

MKA 23/BR 516
Sela Oil Valve
Rack
MKA 23
AA 502
Globe Valve
15
25.0
CS
SC

MKA 23/BR 506
Sela Oil Valve
Rack
MKA 23
AA 501
Globe Valve
50
2.5
CS
FL

MKA 23/BR 506
Sela Oil Valve
Rack
MKA 22
AA 502
Globe Valve
15
25.0
CS
SC

MKA 22/BR 506
Sela Oil Valve
Rack
10
MKA 22
AA 501
Globe Valve
50
2.5
CS
FL

MKA 22/BR 506
Sela Oil Valve
Rack
11
MKA 21
AA 502
Globe Valve
15
25.0
CS
SC

MKA 21/BR 506
Sela Oil Valve
Rack
12
MKA 21
AA 501
Globe Valve
50
2.5
CS
FL

MKA 21/BR 506
Sela Oil Valve
Rack
13
PGB 31
AA 574
Globe Valve
25
1.6
CS
FL
Cooler-D Inlet
Ventilation
Pipe Line
14
PGB 32
AA 571
Globe Valve
25
1.6
CS
FL
Cooler-A Outlet
Ventilation
Pipe Line
15
PGB 32
AA 572
Globe Valve
25
1.6
CS
FL
Cooler-B Outlet
Ventilation
Pipe Line
16
PGB 31
AA 572
Globe Valve
25
1.6
CS
FL
Cooler-C Inlet
Ventilation
Pipe Line
17
PGB 31
AA 573
Globe Valve
25
1.6
CS
FL
Cooler-C Outlet
Ventilation
Pipe Line
18
PGB 31
AA 551
Globe Valve
10
2.5
CS
SC
Cooler-A Drain
Pipe Line
BHEL, Haridwar
2.1-8423-10550/1
0209E
SL.
NO.
VLV
DESG
TYPE OF VALVE
19
PGB 31Needle Valve

AA 551
10
2.5
CS
SC
Cooler-B Drain
Pipe Line
20
PGB 31
AA 553
Needle Valve
10
2.5
CS
SC
Cooler-C Drain
Pipe Line
21
PGB 31
AA 554
Needle Valve
10
2.5
CS
SC
Cooler-D Drain
Pipe Line
22
PGB 31
AA 571
Globe Valve
25
1.6
CS
FL
Cooler-C Drain
Pipe Line
23
PGB 32
AA 504
Globe Valve
200
1.6
CS
FL
Shut off at Outlet of

Cooler-D
Pipe Line
24
PGB 32
AA 503
Globe Valve
200
1.6
CS
FL

Cooler-C
Pipe Line
25
PGB 32
AA 502
Globe Valve
200
1.6
CS
FL

Cooler-B
Pipe Line
26
PGB 32
AA 501
Globe Valve
200
1.6
CS
FL

Cooler-A
Pipe Line
27
PGB 31
AA 504
Globe Valve
200
1.6
CS
FL
Shut off at Inlet of

Cooler-D
Pipe Line
28
PGB 31
AA 503
Globe Valve
200
1.6
CS
FL

Cooler-C
Pipe Line
29
PGB 31
AA 502
Globe Valve
200
1.6
CS
FL

Cooler-B
Pipe Line
30
PGB 31
AA 501
Globe Valve
200
1.6
CS
FL

Cooler-A
Pipe Line
31
PGB 32
AA 573
Globe Valve
25
1.6
CS
FL
Cooler-C Outlet
Ventilation
Pipe Line
32
PGB 32
AA 574
Globe Valve
25
1.6
CS
FL
Cooler-D Outlet
Ventilation
Pipe Line
Legend
FL = Flaged
SC = Screwed
CS = Carbon Steel
SS = Stainless Steel
CA = Cast Steel
2.1-8423-10550/2
0209E
NOM.
NOM BODY END FUNCTION
BORE PRESS MATL CONN
LOCATION
REMARKS
Turbogenerators
Supervision of Bearings
Operation
1
Generator Bearing Temperatures
1
2
3
The generator bearing temperatures are measured

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
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
c o n d i t i o n , v i b r a t i o n p i c k u ps a r e l o c a t e d a t t h e
bearings. Measurement and recording of the
vibrations are performed in conjunction with the
turbine supervision. The overall turbine protection is
tripped when a predetermined amplitude is exceeded.
BHEL, Haridwar
1
2
3
4
Rotor shaft
Babbitt
Thermocouple
Bearing sleeve
Fig. 1
Bearing temperature measurement
2.1-8440-10550/1
0209 E
Turbogenerators
Supervision of Seal Oil System
Operation
The location of the transmitters of the measuring
and supervisory equipment in the seal oil system is
shown in the seal oil diagram [1].
devices in the seal oil are:
Q
Q
Q
Q
Level detectors
Pressure and differential pressure gauges
Temperature detectors
Volume flow measuring devices
Level Detectors
Within the seal oil systemQ
Q
Q
the oil levels in the TE and EE prechambers

the oil levels in the seal oil tank
the oil levels in the seal oil storage tank
are supervised.
A high oil level in the generator prechambers, due
to an increase in the amount of seal oil on the hydrogen
side of the shaft seal, results in an alarm to be initiated
when the probe is immersed in oil.
A low oil level in the seal oil tank is monitored such
that an alarm takes place when the probe is no longer
covered with oil. This prevents dry running of the
hydrogen side seal oil pump.
A low oil level in the seal oil storage tank-only
feasible during the start-up phase- results in an alarm
for protection of the air side pumps. The alarm is initiated
when the probe is no longer covered with oil.
2
Pressure and Differential Pressure Gauges
The following pressure measuring points are

provided:
Q
Pressure downstream of air side seal oil pump-1
On failure of seal oil pump-1, a pressure switch

activates air side seal oil pump-2, If the later is not ready
for operation, air side oil pump 3 is automatically started.
Local indication is required for pressure setting of
the A1 valve and for visual examination.
Q
Pressure downstream of air side seal oil pump 2
On failure of seal oil pump-2, a pressure switch

activates air side seal oil pump-1. If the later is not ready
for operation, air side seal oil pump 3 is automatically
BHEL, Haridwar
started.
Q
Pressure downstream of air side seal oil pump 3
A pressure switch signals the takeover of the seal

oil supply by seal oil pump 3.
Q
Pressure downstream of air side seal oil pumps
Readings from this pressure gauge are required for

pressure setting of the A1 and A2 valves.
Q
H2 casing pressure
This pressure gauge reading is required for setting

the pressure differential between the air side seal oil
pressure and the H2 casing pressure.
Q
Seal oil pressure downstream of oil orifice
At this pressure gauge the seal oil pressure, set by

means of the control orifice, can be observed.
Seal oil pump 3 is activated via a differential
pressure transducer, which detects the pressure
differential between the generator casing pressure and
the air side seal oil, and a pressure switch when pressure
falls below the preset set point value. An additional
pressure switch initiates miscellaneous alarms and is
used for Off control of the hydrogen side seal oil pump.
Q
TE and EE ring relief pressure
The pressure gauges indicate the relief pressure sit

by means of the manual control valves.
In addition, pressure transmitters are provided for
further processing of the pressure signals.
Q
Pressure downstream of hydrogen side seal oil

pump
A pressure switch signals a failure of the oil supply.

The reading is required for setting of the C valve
and for visual examination.
Q
Pressure in hydrogen side seal oil circuit of

shaft seal
This pressure gauge serves for local observation of

2.1-8450-10550/1
0209 E
the set seal oil pressure at the shaft seal.
downstream of air side and hydrogen side seal oil

coolers.
Pressure differentials are sensed at the following points:

Pressure differential between the air side seal oil
before TE and EE shaft seals and the generator casing
pressure is sensed by transducers which initiate an alarm
on falling pressure differential, Local indication is provide
for manual adjustment of the pressure regulating valves
and for visual examination.
Differential Pressure Indication at Air - Cooled
Hydrogen Side Seal Oil Filters
The indicators display the degree of filter
contamination and activate an alarm at preset pressure
differentials.
3.
Temperature Detectors
The following temperatures are measured locally

with thermometers :
In addition, the following temperatures are measured

by means of resistance temperature detectors for remote
indication :
Q
4.
Seal oil temperature upstream and downstream of

air side seal oil coolers.
hydrogen side seal oil coolers.
Cooling water temperature upstream and
2.1-8450-10550/2
0209 E
Volume Flow Meter System
The following volume flows are measured for

comparison measurements :
Q
Q
Seal oil temperature in hydrogen side seal oil drain,

TE and EE.
air side and hydrogen side seal oil coolers.
Seal oil temperature downstream of air side and
hydrogen side seal oil coolers.
Q
Q
Q
Q
Volume
Volume
Volume
Volume
Volume
Volume
flow
flow
flow
flow
flow
flow
of
of
of
of
of
of
EE seal ring relief oil

TE seal ring relief oil
air side seal oil, EE
air side seal oil, TE
hydrogen side seal oil, EE
hydrogen side seal oil, TE

[1] 2.1-7111 Seal Oil Diagram
Turbogenerators
Supervision of Gas System
Operation
The location of the transmitters of the measuring and
supervisory equipment in the gas system is shown in the
Gas Diagram [1].
The essential measuring and supervisory devices in
the gas system are :
Q
Q
Q
Q
Purity meter systems

Volume flow meter system
Pressure gauge
Gas Purity Meter System
The gas purity meter system measures the purity of

the hydrogen gas in the generator as well as the
composition of the gas mixtures (CO2/ air and H2/ CO2)
during filling of the generator. The gas purity meter system
is also used when removing the hydrogen from the
generator, where the hydrogen is replaced with carbon
dioxide and the carbon dioxide in turn with air. The gas
required for the measurement is taken from the generator
or from the filling lines, respectively, and, on completion of
the measurement, is discharged to the atmosphere through
a vent line.
For details on the gas purity meter system, refer
Operation and maintenance manual of the Gas analyser
cabinet [2].
The gas purity meter system is equipped with a limit
switch which provides a signal to initiate an alarm when
the purity drops below a preset value.
Volume Flow System
Measuring gas volume flow
For comparison measurement, a precisely defined

measuring gas flow must be admitted to the gas purity meter
system. The measuring gas volume flow can be read locally
at the flow meter.
Pressure Gauges
The following measuring points are provided :
Q
CO2 bottle pressure
The bottle pressure during CO2 filling can be observed

at a local pressure gauge.
Q
H2 bottle pressure
The bottle pressure can be read at the pressure gauge.

The pressure switch activates a signal at low H2 pressure.
In addition, the pressure is sensed with a pressure
transmitter, the electrical signal being used for remote
control and supervision.
Q
N2 bottle pressure
The bottle pressure can be read at a local pressure

gauge.
Q
H2 pressure at pressure reducers.
For observation of the pressure settings.

Q
H2 casing pressure
The pressure is sensed by pressure transmitters, the

electrical signal of one pressure transmitter being used for
remote control and supervision. The signals of the
remaining two transmitters are converted into alarm and
control signals.
The H2 casing pressure can be read at a local pressure
gauge.
4
Within the gas system, temperature detectors are used

for supervision of CO2 flash evaporator.
The temperatures of the heat transfer liquid in CO2 flash
evaporator is detected by means of RTD and used for
control functions. In addition, the temperature of heat
transfer liquid in the CO2 flash evaporator is indicated locally
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
BHEL, Haridwar
2.1-8460-10550/1
0209
Turbogenerators
Operation
The location of the transmitters of the measuring
and supervisory equipment in the primary water system
is shown in the Primary Water diagram [1].
The essential measuring and supervisory devices
in the primary water system are:
Q
Q
Q
Q
Q
Conductivity meter system

Level monitoring system
Volume flow meters
Pressure gauges
Conductivity Meter System

The conductivity of the primary water is monitored:
Q
Q
Downstream of ion exchanger

Upstream of primary water inlet of generator
Supervision of Primary Water System
The two pressure measuring points are equipped

with pressure switches and are required for automatic
control of the two primary water pumps.
In addition, a pressure gauge is provided
downstream of each pump for local observation of the
pressure.
Q
Gas pressure in primary water tank
A pressure switch activates an alarm at rising gas

pressure in the primary water tank.
In addition, a pressure gauge is provided for local
observation of the tank gas pressure.
Q
Q
Differential pressure across main filter

Differential pressure across fine filter
Differential pressure transmitters are provided

across both these filters for indication of differential
pressure and also for initiating alarm.
Level Monitoring System
The water level in the primary water tank is sensed

by capacitive method, a high or low water level initiating
an alarm.
A local water level gauge is located in parallel to
the electrical monitoring system.
Pressure upstream of stator winding
This pressure measuring point is equipped with

pressure switches and a local pressure gauge. The
pressure switches initiate an alarm at rising primary water
pressure.
The pressure gauge is provided for local
observation.
Q
The measuring point downstream of the ion

exchanger checks the ion exchanger for proper
performance.
The measuring point in the primary water inlet of
the generator permits the conductivity of the entire
cooling system to be assessed.
Both measuring devices are equipped for indication
and alarm.
Pressure downstream of primary water pump 2
Temperature Detectors
The following temperatures are measured locally by
means of thermometers:

Primary water temperature downstream of
coolers
Q
Cooling water temperature upstream and
downstream of coolers
Q
bushings
Q
The primary water volume flows of the stator

winding and
bushings are measured a n d
indicated by a differential pressure flow meter system. If
the flow falls below a minimum value, an alarm is
activated. If the flow continues to fall, the generator
mechanical equipment protection is tripped.
The amount of primary water flowing though the ion
exchanger is monitored by a local flow meter. The amount
of water added to the system during operation is
determined by a water meter.
Resistance temperature detectors are used to

measure the followings temperatures for further
processing according to different methods:
Primary water temperature upstream and
downstream of coolers
Q
stator winding
Q
bushings
Q
coolers
Q
Pressure Gauges
Pressure or pressure differentials are sensed at the

following measuring point in the primary water cooling
circuit:
Q
Pressure downstream of primary water pump 1

[1] 2.1-7311 Primary Water Diagram
BHEL, Haridwar
2.1-8470-10550/1
0209 E
Turbogenerators
Supervision of Exciter
Operation
devices at the exciter are:
Q
Q
Q
Q
Temperature monitoring system

Fuse monitoring system
Ground fault detection system
Excitation current measuring device
Temperature Monitoring System
The exciter is provided with devices for monitoring

the temperatures of the cold air after the exciter cooler
and the hot air leaving the rectifier wheels and hot air
leaving the rectifier wheels and main exciter.
2
Fuse Monitoring System

The indicator flags of the fuses on the rectifier
BHEL, Haridwar
wheels may be checked during operation with the builtin stroboscope.

3
Ground Fault Detection System
Two sliprings are installed on the shaft between the

main exciter and bearing. One is connected to the star
point of the three-phase winding of the main exciter and
the other to the frame. These sliprings permit ground
fault detection.
4
Excitation Current Measuring Device
The excitation current is measured indirectly

through a coil arranged between two poles of the main
exciter. The voltage induced in this coil is proportional
to the excitation current thus enabling a determination
of the excitation current.
2.1-8490-10550/1
0209E
Turbogenerators
Exciter Measuring points
Operation
BHEL, Haridwar
2.1-8491-10550/1
0209E
Exciter
Turbogenerators
Description
1
Design Feature
The exciter consists of
-Rectifier wheels
-Three-phase pilot exciter
-Cooler
-Metering and supervisory equipment
permanent magnet poles. The three-phase AC generated

by the permanent-magnet pilot exciter is rectified and
controlled by the AVR to provide a variable DC current
for exciting the main exciter. The three-phase AC is
induced in the rotor of the main exciter. This three-phase
AC induced in the rotor of the main exciter is rectified by
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
3
4
1
6
1
2
3
4
5
Coupling
Rectifier wheel
Rotor of main exciter
Fan
Permanent magnet rotor
Fig. 2 Exciter Rotor
8
9
10
Automatic voltage regulator
Permanent magnet pilot exciter
Sliprings for field ground fault detection
Quadrature-axis measuring coil
Three-phase main exciter
Diode rectifier set
Three-phase lead
Multicontact connector
Rotor winding of turbogenerator
10 Stator winding of tubogenerator
Fig. 1 Basic Arrangement of Brushless Excitation System

With Rotating Diodes
Fig. 1 shows the basic arrangement of the exciter.

The three-phase pilot exciter has a revolving field with
BHEL, Haridwar
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
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
pilot exciter. The generator and exciter rotors are thus
supported on total of three bearings.
Mechanical coupling of the two shaft assemblies
results in simultaneous coupling of the dc leads in the
central shaft bore through the Multicontact electrical
contact system consisting of plug-in bolts and sockets.
This contact system is also designed to compensate for
length variations of the leads due to thermal expansion.
2
Rectifier Wheels
The main-components of the rectifier wheels are the

silicon diodes which are arranged in the rectifier wheels
in a three-phase bridge circuit. The contact pressure for
the silicon wafer is produced by a plate spring assembly.
The arrangement of the diodes is such that this contact
pressure is increased by the centrifugal force during
rotation.
Fig. 3 shows additional components contained in the
rectifier wheels. Two diodes each are mounted in each
aluminum alloy heat sink and thus connected in parallel.
2.1-9100-10550/1
0209 E
1. Diode
3. Diode Rectifier Wheel
3
2. Fuse
3. Diode Rectifier Wheel

5. Wound armature
4. Exciter 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 resinencapsulated 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
mechanical design and differ only in the forward
directions of the diodes.
The direct current from the rectifier wheels is fed to
DC leads arranged in the center bore of the shaft via
radial bolts.
The three-phase alternating currents is obtained via
copper conductors arranged on the shaft circumference
between the rectifier wheels and the three-phase main
exciter. The conductors are attached by means of
banding clips and equipped with screw-on lugs for the
internal diode connections.
Three-Phase Main Exciter
The three-phase main exciter is a six-pole revolvingarmature unit. Arranged in the stator frame are the poles
with the field and damper winding. The field winding is
arranged on the laminated magnetic poles. At the pole
shoe bars are provided. Their ends being connected so
as to form a damper winding Between two poles a
quadrature-axis coil is fitted for inductive measurement
of the exciter current.
The armature rotor consists of stacked laminations,
which are compressed by through bolts over
2.1-9100-10550/2
0209E
3. Stator
4. Amature Rotor
7. Sliprings for ground fault detection
8. Bearing housing
Fig. 4 Main Exciter
compression rings. The three-phase winding is inserted

in the slots of the laminated armature rotor. The winding
conductors are transposed within the core length, and
the end turns of the rotor winding are secured with steal
bands. The connections are made on the side facing the
rectifier wheels. The winding ends are run to a bus ring
system to which the three-phase leads to the rectifier
wheels are also connected. After full impregnation with
synthetic resin and curing, the complete armature rotor
is shrunk onto the shaft. A journal bearing is arranged
between main exciter and pilot exciter and has forced
oil lubrication from the turbine oil supply.
4
Three-Phase Pilot Exciter
The three-phase pilot exciter is a 16 pole

revolving-field unit. The frame accommodates the
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.
1
1
2
3
Stator
Pilot exciter Stator winding
Permanent magnet rotor
Fig. 5 Permanent-Magnet Pilot Exciter
laminated core with the three-phase winding. The

rotor consists of a hub with mounted poles. Each pole
consists of 12 separate permanent magnets which are
housed in a non-magnetic metallic enclosure. The
magnets are braced between the hub and the external
pole shoe with bolts. The magnet hub is shrunk onto
the free shaft end.
Cooling of Exciter
Replacement of Air Inside Exciter Enclosure
When the generator is filled with hydrogen (operation

or standstill) an adequate replacement of the air inside
the exciter enclosure must be ensured. The air volume
inside the exciter enclosure requires an air change rate
of 125 m3/h.
While the generator is running, the air leaving the
exciter enclosure via the bearing vapor exhaust system
and the leakage air outlet in the foundation provides for
a pull-through system. The volume of air extracted from
the cooling air circuit is replaced via the filters located
at the top of the enclosure.
When the generator is at rest, the air dryer of the
exciter unit discharges dry air inside the exciter
enclosure. The air leaves the exciter enclosure via the
leakage air filter and the leakage air outlet at the shaft
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
BHEL, Haridwar
2.1-9100-10550/3
0209 E
Turbogenerators
Description
Basic Arrangement of Brushless

Excitation System
3
1
4
5
9
10
Diode rectifier set
Permanent magnet pilot exciter
Three-phase lead
Sliprings for field ground fault detection
Multicontact connector
Quadrature-axis measuring coil
Rotor winding of turbogenerator
Three-phase main exciter
10 Stator winding of tubogenerator
BHEL, Haridwar
2.1-9101-10550/1
0209 E
Turbogenerators
Rectifier Wheels
Description
3
4
Current path
7
8
4
3
2
10
1
2
3
4
5
AC lead
Fuse
Heat sink
Diode
Rectifier wheel (+ve polarity)
BHEL, Haridwar
6
7
8
9
10
Hot air outlet

Tension bolt
Terminal bolt
Rectifier wheel (-ve polarity)
DC lead
2.1-9102-10550/1
0209 E
Turbogenerators
Rectifier Wheels and Coupling
Description
5
6
7
Exciter coupling without Contact pin
BHEL, Haridwar
1
2
3
4
5
6
7
8
Balancing Weight
Fuse
Rectifier wheels
Diode
Multi Contact band
DC lead
Coupling
Contact pin
7
8
Exciter coupling with Contact pin
2.1-9103-10550/1
0209 E
Turbogenerators
Permanent-Magnet
Description
Pilot Exciter Rotor and Fan
1
1
2
3
4
BHEL, Haridwar
Permanent magnet pole

Fan
Sliprings of field ground earth fault detection
Rotor of main exciter
2.1-9104-10550/1
0209 E
Turbogenerators
Exciter Cross Section
General
1
20
1
2
3
4
5
Coupling with connector

Fuse
Heat sink
Rectifier wheels
Diode
19
18
6
7
8
9
10
Magnetic pole of main exciter

Main exciter rotor
Main exciter stator
Sliprings for ground fault detection
Bearing
17
10
16
11
12
13
14
15
Radial flow fan

Pilot exciter stator
Pilot exciter rotor
Exciter enclosure
Foundation
16
17
18
19
20
11
12
13
14
15
Cooler
Armature balancing ring
Air housing
Base frame
DC lead
BHEL,Haridwar
2.1-9110-10550/1
0209 E
During operation
Hot air
Cold air
Section C-D
Section A-B
to bearing vapour exhauster
Description
Leakage air and makeup air
Exciter cooling Air circuit
Turbogenerators
BHEL, Haridwar
2.1-9120-10550/1
0209 E
Turbogenerators
Stroboscope for Fuse Monitoring
Description
sequence of flashes can be interrupted at any time by
actuating the Feed or Return push-button. Following
this, a stationary image is obtained which ensures
accurate checking of a single fuse. After approximately
two minutes, the stroboscope is automatically switched
off. If this period should not be sufficient for fuse
checking, switching on the stroboscope for another two
minutes without delay can be repeated for any desired
number of times by depressing the On push-button.
The stroboscope contains four plug-in printed circuit
boards which can be readily replaced in order to remedy
any faults.
The capacitor and high-voltage transformer required
to produce the firing pulses for the flash tubes are located
on a printed circuit board which is accommodated in the
handle of the flash lamp.
The operating elements are located on the front panel
of the control unit for ease of operation. A depressed
push-button is indicated by an illuminated dot in the pushbutton head.
The line connector, the two connectors for the flash
lamps and the fuse are located on the back of the control
unit.
All connectors have a mechanical lock and are
protected against dust and splash water. The cables are
run in flexible metal hoses for protection against
mechanical damage.
The fuses on the rectifier wheels may be checked

during operation with the stroboscope. A separate flash
tube is provided for each wheel (A and B). The tubes,
which are supplied through a common control unit, are
permanently installed in the rectifier wheel enclosure.
This permits easy monitoring without any adjustment
outside the exciter enclosure being required.
Fig. 1 shows the basic arrangement of a fully
transistorized stroboscope The electronics required for
control of the light signals are contained in the control
unit and in the tubular lamps. The tubular lamps are
connected to the control unit by cables.
The stroboscope is located in the rectifier wheel and
exciter enclosure so that the fuses may be observed from
outside the exciter enclosure while controlling the
stroboscope.
To synchronize the sequence of flashes with the
generator rotation, the system frequency is utilized to
activate the flashes. A double synchronous motor,
controlled through two push-button and connected to two
potentiometers and IC's, causes the flash to be timed
so that a slow-motion observation of the fuse becomes
possible.
The Observation period for one full revolution of the
rectifier wheel (3600) is approximately 25 seconds. At
approximately 4500, the flash is reset to its initial rate,
and the observation can be repeated. The continuous
1
1 Flash tube 1 (A wheel)
2 Control unit
3 Pushbutton for flash tube 1
4 Pushbutton for flash tube 2
Fig.1
3 4
5 67
5 Feed pushbutton
6 Pilot lamp for control voltage
7 Return pushbutton
10
8 On pushbutton
9 Off pushbutton
10 Flash tube 2 (B wheel)
Components and Operating Elements of Stroboscope
BHEL, Haridwar
2.1-9140-10550/1
0209 E
Turbogenerators
Exciter Drying System
Description
1
General
A dryer (dehumidifier) and an anti-condensation heating

system are provided to avoid the formation of moisture
condensate inside the exciter with the turbine-generator at
rest or on turning gear.
2
adsorption section of the dryer wheel, with part of the

moisture contained in the air being removed by the
adsorbent material, i.e. lithium chloride. The moisture is
1
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.
The tubular ducts are dimensioned so that a laminar
flow with low pressure loss is obtained even at high air
velocity.
The moisture absorbed by the dryer wheel is removed
in a regeneration section by a stream of hot air directed
through the wheel in the opposite direction of the inlet air
and then discharged to the atmosphere.
After regeneration, the dryer wheel material is again
capable of absorbing moisture.
The adsorption of moisture and regeneration of the
dryer wheel material take place simultaneously, using
separate air streams, which ensures a continuous drying
of the air.
2.1
Operating Principle of Adsorption Dryer

The dehumidification takes place in a slowly rotating
dryer wheel (approximately 7 revolutions per hour). The
honeycomb dryer wheel consists of a magnesium silica
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 adsorption section.
2.1.1 Adsorption Section
The air to be dehumidified passes through the
BHEL, Haridwar
4
1
2
3
4
5
6
7
Regeneration air outlet

Dryer wheel
Heater
Ventilator
Filter
Shutoff valve
Dry air outlet
Fig. 1 Schematic Diagram of Dryer

removed as a result of the partial pressure drop existing
between the air and the adsorbent material.
2.1.2 Regeneration Section
In the regeneration section of the dryer wheel, the
accumulated moisture is removed from the dryer wheel by
the heated regeneration air.
Continuous rotation of the dryer wheel ensures
continuous dehumidification of the air within the exciter.
3
Anti-condensation Heating System

An Anti-condensation heating system to support the
dryer is installed in the exciter base frame. The heaters
are rated and arranged so that the temperature in the exciter
interior.
2.1-9150-10550/1
0209 E
Turbogenerators
Description
The field ground fault detection system detects highresistance and low-resistance ground faults in the exciter
field circuit. It is very important for safe operation of a
generator, because a double fault causes magnetic
unbalances with very high currents flowing through the
faulted part, resulting in its destruction within a very short
time. It is therefore an essential requirement that even
simple ground faults should activate an alarm and
protective measures be initiated, if possible, before the
fault can fully develop. For this reason, the field ground
BHEL, Haridwar

for Exciter Field Circuit
fault detection system consists of two stages and
operates continuously.
If the field ground fault detection system detects a
ground fault, an alarm is activated at RE < 80 k (1st
stage). If the insulation resistance between the exciter
field circuit and ground either suddenly or slowly drops
to RE < 5 k the generator electrical protection is tripped
(2nd stage).
The generator is thus automatically disconected from
the system and de-excited.
2.1-9180-10550/1
0209 E
Turbogenerators
Arrangement of Bursh Holders for
Description
5
1
2
3
4
5
6
7
Measuring sliprings
Measuring brush
Mounting plate
Brush carrier segment
Plug-in brush holder
Measuring rod
Measuring leads
Section A-B
BHEL, Haridwar
2.1-9181-10550/1
0209 E
Turbogenerators
Brush Holders for Ground Fault
Description
Detection System
3
4
1
2
3
4
5
6
Handle
Bayonet sleeve
Brush contact pressure adjustment
Compression spring
Brush pigtail
Measuring brush
BHEL, Haridwar
2.1-9182-10550/1
0209 E
Turbogenerators
Operating and Setting Values
Operation
General
Strict observance of the operating and setting

values is a prerequisite for reliable operation of the
Turbogenerators.
Separate tables are provided for the various
design groups of the generator and its auxiliaries.
They show the transmitters activating the controls and
alarms as well as the transmitters acting on the
generator protection circuits.
The Remark column contains additional
information on controls, temperatures and pressures.
All operating and setting values refer to rated
output of generator and maximum cooling water
temperatures under steady-state conditions.
BHEL, Haridwar
The operating and setting values initially

specified in this manual are based on experience
under due consideration of the specific site conditions,
such as static head in case of pressure measuring
points or thermal characteristics in case of
temperature measuring points. These calculated
values are intended as guiding values for making the
preliminary settings during initial commissioning of the
unit.
These settings require certain corrections to
account for the actual conditions. The final settings
obtained after startup and initial load operation are to
be entered in the Operating Value column.
2.3-4000-10550/1
0209E
Turbogenerators
Gas Quantities
Operation
Gas
CO2
Startup
Shutdown
Replacement of air in
Generator housing*:
Replacement of H2 in
Generator housing*:
V1 = 2.V
V1 = 2.V
Replacement of CO2 in
generator housing*:
H2
V1 = 2.5 V
Filling to operating
pressure :
Operation
Recommended Stock
Startup :
Not permitted
3. V1
During operation :
2. V1
Compensation for H2
losses :
Not required
2.( V1 + V2)
0.5 m3/hr (s.t.p.)

+ consumption**
V2 = p e.V
Air
N2
Replacement of CO2
Not required
in generator housing* :
Supply of 40-60 dm3 /s

(s.t.p.) compressed air
from air system must
be ensured
Not permitted
V1 = 3.V
Reduction of O2
content of Primary
water:
50 m3 (s.t.p.)
Reduction of H2
content of Primary
water to be drained:
10 m3 (s.t.p.)
Reduction of O 2
content of Primary
water introduced by
100 m3 (s.t.p.)
makeup warer:
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
Primary water leakage monitoring system
Primary water purging gas system
: 20 dm3/hr (s.t.p.)
: 120 dm3/hr (s.t.p.)
: 100 - 300 dm3/hr (s.t.p.)
s.t.p. = Standard temperature and pressure, 0oC and 1.013 bar
BHEL, Haridwar
2.3-4010-10550/1
0209 E
In the following, an example is given to illustrate

the calculation of the amounts of CO2, H2 and air required
for filling. In the example one given generator volume
and one given operating pressure are assumed. The
values for other generator sizes, operating pressures and
gas bottle sizes will vary accordingly.
1
Pe
V
V1
V2
V3
V4
Z
Example
=
=
=
=
=
=
=
Operating pressure, e.g. 4 bar

Generator volume, e.g. 85 m 3
Amount of gas to fill or purge generator
Amount of gas to fill generator to operating
pressure
H 2 bottle volume, e.g. 6 M 3 (s.t.p.)
CO 2 bottle volume, e.g. 15 M3 (s.t.p.)
Number of bottles required
1.1 Filling
Amount of CO 2 required for removing air from
generator (2 generator volumes)
V1
2 . 85 m 3 = 170 m 3 (s.t.p.)
V
170 m 3 (s.t.p.)
----1 = -------------------- ~ 12 CO2 bottles
V4
15 m3 (s.t.p.)
Amount of H 2 required for removing CO 2 from

generator (2.5 generator volumes)
V1
2.5 . V = 2.5 . 85 m 3 (s.t.p.)

V1
213 m3 (s.t.p.)
---- = -------------------- ~ 35 H 2 bottles
V3
6 m3 (s.t.p.)
Amount of H2 required to fill generator to operating

pressure (operating pressure in bar x generator volume)
V2
Z
=
=
Pe . V = 4 . 85 m3 = 340 m3 (s.t.p.)
340 m3 (s.t.p.)
V2
---- = -------------------- ~ 57 H 2 bottles
V3
6 m3 (s.t.p.)
1.2 Purging
Amount of CO 2 required for removing H 2 (2
generator volumes)
V1
2 . V = 2 . 85 m 3 = 170 m3 (s.t.p.)
170 m3 (s.t.p.)
V1
---- = ----------------- ~ 12 CO 2 bottles
V4
15 m3 (s.t.p.)
Amount of compressed air required for removing

CO2 (3 generator volumes)
V1 =
3 . V = 3 . 85 m 3 = 255 m3 (s.t.p.)
1.3 Bottle Volume

H2 bottle 40 Liters at 150 bar
H2 bottle 50 Liters at 200 bar
= 6 m 3 (s.t.p.)
= 10 m3 (s.t.p.)
CO 2 bottle : 40 Liters = 15 m3 (s.t.p.)

45
= 17
66.7
= 25.2
It should be taken into consideration that the bottle
contents cannot be completely used up. For H2 bottles it
is assumed that the contents can be expanded to a
pressure of approximately 1 bar above the operation
pressure. This means approximately 3% of the bottle
contents at a final pressure of 4 bar will remain following
a fill to 3 bar.
* For reasons of safety, a sufficient number of full CO2 bottles

must be available prior to starting with any generator filling
operations.
2.3-4010-10550/2
0209E
MEASURING POINT LIST FOR GENERATOR C&I
_________________________________________________________________________________________
0209E
2.3-4030-10550/4
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKA 06 CL001
OIL LVL IN PRECHAMBER(TE)
MKA 06 CP501
S.OIL DIFF. PR. (TE)
MKA 07 CL001
OIL LVL IN PRECHAMBER(EE)
MKA 07 CP501
S.OIL DIFF. PR. (EE)
MKA 11 CT001
TEMP.STATOR CORE (TE)
MKA 11 CT002
MKA 11 CT003
MKA 11 CT004
MKA 11 CT005
MKA 11 CT006
MKA 11 CT007
MKA 11 CT008
MKA 11 CT009
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
LS
CAP
-50+50
DPG
mBAR
LS
CAP
-50+50
DPG
mBAR
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCUNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
A-U
X
>1860 mm
<MAX
LVL BELOW CASING C.LINE

COMMON ANN. WITH
MKA07CL001
10-20
A-U
X
>1530 mm
<MAX
LVL BELOW CASING C.LINE

COMMON ANN. WITH
MKA06CL001
10-20
<90 C
>90 C
<90 C
SPARE
<90 C
>90 C
<90 C
SPARE
<90 C
>90 C
<90 C
SPARE
<90 C
>90 C
<90 C
SPARE
<90 C
>90 C
_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKA 11 CT010
MKA 11 CT011
MKA 11 CT012
MKA 12 CT001
TEMP.STATOR SLOT - 1
MKA 12 CT002
MKA 12 CT003
MKA 12 CT004
MKA 12 CT005
MKA 12 CT006
MKA 12 CT007
TEMP.STATOR SLOT -12
MKA 12 CT008
MKA 12 CT009
MKA 12 CT010
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0209E
2.3-4030-10550/5
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
<90 C
SPARE
<90 C
>90 C
<90 C
SPARE
<80 C
>80 C
<80 C
SPARE
<80 C
>80 C
<80 C
SPARE
<80 C
>80 C
<80 C
SPARE
<80 C
>80 C
<80 C
SPARE
<80 C
>80 C
<80 C
SPARE
_________________________________________________________________________________________
0209E
2.3-4030-10550/6
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKA 12 CT011
MKA 12 CT012
MKA 12 CT013
MKA 12 CT014
MKA 12 CT015
MKA 12 CT016
MKA 12 CT017
MKA 12 CT018
MKA 12 CT019
MKA 12 CT020
MKA 12 CT021
MKA 12 CT022
MKA 12 CT023
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
<80 C
>80 C
<80 C
SPARE
<80 C
>80 C
<80 C
SPARE
<80 C
>80 C
<80 C
SPARE
<80 C
>80 C
<80 C
SPARE
<80 C
>80 C
<80 C
SPARE
<80 C
>80 C
<80 C
SPARE
<80 C
>80 C
_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKA 12 CT024
MKA 13 CT001
TEMP.STATOR CORE (EE)
MKA 13 CT002
MKA 13 CT003
MKA 13 CT004
MKA 13 CT005
MKA 13 CT006
MKA 13 CT007
MKA 13 CT008
MKA 13 CT009
MKA 13 CT010
MKA 13 CT011
MKA 13 CT012
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0209E
2.3-4030-10550/7
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-100
RTD
DEG.C
Pt 100
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
0-150
TC
DEG.C
CuCuNi
<80 C
SPARE
<90 C
>90 C
<90 C
SPARE
<90 C
>90 C
<90 C
SPARE
<90 C
>90 C
<90 C
SPARE
<90 C
>90 C
<90 C
SPARE
<90 C
>90 C
<90 C
SPARE
<90 C
>90 C
<90 C
SPARE
_________________________________________________________________________________________
0209E
2.3-4030-10550/8
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKA 21 CL001
LIQUID IN GEN.(TE)
MKA 22 CL001
LIQUID IN GEN.(CENTRE)
MKA 23 CL001
LIQUID AT M.LEADS BOTTOM
MKA 23 CL011
LIQUID AT M.LEADS BOTTOM
MKA 23 CP501
GAS IMPULS TO DPR(H2 PR.)
MKA 24 CL001
LIQUID AT MAIN LEADS TOP
MKA 24 CL011
MKA 24 CL021
MKA 61 CT001A
TEMP. PW O/L MANIFOLD
MKA 61 CT001B
MKA 61 CT002A
MKA 61 CT002B
MKA 61 CT003A
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-149-00-01164
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
LS
MM
LS
MM
LS
MM
LS
MM
0-10
PG
KG/CM2
LS
MM
LS
MM
LS
MM
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
<MAX
A-U
X
>MAX
<MAX
COMMON ANNUN.
& ATRS
A-U
X
>MAX
<MAX
COMMON ANNUN.
& ATRS
A-U
X
>MAX
<MAX
COMMON ANNUN.
& ATRS
A-U
X
>MAX
<MAX
COMMON ANNUN.
& ATRS
A-U
X
>MAX
>MAX
LVL ABOVE BTM

OF CASING
2V3(12) PROTN.,
A-U
X
>MAX
>MAX
LVL ABOVE BTM

OF CASING
2V3(12) PROTN.,
A-U
X
>MAX
>MAX
LVL ABOVE BTM

OF CASING
2V3(12) PROTN.,
<75 C
>80 C
<75 C
<75 C
>80 C
<75 C
<75 C
>80 C
SPARE
SPARE
_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKA 61 CT003B
MKA 71 CT002A
TEMP.H.GAS.CLRS A&B
MKA 71 CT002B
TEMP.H.GAS.CLRS A&B
MKA 71 CT003A
TEMP.H.GAS.CLRS A&B
MKA 71 CT003B
TEMP.H.GAS.CLRS A&B
MKA 71 CT004A
TEMP.H.GAS.CLRS A&B
MKA 71 CT004B
TEMP.H.GAS.CLRS A&B
MKA 72 CT002A
TEMP.H.GAS.CLRS C&D
MKA 72 CT002B
TEMP.H.GAS.CLRS C&D
MKA 72 CT003A
TEMP.H.GAS.CLRS C&D
MKA 72 CT003B
TEMP.H.GAS.CLRS C&D
MKA 72 CT004A
TEMP.H.GAS.CLRS C&D
MKA 72 CT004B
TEMP.H.GAS.CLRS C&D
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
2.3-4030-10550/9
0209E
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
<75 C
SPARE
65-72
>80 C
FOR FAST
FEED BACK TO C.V.
65-72
65-72
>80 C
65-72
65-72
>80 C
65-72
SPARE
-
65-72
>80 C
FOR FAST
FEED BACK TO C.V.
65-72
65-72
>80 C
65-72
65-72
>80 C
65-72
SPARE
-
SPARE
-
SPARE
-
_________________________________________________________________________________________
2.3-4030-10550/10
0209E
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKA 75 CT002A
TEMP.COLD GAS CLRS A&B
MKA 75 CT002B
MKA 75 CT003A
MKA 75 CT003B
MKA 75 CT004A
MKA 75 CT004B
MKA 75 CT005A
TEMP.COLD GAS (LEFT)
MKA 75 CT005B
TEMP.COLD GAS (LEFT)
MKA 78 CT002A
TEMP.COLD GAS CLRS C&D
MKA 78 CT002B
MKA 78 CT003A
MKA 78 CT003B
MKA 78 CT004A
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
PT 100
0-100
RTD
DEG.C
Pt 100
51-44
>55 C
>60 C
2V3 (1)
-
51-44
>55 C
>60 C
2V3(1)*
* - 2ND PROTECTION
CHANNEL
51-44
>55 C
>60 C
2V3 (1)
-
51-44
>55 C
>60 C
2V3(1)*
-
51-44
>55 C
>60 C
2V3 (1)
-
51-44
>55 C
>60 C
2V3(1)*
-
51-44
A-U
X
>55 C
>55C,<45C
DT PW/H2 LO & V.LO

MKF80CT004A & 4B
ATRS <45C
51-44
SPARE
<50 C
>55 C
>60 C
2V3 (2)
-
<50 C
>55 C
>60 C
<50 C
>55 C
>60 C
<50 C
>55 C
>60 C
<50 C
>55 C
>60 C
2V3 (2)*
2V3 (2)
2V3 (2)*
2V3 (2)
-
_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKA 78 CT004B
MKA 78 CT005A
TEMP.COLD GAS (RIGHT)
MKA 78 CT005B
TEMP.COLD GAS (RIGHT)
MKC 21 CE001
QUAD. AXIS MEASURING COIL-1
MKC 21 CE002
QUAD. AXIS MEASURING COIL-2
MKC 41 CU001
STROBO. FOR FUSE CHECKING
MKC 80 CT012A
TEMP.COLD AIR M.EXCITER
MKC 80 CT012B
MKC 80 CT014A
MKC 80 CT014B
MKC 82 CT001A
TEMP.HOT AIR M.EXCITER
MKC 82 CT001B
MKC 82 CT002A
0-139-00-01241
0-139-00-01241
0-139-00-01241
2-145-00-01021
2-145-00-01021
2-145-00-01021
2-145-00-01021
2-145-00-01021
2-145-00-01021
2-145-00-01021
2.3-4030-10550/11
0209E
2-145-00-01021
2-145-00-01021
2-145-00-01021
0-100
RTD
DEG.C
PT 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-8000
COL
VOLT
0-8000
COL
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
<50 C
>55 C
>60 C
2V3 (2)*
<45 C
A-U
X
>55 C,<45C
>55 C
DT PW/H2 LO & V.LO

MKF80CT004A & 4B
ATRS<45C
<45 C
SPARE
-
>110 C
-NON LINAR CURVE(SEE NOTE 7)

FIELD CURRENT MEAS. BY EDN
SPARE
VISUAL CHECKING OF FUSES
45C
>45C
<45C,>50C
SWITCHING ON/OFF EX.SHUT

DOWN HEATER / AIR DRIER
45C
SPARE
45C
>90
SWITCHING OFF EX. SHUT

HEATER/AIR DRIER BY PROT.
45C
SPARE
75C
>75 C
>80 C
2V3 (3)
-
75C
>75 C
>80 C
2V3 (3)*
75C
>75 C
>80 C
2V3 (3)
-
_________________________________________________________________________________________
2.3-4030-10550/12
0209E
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKC 82 CT002B
MKC 82 CT003A
MKC 82 CT003B
MKC 84 CT002A
TEMP.HOT AIR RECT.WHEEL
MKC 84 CT002B
TEMP.HOT AIR RECT.WHEEL
MKD 11 CT014A
TEMP.BEARING METAL (TE)
MKD 11 CT014B
MKD 11 CT014C
MKD 11 CT018A
MKD 11 CT018B
MKD 11 CT018C
MKD 12 CT014A
TEMP.BEARING METAL (EE)
MKD 12 CT014B
2-145-00-01021
2-145-00-01021
2-145-00-01021
2-145-00-01021
2-145-00-01021
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt100
0-140
RTD
DEG.C
Pt100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
75C
>75 C
>80 C
2V3 (3)*
75C
>75 C
>80 C
75C
>75 C
>80 C
75C
> 75 C
75C
<75 C
A-U
X
>90
>130
2V4(4)
-
<75 C
A-U
X
>90
>130
2V4(4)
-
<75 C
SPARE
<75 C
A-U
X
>90
>130
2V4(4)
-
<75 C
A-U
X
>90
>130
2V4(4)
-
<75 C
SPARE
<75 C
A-U
X
>90
>130
2V4(5)
-
<75 C
A-U
X
>90
>130
2V4(5)
-
2V3 (3)
2V3 (3)*
_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKD 12 CT014C
MKD 12 CT018A
MKD 12 CT018B
MKD 12 CT018C
MKD 15 CT014A
TEMP.EXCITER BEARING
MKD 15 CT014B
MKD 15 CT014C
MKD 15 CT018A
MKD 15 CT018B
TEMP. EXCITER BEARING
MKD 15 CT018C
MKF 01 CL001
LVL PW TANK
MKF 01 CL501
LVL PW TANK
MKF 12 CP001
PR. AFTER PUMP 1
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
2-145-00-01021
2-145-00-01021
2-145-00-01021
2-145-00-01021
2-145-00-01021
2-145-00-01021
2.3-4030-10550/13
0209E
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
0-150
TC
DEG.C
NiCrNi
0-470
LT
MM
0-470
LG
MM
0.5-16
PS
Kg/CM2
<75 C
SPARE
<75 C
A-U
X
>90
>130
2V4(5)
-
<75 C
A-U
X
>90
>130
2V4(5)
-
<75 C
SPARE
<75 C
A-U
X
>90
>130
2V4(6)
-
<75 C
A-U
X
>90
>130
2V4(6)
-
<75 C
SPARE
<75 C
A-U
X
>90
>130
2V4(6)
<75 C
A-U
X
>90
>130
2V4(6)
-
<75 C
SPARE
-
195-255
A-U
X
>255,<195,<10
>155
LVL ABOVE BTM PERMISSIVE

FOR SWITCHING ON SLC &
195-255
8-9
A-U
X
<5
>5,<5
& ATRS
_________________________________________________________________________________________
2.3-4030-10550/14
0209E
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKF 12 CP501
PR. AFTER PUMP 1
MKF 22 CP001
PR. AFTER PUMP 2
0-153-00-01065
0-153-00-01065
0.5-16
PG
Kg/CM2
0.5-16
PS
Kg/CM2
0.5-16
PG
Kg/CM2
LS
0-1.6
DPT
Kg/CM2
0-1.6
DPT
Kg/CM2
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
TG
MKF 22 CP501
PR. AFTER PUMP 2
MKF 36 CL001
NaOH TANK LVL
MKF 52 CP001
DIFF PR. MAIN FILTER 1
MKF 52 CP002
DIFF PR. MAIN FILTER 2
MKF 52 CT001A
TEMP.AFTER PUMP 1 + 2
MKF 52 CT001B
TEMP.AFTER PUMP 1 + 2
MKF 52 CT501
TEMP-C.INLET TO PW CLR
0-153-00-01065
DEG.C
MKF 52 CT506
TEMP.AFTER PW CLR
0-100
TG
0-153-00-01065
DEG.C
MKF 60 CF002
FLOW OF TREATED WATER
6-60
FM
LPM
MKF 60 CF501
FLOW OF TOP UP WATER
0-7
FG
M3/HR
MKF 60 CP001
DIFF PR. FINE MESH FILTER
0-1.6
DPT
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
Kg/CM2
8-9
8-9
A-U
X
<5
>5,<5
8-9
< MIN
STOP D.PUMP ON LO LVL

LVL
<0.9
>0.9
C. ANN. WITH MKF52CP002
<0.9
>0.9
C. ANN. WITH MKF52CP001
61-77C
>80 C
61-77C
SPARE
61-77C
61-77C
30-36
< MIN
<MIN,>MIN
CONTROL OF DSNG PUMP

FLOW METER WITH CONTACT
<0.9
>0.9
& ATRS
_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKF 60 CQ001
COND.AFT ION EXCHANGER
0-5
CC
MKF 80 CQ001
COND. AFTER MAIN FILTER
uS/CM
0-5
CC
MKF 80 CT002A
0-153-00-01065
uS/CM
TEMP.OF PW AT INLET
0-100
RTD
MKF 80 CT002B
0-153-00-01065
DEG.C
Pt 100
TEMP.OF PW AT INLET
0-100
RTD
MKF 80 CT003A
0-153-00-01065
DEG.C
Pt 100
TEMP.OF PW AT INLET
0-100
RTD
MKF 80 CT003B
0-153-00-01065
DEG.C
Pt 100
TEMP.OF PW AT INLET
0-100
RTD
MKF 80 CT004A
0-153-00-01065
DEG.C
Pt 100
TEMP.OF PW AT INLET
0-100
RTD
0-153-00-01065
MKF 80 CT004B
TEMP. OF PW AT INLET
DEG.C
Pt 100
0-100
RTD
MKF 80 CT501
TEMP. OF PW AFTER CLR
DEG.C
Pt 100
0-100
TG
MKF 82 CF001
0-153-00-01065
DEG.C
FLOW SW AT OUTLET
0-250
OP
MKF 82 CF001A
0-153-00-01065
mBar
DP
FLOW SW AT OUTLET
0-72
DPT
MKF 82 CF001B
0-153-00-01065
m3/hr
FLOW SW AT OUTLET
0-72
DPT
MKF 82 CF001C
0-153-00-01065
m3/hr
FLOW SW AT OUTLET
0-72
DPT
0-153-00-01065
m3/hr
0-153-00-01065
0-153-00-01065
2.3-4030-10550/15
0209E
1.8
<1.0
<1.0,>3.0
SWITCH ON&OFF OF DOSING

PUMP
3-4.8
A-U
X
>3.0
>4.0
>2.5
>4.0
SWITCH OFF- DOSING PUMP

FLUSHING WITH FRESH DM
WATER FOR COND >4.0
61-49C
>55 C
>60 C
2V3(13) PROTN.
ATRS <50 C
61-49C
>55 C
>60C
2V3(13)* PROTN.
* - 2ND PROTECTION CHANNEL
61-49C
>55 C
>60 C
2V3(13) PROTN.
61-49C
<3,1C;>55C
>1C,>60C
PW/H2 DT LO & VERY LO

WITH MKA75CT005A,ATRS>1C.
2V3(13)*PROTN.
dt -5C
>55 C
>60 C
2V3(13) PROTN.
dt -5C
<3,1C;>55C
>1C,>60C
PW/H2 DT LO & VERY LO

WITH MKA78CT005A ,ATRS>1C.
2V3(13)* PROTN.
61-49C
60
A-U
X
<54
<48,>54
2V3(7) WITH 1 MINUTE DELAY,

MED.IND WITH.1B,1C
60
A-U
X
<54
<48

MED.IND WITH.1A,1C
60
A-U
X
<54
<48

MED.IND WITH.1A,1B
_________________________________________________________________________________________
2.3-4030-10550/16
0209E
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKF 82 CP003
PR. SW INLET
MKF 82 CP005
DIFF PRESS SW
MKF 82 CP501
PR. SW INLET
MKF 82 CQ001
PW COND.AT GEN OUT LET
MKF 82 CT001A
TEMP.SW AT OUTLET
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-10
PT
Kg/Cm2
0-2.5
DPT
Kg/Cm2
0-10
PG
Kg/Cm2
0-5
CC
Kg/Cm2
0-100
RTD
2.6
<3.0
>3.8
1.1
>MAX
2.6
3-4.8
>3.0
61-77C
>80 C
FOR FAST FEED BACK PW
61-77C
SPARE
61-77C
WDG TEMP MONITRNG ON CRT

(NOTE 10),*AS PER SITE COND
61-77C

(NOTE 10),*..AS PER SITE COND
61-77C

(NOTE 10),*...AS PER SITE COND
61-77C

61-77C

61-77C

61-77C

TEMP
0-153-00-01065
DEG.C
Pt 100
MKF 82 CT001B
TEMP.SW AT OUTLET
0-100
RTD
0-153-00-01065
DEG.C
Pt 100
MKF 82 CT002
TEMP.UPPER BAR PW O/L
0-100
RTD
DEG.C
Pt 100
MKF 82 CT003
TEMP.LOWER BAR PW O/L
0-100
RTD
DEG.C
Pt 100
MKF 82 CT004
0-100
RTD
DEG.C
Pt 100
MKF 82 CT005
0-100
RTD
DEG.C
Pt 100
MKF 82 CT006
0-100
RTD
DEG.C
Pt 100
MKF 82 CT007
0-100
RTD
DEG.C
Pt 100
MKF 82 CT008
0-100
RTD
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
DEG.C
Pt 100
_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKF 82 CT009
MKF 82 CT010
MKF 82 CT011
MKF 82 CT012
MKF 82 CT013
MKF 82 CT014
MKF 82 CT015
MKF 82 CT016
MKF 82 CT017
MKF 82 CT018
MKF 82 CT019
MKF 82 CT020
MKF 82 CT021
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
2.3-4030-10550/17
0209E
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

_________________________________________________________________________________________
2.3-4030-10550/18
0209E
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKF 82 CT022
MKF 82 CT023
MKF 82 CT024
MKF 82 CT025
MKF 82 CT026
MKF 82 CT027
MKF 82 CT028
MKF 82 CT029
MKF 82 CT030
MKF 82 CT031
MKF 82 CT032
MKF 82 CT033
MKF 82 CT034
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKF 82 CT035
MKF 82 CT036
MKF 82 CT037
MKF 82 CT038
MKF 82 CT039
MKF 82 CT040
MKF 82 CT041
MKF 82 CT042
MKF 82 CT043
MKF 82 CT044
MKF 82 CT045
MKF 82 CT046
MKF 82 CT047
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
2.3-4030-10550/19
0209E
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

_________________________________________________________________________________________
2.3-4030-10550/20
0209E
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKF 82 CT048
MKF 82 CT049
MKF 82 CT050
MKF 82 CT051
MKF 82 CT052
MKF 82 CT053
MKF 82 CT054
MKF 82 CT055
MKF 82 CT056
MKF 82 CT057
MKF 82 CT058
MKF 82 CT059
MKF 82 CT060
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKF 82 CT061
MKF 82 CT062
MKF 82 CT063
MKF 82 CT064
MKF 82 CT065
MKF 82 CT066
MKF 82 CT067
MKF 82 CT068
MKF 82 CT069
MKF 82 CT070
MKF 82 CT071
MKF 82 CT072
MKF 82 CT073
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
2.3-4030-10550/21
0209E
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

_________________________________________________________________________________________
2.3-4030-10550/22
0209E
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKF 82 CT074
MKF 82 CT075
MKF 82 CT076
MKF 82 CT077
MKF 82 CT078
MKF 82 CT079
MKF 82 CT080
MKF 82 CT081
MKF 82 CT082
MKF 82 CT083
MKF 82 CT084
MKF 82 CT085
MKF 82 CT086
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKF 82 CT087
MKF 82 CT088
MKF 82 CT089
MKF 82 CT090
MKF 82 CT091
MKF 82 CT092
MKF 82 CT093
MKF 82 CT094
MKF 82 CT095
MKF 82 CT096
MKF 82 CT097
MKF 82 CT501
TEMP.SW OUTLT
MKF 83 CF001
FLOW MAIN BUSHING "R"
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
2.3-4030-10550/23
0209E
0-139-00-01241
0-153-00-01065
0-153-00-01065
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
TG
DEG.C
0-250
OP
mBar
DP
61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C

61-77C
_________________________________________________________________________________________
0209E
2.3-4030-10550/24
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKF 83 CF001A
FLOW MAIN BUSHING 'R'
MKF 83 CF001B
MKF 83 CF001C
MKF 83 CF011
FLOW MAIN BUSHING "S"
MKF 83 CF011A
FLOW MAIN BUSHING 'S'
MKF 83 CF011B
MKF 83 CF011C
MKF 83 CF021
FLOW MAIN BUSHING "T"
MKF 83 CF021A
FLOW MAIN BUSHING 'T'
MKF 83 CF021B
MKF 83 CF021C
MKF 83 CT001A
TEMP.AFTER M. BUSHING
MKF 83 CT001B
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-1.8
DPT
m3/hr
0-1.8
DPT
m3/hr
0-1.8
DPT
m3/hr
0-250
OP
mBar
DP
0-1.8
DPT
m3/hr
0-1.8
DPT
m3/hr
0-1.8
DPT
m3/hr
0-250
OP
mBar
DP
0-1.8
DPT
m3/hr
0-1.8
DPT
m3/hr
0-1.8
DPT
m3/hr
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
1.5
A-U
X
<1.4
<1.33,>1.4
2V3 (8) WITH 1 MIN DELAY

,MED.IND WITH.1B,1C
1.5
A-U
X
<1.4
<1.33

,MED.IND WITH.1A,1C
1.5
A-U
X
<1.4
<1.33

,MED.IND WITH.1A,1B
1.5
A-U
X
<1.4
<1.33,>1.4

MED.IND WITH.1B,1C
1.5
A-U
X
<1.4
<1.33

MED.IND WITH.1A,1C
1.5
A-U
X
<1.4
<1.33

MED.IND WITH.1A,1B
1.5
A-U
X
<1.4
<1.33,>1.4

MED.IND WITH.1B,1C
1.5
A-U
X
<1.4
<1.33

MED.IND WITH.1A,1C
1.5
A-U
X
<1.4
<1.33

MED.IND WITH.1A,1B
60 C
>70 C
60 C
SPARE
_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKF 83 CT501
MKF 91 CP001
GAS PR. PW TANK
MKF 91 CP501
GAS PR. PW TANK
MKG 11 CP001
PR. H2 CYLINDER
MKG 11 CP501
PR. H2 CYLINDER
MKG 25 CP001
PR. H2-STATOR FRAME
MKG 25 CP002
PR. H2-STATOR FRAME
MKG 25 CP003
PR. H2-STATOR FRAME
MKG 25 CP503
PR. H2-STATOR FRAME
MKG 25 CQ001
PURITY H2 GEN CASING
MKG 31 CP502
PR. N2 BEHIND FLASH
MKG 51 CP501
PR. CO2 CYLINDER
MKG 51 CT001A
TEMP.CO2 FLASH EVAP.
0-153-00-01065
2-149-00-01051
2-149-00-01051
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
2.3-4030-10550/25
0209E
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-100
BT
DEG.C
0-1
PS
Kg/Cm2
0-1
PG
Kg/Cm2
0-250
PT
Kg/Cm2
0-250
PG
Kg/Cm2
0-10
PT
Kg/Cm2
0-10
PT
Kg/Cm2
0-6
PT
Kg/Cm2
0-6
PG
Kg/Cm2
100-85%
GA
0-250
PG
Kg/Cm2
0-160
PG
Kg/Cm2
0-250
RTD
DEG.C
60 C
0-0.2
>0.3
LEAKAGE OF H2 IN PW CKT.
0-0.2
15-150
<15
3.5
DP WITH MKW71CP011
4-20 mA OUTPUT FOR DPM
3.5
>3.7,<3.3
DP WITH MKW71CP021
3.5
>3.0
ATRS
>97%
<95%,<90%
>94%
3 RANGE GAS ANALYSER

& ATRS. M/C OPN NOT
BELOW 90%H2 PURITY IN AIR.
150
100
0-150
>150 C
<145,>150
INHERENT HYST. OF 5 DEG

FOR 2 SET VALUES TO SWITCH
ON/OFF CO2 FLASH EVAP.
_________________________________________________________________________________________
2.3-4030-10550/26
0209E
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKG 51 CT001B
0-250
RTD
MKG 51 CT501
DEG.C
0-250
TG
MKG 69 CL001
OIL LVL IN TRAP AT DRIER
DEG.C
0-100
LS
MKG 69 CM001
DEW POINT OF H2 GAS
DEG.C
-60+20C
MS
MKW 01 CL001
LVL IN S.OIL STORAGE TANK
LS
MKW 01 CL002
LVL IN S.OIL STORAGE TANK
LS
MKW 01 CP501
PR. OIL INLET HEADER
0-2.5
PG
MKW 03 CL001
OIL LVL IN S.OIL TANK
KG/CM2
LS
MKW 03 CL002
0-149-00-01199
LS
0-149-00-01199
MKW 03 CL501
0-470
LG
MM
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
MKW 03 CT001A
MKW03CT002A
TEMP H2-S S.OIL DRAIN (TE)
0-150
SPARE
A-U
X
>MAX
>MAX
4-20 mA OUT PUT TO GAMP

AVAILABLE FOR DDCMIS
A-U
X
< MIN
>MIN
SO PUMPS INTERLOCK
COMM ANN. WITH MKW01CL002
A-U
X
< MIN
COMM ANN. WITH MKW01CL001
A-U
X
<MIN
-SWITCHINF OFF H2 SIDE

SEAL OIL PUMP
A-U
X
<MIN
<70C
>70 C
COMM ANN. WITH
X
0-149-00-01199
MKW 03 CT001B
TEMP H2-S S.OIL DRAIN (TE)
MKW 03 CT002A
MKW03CT001A
TEMP H2-S S.OIL DRAIN (EE)
0-149-00-01199
0-149-00-01199 DEG.C
Pt 100
<70C
SPARE
<70C
>70 C
COMM ANN. WITH
_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKW 03 CT002B
TEMP H2-S S.OIL DRAIN (EE)
MKW 11 CP001
PR. AFT SO PUMP 1 A-S
MKW 11 CP501
MKW 13 CP001
PR. AFT SO PUMP 4 H2-S
MKW 13 CP501
PR. AFT SO PUMP 4 H2-S
MKW 21 CP001
MKW 21 CP501
MKW 31 CP001
MKW 31 CP501
MKW 51 CP001
DIFF.PR. S.OIL FILTER A-S
MKW 51 CT001A
S.OIL TEMP BEF SO CLR (A-S)
MKW 51 CT001B
MKW 51 CT501
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
0-149-00-01199
0209E
2.3 -4030-10550/27
0-149-00-01199
0-149-00-01199
0-149-00-01200
0-100
RTD
DEG.C
Pt 100
0.5-16
PS
Kg/Cm2
0-16
PG
Kg/Cm2
0.5-16
PS
Kg/Cm2
0-16
PG
Kg/Cm2
0.5-16
PS
Kg/CM2
0-16
PG
Kg/Cm2
0.5-16
PS
Kg/Cm2
0-16
PG
Kg/Cm2
0-1.6
DPT
Kg/Cm2
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
TG
DEG.C
<70C
SPARE
A-U
X
<5.0
>5.0,<5.0
COMMON ANN. WITH
10
A-U
X
<7.0
>7.0
ATRS
10
A-U
X
<5.0
>5.0,<5.0
C. ANN. WITH MKW11CP001
A-U
X
<7.5
<0.9
>0.9
<70C
>70 C
<70C
SPARE
<70C
_________________________________________________________________________________________
2.3-4030-10550/28
0209E
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKW 53 CP001
DIFF PR. S.OIL FILTER H2-S
MKW 53 CT001A
S.OIL TEMP BEF SO CLR (H2-S)
MKW 53 CT001B
MKW 53 CT501
MKW 71 CF511
S.OIL FLOW (TE) A-S
MKW 71 CF521
S.OIL FLOW (EE) A-S
MKW 71 CP001
S.OIL PR. A-S
MKW 71 CP002
S.OIL PR. A-S
MKW 71 CP003
S.OIL PR. A-S
MKW 71 CP011
S.OIL PR. (TE) A-S
MKW 71 CP021
S.OIL PR. (EE) A-S
MKW 71 CP501
S.OIL PR. (A-S)
MKW 71 CP511
S.OIL PR. (TE) A-S
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-1.6
DPT
Kg/CM2
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
TG
DEG.C
10-100
FM
LPM
10-100
FM
LPM
0-10
PT
Kg/CM2
0-10
PT
Kg/CM2
0.5-10
PS
Kg/CM2
0-10
PT
Kg/CM2
0-10
PT
Kg/CM2
0-10
PG
Kg/CM2
0-10
PG
Kg/CM2
<0.9
A-U
X
>0.9
<70C
A-U
X
>70 C
<70C
SPARE
<70C
5.2
A-U
X
<4.5, >0.6
>0.6
DP WITH MKG25CP001
5.2
<4.5,>4.5
TO SWITCH OFF H2-S SO PUMP

ATRS > 4.5
5.2
DIRECT SWITCH 'ON' OF DC

OIL PUMP.
5.2
A-U
X
<4.9
COMMON ANN. & IND.

WITH MKW71CP021 FOR DP
WITH MKG25CP001, ATRS
5.2
A-U
X
<4.9
DP WITH MKG25CP002, ATRS

COMMON ANN. & IND WITH
MKW71CP011
5.2
5.2
_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKW 71 CP521
S.OIL PR. (EE) A-S
MKW 71 CT001A
S.OIL TEMP AFT SO CLR (A-S)
MKW 71 CT001B
MKW 71 CT002A
MKW 71 CT002B
MKW 71 CT003A
MKW 71 CT003B
MKW 71 CT501
MKW 73 CF511
S.OIL FLOW TE H2-S
MKW 73 CF521
S.OIL FLOW EE H2-S
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0209E
2.3-4030-10550/29
MKW 73 CP001
<1.0
S.OIL PR. (TE) H2-S
0-10
PG
Kg/CM2
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
RTD
DEG.C
Pt 100
0-100
TG
DEG.C
10-100
FM
LMP
10-100
FM
LMP
0-10
PT
Kg/CM2
0-10
PT
Kg/CM2
0-10
PG
Kg/CM2
5.2
<50C
>50 C
>55 C
2V3 (11)
-
<50C
>50 C
>55 C
2V3* (11)
-
<50C
>50 C
>55 C
2V3 (11)
-
<50C
>50 C
>55 C
2V3 *(11)
-
<50C
>50 C
>55 C
2V3 (11)
-
<50C
>50 C
>55 C
2V3* (11)
-
<50C
<MIN
DP WITH MKW71CP011, ALM
X
0-149-00-01200
MKW 73 CP011
<1.0
S.OIL PR. (EE) H2-S
COMM ANN. WITH MKW73CP011

<MIN
X
0-149-00-01200
MKW 73 CP511
S.OIL PR. (TE) H2-S

0-149-00-01200
5.2
DP WITH MKW71CP021, ALM

COMM ANN. WITH MKW73CP001
_________________________________________________________________________________________
2.3-4030-10550/30
0209E
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKW 73 CP521
S.OIL PR. (EE) H2-S
0-10
PG
MKW 73 CT001
TEMP.S.OIL AFT CLR H2-S
Kg/CM2
0-140
TS
MKW 73 CT002A
TEMP.S.OIL AFT CLR H2-S
DEG.C
0-100
RTD
MKW 73 CT002B
0-149-00-01200
DEG.C
Pt 100
TEMP.S.OIL CLR H2-S
0-100
RTD
MKW 73 CT501
0-149-00-01200
DEG.C
Pt 100
TEMP S.OIL CLR H2-S
0-100
TG
0-149-00-01200
MKW 76 CF511
SEAL FLOW R.RELIEF OIL(TE)
DEG.C
2.66-26.
6
LPM
FM
MKW 76 CF521
SEAL FLOW R.RELIEF OIL(EE)
2.66-26.
6
LPM
FM
MKW 76 CP001
PR. R.RELIEF OIL S.RING (TE)
0-10
PT
MKW 76 CP011
PR. R.RELIEF OIL S.RING (EE)
Kg/CM2
0-10
PT
MKW 76 CP511
PR. R.RELIEF OIL S.RING (TE)
Kg/CM2
0-10
PG
MKW 76 CP521
PR. R.RELIEF OIL S.RING (EE)
Kg/CM2
0-10
PG
MKX 81 CL011
W. FLUID LVL IN DRN TANK
Kg/CM2
LS
MKY 01 CE001
M.BRUSH FOR ROTOR E/F
100
REF
K.Ohm
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
3-149-00-01021
2-145-00-01021
5.2
<50C
>50 C
C.ALARM WITH MKW73CT002A
<50C
>50 C
C.ALARM WITH MKW73CT001
<50C
<50C
6.5
<MIN
C.ALARM WITH MKW76CP011
6.5
<MIN
C.ALARM WITH MKW76CP001
6.5
6.5
A-U
X
>MAX
>80
A-U
X
<80,<5
2 STAGE ALARMS AT <80K

AND E. ALARM AT <5K,
MANUAL TRIPPING ONMACHINE
_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
MKY 03 CE001
GEN END WDG VIB(EE)-2
MKY 03 CE001
MKY 03 CE001
MKY 03 CE001
MKY 03 CE001
MKY 03 CE001
MKY 03 CE001
GEN END WDG VIB(TE)-1
MKY 03 CE001
MKY 03 CE001
MKY 03 CE001
MKY 03 CE001
MKY 03 CE001
PGB 30 CP001
PR. H2 CLRS WATER INLET
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
2.3-4030-10550/31
0209E
0-139-00-01241
0-139-00-01241
0-139-00-01241
10-100
ACC
PC/G
CHARGE
10-100
ACC
PC/G
CHARGE
10-100
ACC
PC/G
CHARGE
10-100
ACC
PC/G
CHARGE
10-100
ACC
PC/G
CHARGE
10-100
ACC
PC/G
CHARGE
10-100
ACC
PC/G
CHARGE
10-100
ACC
PC/G
CHARGE
10-100
ACC
PC/G
CHARGE
10-100
ACC
PC/G
CHARGE
10-100
ACC
PC/G
CHARGE
10-100
ACC
PC/G
CHARGE
PT
KG/CM2
>MAX
STAND ALONE CABINET

MONITORING IN BHEL-MMI
>MAX
STAND ALONE CABINET

>MAX
STAND ALONE CABINET

>MAX
STAND ALONE CABINET

>MAX
STAND ALONE CABINET

>MAX
STAND ALONE CABINET

>MAX
STAND ALONE CABINET

>MAX
STAND ALONE CABINET

>MAX
STAND ALONE CABINET

>MAX
STAND ALONE CABINET

>MAX
STAND ALONE CABINET

>MAX
STAND ALONE CABINET

>MAX
_________________________________________________________________________________________
2.3-4030-10550/32
0209E
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
PGB 30 CT501
TEMP.BEFORE H2 CLR
0-100
TG
0-139-00-01241
DEG.C
PGB 31 CP501
PR. AT THE INLET OF H2 CLR A
0-10
PG
KG/CM2
PGB 31 CP502
PR. AT THE INLET OF H2 CLR B
0-10
PG
KG/CM2
PGB 31 CP503
PR. AT THE INLET OF H2 CLR C
0-10
PG
KG/CM2
PGB 31 CP504
PR. AT THE INLET OF H2 CLR D
0-10
PG
KG/CM2
PGB 31 CT001A
TEMP.BEFORE H2 CLRS
0-100
RTD
DEG.C
Pt 100
PGB 31 CT001B
TEMP.BEFORE H2 CLRS
0-100
RTD
DEG.C
Pt 100
PGB 31 CT002A
TEMP.BEFORE H2 CLRS
0-100
RTD
DEG.C
Pt 100
PGB 31 CT002B
TEMP.BEFORE H2 CLRS
0-100
RTD
DEG.C
Pt 100
PGB 32 CP501
PR. AT O/L OF H2 CLR A
0-10
PG
KG/CM2
PGB 32 CP502
PR. AT O/L OF H2 CLR B
0-10
PG
KG/CM2
PGB 32 CP503
PR. AT O/L OF H2 CLR C
0-10
PG
KG/CM2
PGB 32 CP504
PR. AT O/L OF H2 CLR D
0-10
PG
KG/CM2
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
0-139-00-01241
<38 C
>38 C
<38 C
SPARE
<38 C
>38 C
<38 C
SPARE
_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
PGB 32 CT001A
TEMP.AFTER H2 CLR A
0-100
RTD
0-139-00-01241
DEG.C
Pt 100
PGB 32 CT001B
TEMP.AFTER H2 CLR A
0-100
RTD
0-139-00-01241
DEG.C
Pt 100
PGB 32 CT002A
TEMP.AFTER H2 CLR B
0-100
RTD
0-139-00-01241
DEG.C
Pt 100
PGB 32 CT002B
TEMP.AFTER H2 CLR B
0-100
RTD
0-139-00-01241
DEG.C
Pt 100
PGB 32 CT003A
TEMP.AFTER H2 CLR C
0-100
RTD
0-139-00-01241
DEG.C
Pt 100
PGB 32 CT003B
TEMP.AFTER H2 CLR C
0-100
RTD
0-139-00-01241
DEG.C
Pt 100
PGB 32 CT004A
TEMP.AFTER H2 CLR D
0-100
RTD
0-139-00-01241
DEG.C
Pt 100
PGB 32 CT004B
TEMP.AFTER H2 CLR D
0-100
RTD
0-139-00-01241
DEG.C
Pt 100
PGB 32 CT501
TEMP. AT O/L OF H2 CLR A
0-100
TG
DEG.C
PGB 32 CT502
TEMP. AT O/L OF H2 CLR B
0-100
TG
DEG.C
PGB 32 CT503
TEMP. AT O/L OF H2 CLR C
0-100
TG
DEG.C
PGB 32 CT504
TEMP. AT O/L OF H2 CLR D
0-100
TG
DEG.C
PGB 33 CG001A
C.GAS TEMP.CNTRL VALVE
0-100
0-139-00-01241
0-139-00-01241
2.3-4030-10550/33
0209E
0-139-00-01241
0-139-00-01241
0-139-00-01241
62-45C
>67 C
62-45C
SPARE
62-45C
>67 C
62-45C
SPARE
62-45C
>67 C
62-45C
SPARE
62-45C
>67 C
62-45C
SPARE
ANALOG CONTROL WITH

MOTORISED ACTUATOR,
INDICATION ON CRT CONSOLE
_________________________________________________________________________________________
2.3-4030-10550/34
0209E
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
PGB 33 CT001A
TEMP.AFTER H2 CLR
0-100
RTD
0-139-00-01241
DEG.C
Pt 100
PGB 33 CT001B
TEMP.AFTER H2 CLR
0-100
RTD
0-139-00-01241
DEG.C
Pt 100
PGB 33 CT501
TEMP.AFTER H2 CLR
0-100
TG
0-139-00-01241
DEG.C
PGB 42 CP503
PR. AT INLET OF AIR CLR E
0-10
PG
Kg/CM2
PGB 42 CP504
PR. AT INLET OF AIR CLR F
0-10
PG
Kg/CM2
PGB 42 CP505
PR. AT O/L OF AIR CLR E
0-10
PG
Kg/CM2
PGB 42 CP506
PR. AT O/L OF AIR CLR F
0-10
PG
Kg/CM2
PGB 42 CT001A
TEMP.AFTER EXCITER CLR E
0-100
RTD
DEG.C
Pt 100
PGB 42 CT001B
TEMP.AFTER EXCITER CLR E
0-100
RTD
DEG.C
Pt 100
PGB 42 CT002A
TEMP.AFTER EXCITER CLR F
0-100
RTD
DEG.C
Pt 100
PGB 42 CT002B
TEMP.AFTER EXCITER CLR F
0-100
RTD
DEG.C
Pt 100
PGB 50 CT001A
TEMP-INLET TO SO CLRS
0-100
RTD
DEG.C
Pt100
PGB 50 CT001B
TEMP-INLET TO SO CLRS
0-149-00-01200
0-100
DEG.C
RTD
Pt100
2-145-00-01021
2-145-00-01021
2-145-00-01021
2-145-00-01021
2-145-00-01021
2-145-00-01021
2-145-00-01021
2-145-00-01021
31490001021
62-45C
>67 C
62-45C
SPARE
<42 C
>42 C
<42 C
SPARE
<42 C
>42 C
<42 C
SPARE
SPARE
_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
PGB 50 CT501
WATER TEMP BEF SO CLRS
PGB 51 CP501
PR. BEF SO CLR 2 (H2-S)
PGB 51 CP502
PR. BEF SO CLR 2 (H2-S)
PGB 52 CP501
PR. AFTER SO CLR 1 (H2-S)
PGB 52 CP502
PR. AFTER SO CLR 2 (H2-S)
PGB 52 CT001A
TEMP-OUTLET H2-S SO CLRS
PGB 52 CT001B
TEMP-OUTLET H2-S SO CLRS
PGB 52 CT501
TEMP AFTER SO CLR 1 (H2-S)
PGB 52 CT502
TEMP AFTER SO CLR 2 (H2-S)
PGB 61 CP501
PR. BEFOR SO CLR 2 (H2-S)
PGB 61 CP502
PR. BEFOR SO CLR 2 (H2-S)
PGB 62 CP501
PR. AFTER SO CLR 1 (A-S)
PGB 62 CP502
PR.AFTER SO CLR 2 (A-S)
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0209E
2.3-4030-10550/35
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-100
TG
DEG.C
0-10
PG
KG/CM2
0-10
PG
KG/CM2
0-10
PG
KG/CM2
0-10
PG
KG/CM2
0-100
RTD
DEG.C
Pt100
0-100
RTD
DEG.C
Pt100
0-100
TG
DEG.C
0-100
TG
DEG.C
0-10
PG
KG/CM2
0-10
PG
KG/CM2
0-10
PG
KG/CM2
0-10
PG
KG/CM2
<38 C
SPARE
<43 C
<43 C
<43 C
<43 C
<43 C
<43 C
_________________________________________________________________________________________
2.3-4030-10550/36
0209E
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
PGB 62 CT001A
TEMP- O/L A-S SO CLRS
PGB 62 CT001B
TEMP- O/L A-S SO CLRS
PGB 62 CT501
TEMP AFT SO CLR 1 (A-S)
PGB 62 CT502
TEMP AFT SO CLR 2 (A-S)
PGB 70 CT001A
TEMP AT INLET PW CLR
PGB 70 CT001B
TEMP AT INLET PW CLR
PGB 70 CT501
TEMP.BEFORE PW CLRS
PGB 71 CP501
CW PR.AT INLET PW CLR-1
PGB 71 CP502
CW PR.AT INLET PW CLR-2
PGB 72 CP501
PR. AT O/L OF PW CLR 1
PGB 72 CP502
PR. AT O/L OF PW CLR 2
PGB 72 CT001A
TEMP- O/L OF PW CLR-1
PGB 72 CT001B
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-149-00-01200
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-100
RTD
DEG.C
Pt100
0-100
RTD
DEG.C
Pt100
0-100
TG
DEG.C
0-100
TG
DEG.C
0-100
RTD
DEG.C
Pt100
0-100
RTD
DEG.C
Pt100
0-100
TG
DEG.C
0-10
PG
KG/CM2
Pt100
0-10
PG
KG/CM2
Pt100
0-10
PG
KG/CM2
0-10
PG
KG/CM2
0-100
RTD
DEG.C
Pt100
0-100
RTD
DEG.C
Pt100
SPARE
<43 C
<43 C
<38C
<38C
SPARE
<38.0 C
38-67C
38-67C
SPARE
_________________________________________________________________________________________
TAG NUMBER
SERVICE
RANGE
INSTRUMENT
OPERATING
--------------
------------
-----------------
---------------
TYPE
VALUE
PID_REF DRAWING
UNIT
ANNUN
SET_PTS
----------
VALUE
REMARKS
--------
DDCMIS
CODE
________________________________________________________________________________________________________________
PGB 72 CT002A
PGB 72 CT002B
PGB 72 CT501
TEMP.AFTER PW CLR-1
PGB 72 CT502
TEMP.AFTER PW CLR-2
PGB 73 CG001
PW TEMP.CNTRL VALVE
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-153-00-01065
0-100
RTD
DEG.C
Pt100
0-100
RTD
DEG.C
Pt100
0-100
TG
DEG.C
0-100
TG
DEG.C
0-100
38-67C
38-67C
SPARE
38-67C
38-67C
ANALOG CNTRL WITH

MOTORISED ACTUATOR,
INDICATION ON CRT
2.3-4030-10550/37
0209E
Turbogenerators
Running Routine
Operation
General
1.
Operating Log
During initial startup and during normal operation, the
hydrogen-cooled Turbogenerators, auxiliaries and all
instruments and controls should be monitored to assure
continuous reliable operation. The observations and
readings should be recorded. A typical operating log is
contained in these operating instructions. This table will,
of course, have to be adapted to the particular conditions
of the plant. The important requirement is that all checks
and readings be made at certain predetermined intervals
and preferably at the same load point. Any special
conditions regarding the operation of the hydrogen-cooled
BHEL, Haridwar
turbogenerators should be noted separately. Such notes

may be useful in determining the cause of any subsequent
trouble and speeding up corrections.
2.
Normal and Special Operating Conditions

The Generator should be continuously monitored from
startup to shutdown. During initial startup, all checks should
be made at frequent intervals. Hourly readings may be
taken after completion of the initial period.
A generator at standstill is considered to have been
taken into service and must be continuously monitored after
one supply system was placed in operation.
2.3-4100-10550/1
0209 E
Turbogenerators
Operating Log
Operation
Generator Supervision
Job name ............................................................ Sl. No. ............................................ Remark .............................................
Operating values*
Unit
Tag
Number
Active power
MW
Reactive power
MVAR
Stator current
kA
Stator voltage
kV
Rotor current
Speed
Generator gas pressure
kg/cm
Slot 1
3
Primary water
Measuring point 1
outlet temperature
Measuring point 2
measuring point 3
C
C
C
C
C
C
C
C
Measuring point 1
TE Measuring point 2
Stator core
Measuring point 3
temperature
Measuring point 1
EE Measuring point 2
Measuring point 3
Coolers a/b
cold
Coolers c/d
cold
Coolers a/b
hot
Coolers c/d
hot
Gas temperature
TE water manifold
-1
2
Slot temperature
C
C
C
C
C
C
C
C
C
C
EE After coolers a/b
EE After coolers c/d
C
C
Inlet
TE
EE
Generator bearing
TE
temperatures
EE
TE
kg/cm
EE
kg/cm
TE ahv
mm
EE ahv
mm
Bearing oil
temperature
Outlet
Shaft lift oil pressure

Generator bearing vibration
Date
C
C
C
C
Data should be recorded during steady-state conditions after constant operation for several hours.
BHEL, Haridwar
2.3-4120-10550/1
0209 E
Turbogenerators
Operating Log
Operation
Seal Oil System
Operating values*
Unit
Air side pressure after seal oil pumps
kg/cm
Hydrogen side pressure after seal oil pump
kg/cm
Air side seal oil pressure after orifice
kg/cm
TE
kg/cm
EE
kg/cm
TE
kg/cm
EE
kg/cm
TE
mbar
EE
mbar
TE
kg/cm
EE
kg/cm
TE
kg/s
EE
kg/s
TE
kg/s
EE
kg/s
TE
kg/s
Air side seal oil pressure
Hydrogen side seal oil pressure
Seal oil differential pressure
Ring relief oil pressure
Air side seal oil volume flow
Hydrogen side seal oil volume flow
Ring relief oil volume flow
kg/s
Inlet
Outlet
TE
oil drain temperature
EE
Seal oil temperatures,
Inlet
Outlet
Inlet
hydrogen side seal oil cooler

Hydrogen side seal
air side seal oil coolers
Cooling water
temperatures
Date
EE
Seal oil temperatures,
Tag
Number
C
C
C
C
C
C
C
Outlet, H2 side cooler 1
Outlet, H2 side cooler 2
Outlet, air side cooler 1
Outlet, air side cooler 2
C
C
C
C
Data should be recorded during steady-state conditions after constant operation for several hours.
BHEL, Haridwar
2.3-4150-10550/1
0209 E
Turbogenerators
Operating Log
Operation
Gas System
Operating values*
Unit
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
Pressure before gas dryer
kg/cm2
Tag.
Number
Data should be recorded during steady-state conditions after constant operation several hours.
**
To be recordced only on failure of electrical purity meter system.
BHEL, Haridwar
Date
2.3-4160-10550/1
0209 E
Turbogenerators
Operating Log
Operation
Operating values*
Unit
Generator inlet
Prinary water
Stator winding outlet
Temperature
Bushing outlet
Before coolers
After collers
Stator winding oulet
dm3/s
Bushing outlet U
dm3/s
Bushing outlet V
dm3/s
Bushing outlet W
dm3/s
Treated water
dm3/s
Primary water
Stator winding inlet
kg/cm2
pressure
After PW pumps 1/2
kg/cm2
Primary water
conductivity
After main filter
S/cm
After ion exchanges
S/cm
Prinary water flow
Primary water level in primary water tank
Gas pressure in primary water tank
kg/cm2
BHEL, Haridwar
Tag.
Number
Date
2.3-4170-10550/1
0209 E
Turbogenerators
Operating Log
Operation
Exciter Supervision
Operating values*
Cooling air
temperature
Unit
Cold air
Hot air
Rectifier wheels Hot air
Main exciter
Coolers e/f
Cooling water
temperature Cooler e
Cooler f
Exciter bearing temperature
C
C
Inlet
Outlet
Outlet
Measuring Point 1
Measuring point 2
C
C
C
C
C
Exciter shaft vibration
Relative
Exciter bearing vibration
Absolute
Date
Bearing oil outlet temperature
Shaft lift oil pressure
Tag
Number
kg
Data should be recorded during steady-state conditions after constant operation several hours.
BHEL, Haridwar
2.3-4190-10550/1
0209 E
Turbogenerators
Operation
It is a prerequisite for startup of the turbine generator
that continuous contracts be maintained between all plant
sections directly or indirectly involved in the starting
procedure.
Prior to startup, it should be ascertained that the
following auxiliaries are in operation and will continue to
remain in service.
Q
Q
Q
Q
Seal oil system

Gas system
Secondary cooling water system
If auxiliaries were taken out of operation, the

operating media required to fill the auxiliary systems
should be made available.
1.
Operating Media
Preparations for Starting

Introduction
im mediate removal of the hydrogen from the generator.

1.2.2 Hydrogen (H2)
The hydrogen gas quantity to be provided should
suffice for displacing the CO2, for filling the generator to
operating pressure and to compensate for the H2 losses
during operation [4].
1.2.3 Nitrogen (N2)
For primary water purging [4].
1.3 Primary Water Supply
The water quantity to be provided for filling the entire
primary water circuit should amount to approximately two
times the primary water filling quantity. This allows for the
water quantity required for rinsing the primary water circuit.
1.4 Cooling Water Supply
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.

Q
Q
Q
Q
Q
Turbine oil
Carbon dioxide (CO2)
Hydrogen (H2)
Nitrogen (N2)
Primary water
Note : Continuous vents should remain open. The vents

should be kept open until the air on the water side of
the coolers has been completely expelled.
Before startup, the operating staff should ensure that
a sufficient cooling water supply is available.
must conform to the specifications [1] and [2].
2.
1.1 Seal Oil System

The seal oil circuits should be filled with turbine oil.
The quantity of turbine oil required to fill the seal oil circuits
should be taken into consideration when filling the turbine
oil tank.
Prior to startup, all connections should be rechecked.

This applies to piping as well as to cabling. When checking
the cabling special attention should be paid to testing the
metering and signal cables. All alarm systems should be
checked.
All temperature measuring points should also be
checked. This applies to the local as well as the remote
reading thermometers. Unless temperature rises were
brought about by other preparatory work at the measuring
points, temperatures of approximately ambient or room
temperature should be indicated. When doubts exist
regarding the electrical temperature measurement,
calibration and line compensation should be repeated.
1.2 Gas System

1.2.1 Carbon Dioxide (CO2)
The carbon dioxide quantity to be provided should
suffice for two complete generator fillings [3], i.e. for
displacement of the air prior to hydrogen filling and for
Checking the Transmitters
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
BHEL, Haridwar
2.3-5000-10550/1
0209 E
Turbogenerators
Hints for Cooler Operation
Operation
1 General
The heat exchangers of the generator and its
auxiliaries have copper, copper alloy or stainless steel
tubes. Admiralty brass (CuZn28Sn) is primarily used for
fresh-water applications, while aluminium brass
(CuZn20Al) is selected for seawater service.
Copper and copper alloy tubes must from a
protective film on the cooling water side to ensure
adequate resistance to corrosion attack. The formation
and the preservation of the protective film are essentially
dependent on the conditions during initial commissioning
and subsequent service.
2 Cooler Tube Materials
The coolers of the unit described have copper,
copper alloy or stainless steel tubes.
Details of the cooler tube materials are specified
in the Technical Data section of this manual [1].
2.1 Copper or Copper Alloy Cooler Tubes
Influences on the cooling water side can cause
damage to the copper or copper alloy tubes of the
coolers, primarily in the form of erosion/corrosion and
corrosion attack due to
Q
Q
Q
2.2
insufficient protective film formation

excessive cooling water velocity
localized, excessive cooling water velocity resulting
from tube blockage by foreign bodies.
deposits on tubes caused by suspended material
and/or remnants of microorganisms which impair
the formation of a protective film and promote
corrosion, especially in (standby) coolers having
no cooling water flow for some time.
Stainless Steel Cooler Tubes
Cooler tubes of stainless steel are susceptible to

pitting and crevice corrosion under deposits, especially
when the cooling water has a high salt content and
primarily when no cooling water is passed through the
(standby) coolers for some time. The corrosion rate
decreases with increasing cooling water velocity.
3
Cooling Water Properties
The cooling water used for the coolers must meet

the following requirements :
The cooling water must be free from coarse
impurities
BHEL, Haridwar
The amount of suspended material must be as

small as possible.
The growth of micro organisms and, in case of
seawater installations, the growth of mussels must
be prevented.
Cooling water obtained from a closed secondary

cooling water circuit mostly meets these requirements
provided that the necessary care is exercised during
initial operation, for example, by flushing the system
without passing water through the coolers.
When using water directly obtained from natural
water sources, adverse influences should be minimized
by suitable treatment procedures (e.g. filtration, dispersant
dosing, chlorination and similar methods as specified in
the literature).
4
Initial Operation of Coolers
Prior to placing the coolers in operation for the first

time the cooling water system should be thoroughly
cleaned by flushing to remove impurities and foreign
matter.
During this flushing procedure, the coolers should
not be in service on their cooling water sides, i.e. bypass
arrangements must ensure that the flushing procedure
can be carried out without passing water through the
coolers. Following the flushing procedure, cooling water
must be continuously passed through coolers with copper
alloy materials for the longest possible period of time
(four to eight weeks) to ensure the formation of an
effective protective film on the cooler tubes.
5
Preventing Standstill Corrosion
Depending on the cooler material and the kind and

properties of the cooling water, standby coolers through
which no cooling water flows for some period of time are
subjected to all corrosive influences that can occur during
an outage.
This involves the risk that the microorganisms on
the tube walls will die due to the lack of oxygen resulting
from the loss of fresh water supply and form decay
products during decomposition, such as ammonia.
Depending on the material used, this may lead to
corrosion and/or stress corrosion cracking.
Using cooler tubes of stainless steel with cooling
water having a high salt content involves the risk of pitting
and crevice corrosion when residual amounts of cooling
water, possibly in conjunction with deposits, produce a
corrosive influence.
Corrosion damage can only be safely prevented if
the standby coolers are drained on their water sides,
2.3-5003-10550/1
0209E
cleaned, completely dried, vented, and maintained in a

dry condition.
For cleaning, the coolers may be flushed with water
having a low salt content (Cl content < 500 mg/l for
copper alloy tubes, < 100 mg/1 for stainless steel tubes).
For drying the medium to be cooled can be passed
through the coolers via the filler and vent pipes. However,
this measure cannot be always implemented in practice,
especially in the case of brief outages and because of
the need to maintain the cooler ready for operation.
If a cooler has to maintained ready for service in
filed condition, it should be flushed with the full cooling
water volume flow for a brief period twice every week. In
addition, it is recommended to perform a cooler
changeover once every week so that the normal-service
cooler and the standby cooler will be alternately in
operation.
7.
6.
8.
Preventing Deposits in Cooler Tubes
Deposits in the cooler tubes are best prevented

by supplying the normal-service coolers with the full
cooling water volume flow.
If the temperature of the medium to be cooled is
controlled by varying the cooling water volume flow, it is
recommended to supply the normal-service cooler with
the full cooling water volume for a brief period twice every
week in order to flush away any deposits formed on the
tubes due to insufficient cooling water velocity.
During occasional outages of sufficient duration or
during an overhaul, it should than be checked whether
in-service flushing is sufficient or whether manual
cleaning is required. If frequent manual cleaning is
necessary on account of poor cooling water conditions,
the installation of a high-velocity water cleaning system
or of a cleaning system using sponge rubber balls should
be considered.
Special Measures for Wet Preservation
If a cooler has to be maintained ready for service

in filled condition, the water volume in the cooler must
not be hermetically sealed from the cooling water system
or from the surrounding atmosphere, respectively
improper cooler changeover would then result in heating
and excessive expansion of the cooling water volume,
leading to damage to the cooler gaskets or piping due to
excessive pressure.
For wet preservation always open a cooler vent
on the water side or a shutoff valve by a small amount
making sure to avoid a low-velocity water flow that would
promote the entry of suspended material.
Note : Standby coolers should be maintained ready for
operation in dry condition in preference to wet
preservation.
Cooler Changeover
Make sure to fill and vent standby coolers on their

water sides prior to changing over the coolers. Fully open
shutoff valves. After cooler changeover, which must be
performed by experienced personnel, perform all
measures required for preservation of the cooler
removed from normal service and now on standby.
To do this, close shutoff valves upstream and
downstream of the standby cooler, since the cooling
water system is mostly designed only for supply of the
cooling water flow through the normal-service cooler(s).
Then open the shutoff valve on the outlet side by a small
amount to avoid the effects of a water expansion due to
water heating.
8.1
Criteria for Cooler Changeover

A cooler changeover is necessary when, with the
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
2.3-5003-10550/2
0209 E
Turbogenerators
Filling and Initial Operation
Operation
of Air Side Seal Oil Circuit
Prerequisites for filling of air side seal oil circuit

1
Preparatory work for

start-up
Q
Q
Q
Q
Seal oil circuit must have been cleaned and flushed.

Direction of pump rotation and oil level in seal oil
pumps must have been checked.
All level detectors in seal oil system must be calibrated
and activated.
All relief valves must be set.
Seal oil storage tank must be filled with oil.
Note: All operating procedures should be performed

in sequence specified.
2
Fill air side seal oil circuit
2.1
Open all pressure gauge shutoff valves
2.2
Open shutoff valves in signal pipes
2.3
Open shutoff and gate valves in air side seal
oil circuit
BHEL, Haridwar
MKW11 AA506
MKW31 AA506
MKA23 AA503
MKA23 AA504
MKW71 AA513
MKW73 AA513
MKW71 AA523
MKW73 AA523
(air side oil signal to A1 valve)

(gas signal to A1 valve)
(air side oil signal, TE)
(hydrogen side oil signal, TE)
(air side oil signal, EE)
(hydrogen side oil signal, EE)
MKW01 AA503
MKW11 AA504
MKW11 AA505
MKW31 AA504
MKW33 AA 505
MKW11 AA501
MKW21 AA501
MKW31 AA501
MKW11 AA003
MKW21 AA002
MKW31 AA003
MKW31 AA004
MKW11 AA004
MKW03 AA502
MKW03 AA501
MKW03 AA505
(at seal oil storage tank)

(before A1 valve)
(after A1 valve)
(before A2 valve)
(After A2 Valve)
(before seal oil pump 1)
(before stand by seal oil pump 3)
(after seal oil pump 1)
(after standby seal oil pump 3)
(after seal oil pumps)
(before float valve, oil inlet)
(after float valve, oil drain)
(for oil level gauge)
2.3-5110-10550/1
0209E
MKW03 AA506
MKW71 BP501
MKW71 AA512
MKW71 AA522
MKW76 AA512
MKW76 AA522
MKW76 AA513
MKW76 AA523
2.4
Place seal oil coolers in operation
2.5
Place seal oil filters in operation
2.6
Place bearing vapor exhausters in
operation
2.7
Start air side seal oil pump MKW11 AP001

(adjustable orifice)
(after volume flow indicator
MKW71 CF511)
MKW71CF521)
MKW76 CF511)
MKW76 CF521)
(seal ring relief oil, TE)
(seal ring relief oil, EE)
Place both seal oil coolers in operation on oil side

with rotary transfer valve assembly in its center position.
When the coolers are filled with seal oil, turn rotary
transfer valve assembly to right-hand or left-hand stop. With
the valve, assembly in this position, one cooler is in service
and one cooler on standby.
The seal oil cooler placed in operation on the oil
side should also be filled and vented on its water side.
Note : After filling, the shutoff valve for cooling water after
the cooler should be closed.
Place both seal oil, filters in operation with rotary
transfer valve assembly in its center position.
When the filters are filled with seal oil, turn rotary
the valve assembly in this position, one filter is in service
and one filter on standby.
Place one exhauster in operation electrically.

Ensure that second exhauster is ready for start-up.
With seal oil storage tank MKW01 BB001 filled and

shutoff valve MKW01 AA503 open, seal oil is available at
seal oil pump 1 after a short time. Start seal oil pump 1.
Note : To avoid a temporary excessive pressure built up in
the piping system, air in the piping must be slowly displaced
with oil. Start and immediately stop main seal oil pump
several times until the pressure gauges at the generator,
i.e.
MKW71 CP511
MKW73 CP521
(air side seal oil pressure, TE)

(air side seal oil pressure, EE)
indicate a constant pressure. The pump should then remain

in continuous operation.
De-energize seal oil pump immediately when the
2.3-5110-10550/2
0209E
Turbogenerators
Operation
level detector system in the seal oil storage tank signals a

low oil level. Restarting the seal oil pump is only permissible
after the seal oil storage tank has been filled to the required
level.
2.8
Observe oil level in seal oil tank MKW03
BB001
During filling of the air side circuit, the seal oil tank
is simultaneously filled with seal oil via float valve MKW03
AA002. The float valve closes when the oil level reaches a
predetermined level, and the flow of oil from the air side
circuit into the seal oil tank is interrupted. However, oil will
continue to flow from the hydrogen side of the shaft seal
into the seal oil tank, resulting in a rise of the oil level above
the sight glass. This is caused by the lack of pressure in
the generator.
2.9
Set three-way valves before volume flow
indicators to position for normal operation
3
Air side seal oil circuit is filled
Set three-way valves

MKW71 AA511
(before volume flow indicator
MKW71 CF511)
MKW71 AA521
MKW71 CF521)
MKW76 AA511
MKW76 CF511)
MKW76 AA521
MKW76 CF521)
to position where no oil passes through the volume flow
indicators.
Start with filling of hydrogen side seal oil circuit.
BHEL, Haridwar
2.3-5110-10550/3
0209E
Turbogenerators
Operation
of Hydrogen Side Seal Oil Circuit
Prerequisites for filling of hydrogen side seal oil circuit :

1
Preparatory work for

start-up
2
Fill hydrogen side seal oil circuit
2.1
Open shutoff and signal pipes
2.2
Open shutoff and gate valves
Air side seal oil circuit was filled and is in operation.
Note: All operating procedures should be performed in

sequence specified.
MKW13 AA507
MKW13 AA505
MKA13 AA506
(signal equalization, C valve)

(air side oil signal, C valve)
(hydrogen side oil signal, C valve)
MKA13 AA501
MKW13 AA003
MKW13 AA510
MKW73 AA512
(before hydrogen side seal oil pump)

(after hydrogen side seal oil pump)
(after C valve)
MKW73 CF511)
MKW73 CF512)
(before seal oil cooler)
MKW73 AA522
2.3
Place seal oil coolers in operation
MKW13 AA503
Place both seal oil coolers in operation on oil side

with rotary transfer valve assembly in its center position.
When the coolers are filled with seal oil, turn rotary
the valve assembly in this position, one cooler is in service
and one cooler on standby.
The seal oil cooler placed in operation on the oil
side should also be filled and vented on its water side.
Note : After filling, the shutoff valve for cooling water after
the cooler should be closed.
2.4
Place seal oil filters in operation.
BHEL, Haridwar
Pace both seal oil filters in operation with rotary

transfer valve assembly in its center position.
When the filters are filled with seal oil, turn rotary
the valve assembly in this position, one filter is in service
and one filter on standby.
2.3-5120-10550/1
0209 E
2.5
Place and keep hydrogen side seal oil pump
MKW13 AP001 in operation
Place hydrogen side seal oil pump in operation

electrically. Start and immediately stop pump several times
until the air has been displaced from the piping. The pump
should then remain in continuous operation.
2.6
Close signal equalizing valve MKW13
AA507 at C valve
2.7
Set three-way valves before volume flow
indicators to position for normal operation
Set three-way valves :

MKW73 AA511
MKW73 CF511)
MKW73 AA521
MKW73 CF521)
to position where no oil passes through the volume flow
indicators.
3
Hydrogen side seal oil circuit is filled.
2.3-5120-10550/2
0209E
Start with venting of seal oil circuits.
Turbogenerators
Venting of Seal Oil Circuits
Operation
Vent seal oil circuit
1.1
Vent signal pipes and main bellows of
differential pressure regulating valves (A1,
A2 and C valves)
1.2
Vent seal oil coolers
Keep vent valves at differential pressure regulating

valves open until oil emerges without bubbles.
Then loosen venting screws and vent main bellows
of differential pressure regulating valves.
Vent seal oil coolers in air side and hydrogen side

seal oil circuits by means of vent valves :
MKW51 AA511
MKW51 AA510
MKW53 AA511
MKW53 AA510
(air side seal oil cooler 1)

(air side seal oil cooler 2)
*hydrogen side seal oil cooler 1)
(hydrogen side seal oil cooler 2)
Close vent valves when oil emerges without bubbles.
1.3
Vent seal oil filters
Vent seal oil filters in air side and hydrogen side

circuits through venting screws on filter housings.
1.4
Vent all signal pipes to the pressure
measuring devices through the venting
screw of the respective pressure gauge
shutoff vale.
1.5
pressure equalizing value MKW73 AA011
Venting should be performed as follows :

Q
BHEL, Haridwar
Open vent valves

MKW73 AA514
(in hydrogen side signal pipe)
MKW71 AA514
(in air side signal pipe)
for venting the signal pipes up to the pressure

equalizing valve. Close valves when oil emerges
without bubbles.
Close shutoff valve
MKW71 AA513
(for air side oil signal)
2.3-5130-10550/1
0209 E
and open vent valve

MKW71 AA514
to vent the main bellows of the pressure equalizing
valve close vent valve when oil emerges without
bubbles. Shutoff valve MKW71 AA513 should then
be reopened.
1.6
pressure equalizing valve MKW73 AA021
Venting should be performed as follows :

Q
Open vent valves:

MKW71 AA524
(in hydrogen side signal pipe)
MKW71 AA524
*in air side signal pipe)
for venting the signal pipes up to the pressure

equalizing valve. Close valves when oil emerges
without bubbles.
Close shutoff valve
MKW71 AA523
(for air side oil signal)
and open vent valve

MKW71 AA524
valve. Close vent valve when oil emerges without
bubbles. Shutoff valve MKW71 AA523 should then
be reopened.
Q
Close shutoff valve

MKW73 AA523
(for hydrogen side oil signal)
and open vent valve
MKW73 AA524
2
Venting of all circuits and components of
the seal oil system is cimpleteed.
2.3-5130-10550/2
0209E

valve close vent valve when oil emerges with bubbles.
Shutoff valve MKW73 AA523 should then be
reopened.
Turbogenerators
Setting of Seal Oil Pressures
Operation
Set seal oil pressures
1.1
Adjust A1 valve MKW11 AA002
1.2
Set seal oil pressure for seal ring relief
1.3
Adjust C valve MKW13 AA002
1.4
Adjust pressure equalizing valves MKW73
AA011 and MKW73 AA021 for hydrogen
side circuit
BHEL, Haridwar
Note : Values indicated below apply to the generator at

standstill and seal oil temperatures after coolers of 20 to
300C. Check that temperatures of air side and hydrogen
side seal oil are approximately equal.
When setting the pressures, make sure to observe
the static head of the respective units and instruments.
Loosen lock nut at valve stem. Turn adjusting nut

to set A11 valve so that a seal oil pressure of approximately
1.5 bar above the gas pressure in the generator is
established at shaft seals.
Note : Clockwise turning of adjusting nut increases seal
oil pressure at shaft seals.
Counterclockwise tuning of adjusting nut decreases
seal oil pressure at shaft seals.
Adjust orifice MKW71 BP501 and A valve MKW11

AA002 so that the seal oil pressure for seal ring relief will
be higher than the seal oil pressure at the shaft seals by
approximately 1 bar.
Note : Adjustment is preliminary only since shaft seals are
not yet subjected to generator casing pressure.
Final adjustment can only be made when the
generator is filled to rated pressure and operated at rated
speed. When making the final adjustment, also check the
running condition of the turbine-generator, since an
incorrectly set seal oil pressure may impair the running
condition of the generator.
Use C valve to adjust oil pressure after hydrogen

side seal oil pump. Setting should be made in the same
way as for the A valve by turning the adjusting nut.
The seal oil pressure after the hydrogen side seal
oil pump must be higher than the seal oil pressure at the
shaft seals. This higher pressure is required to enable the
pressure equalizing valves to maintain a constant seal oil
pressure.
Remove lower cap and loosen lock nut.
Hydrogen side seal oil pressure is decreased by
turning threaded stem clockwise and increased by turning
counterclockwise.
pressure differences between air side and hydrogen
side seal oil pressures are indicated by differential pressure
gauges MKA06 CP501 and MKA07 CP501.
2.3-5150-10550/1
0209 E
After completion of the adjustment, tighten lock nut

and replace cap.
Make sure that position of upper threaded stem has
not been changed.
1.5
Adjust A2 valve MKW31 AA002
Note : The operating values for the A1 and C valves should

be measured so they can be used as target values before
starting with adjustment of A2 valve.
Stop operation of seal oil pumps 1 and 2. Standby
seal oil pump 3 will start automatically.
Make adjustment in the same manner as was done
for A1 valve. During operation with A2 valve, the seal oil
pressure must be the same as when operating with A1
valve. Under normal condition, A1 valve is the controlling
valve.
Recheck and , if required, correct setting when the
generators is in operation.
2
Setting of seal oil pressures is completed
Set alarm and changeover contacts.
2.3-5150-10550/2
0209E
Turbogenerators
Setting of Operating Values
Operation
for Seal Oil system
Set operating values

for seal oil system
2
Alarm contacts at twin filters in air side and
hydrogen side circuits
3
Check function of pressure switches
4
Check function of level detectors
MKA06CL001 and MKA07 CL001 in
installed condition
Check function of complete control and supervisory

equipment.
Alarm contacts at differential pressure indicators are

set so that alarm will be initiated when filters are
contaminated.
Check function of all pressure switches in installed

condition. If necessary, correct pressure switch setting to
match actual pressure conditions.
This check is only permissible when the generator

is filled with air at 0 bar. Separate functional testing is
required for each level detector.
Remove hex plug from stator end shield located
near the level detector. Close shutoff valve MKW03 AA501.
Take seal oil pump MKW13 AP001 out of service. The oil
level in the generator pre-chambers will rise. The alarm is
activated as soon as the oil level reaches the level detector.
Shutoff valve MKW03 AA501 should then be
opened immediately and secured to prevent closing. The
oil level will drop. Cancel the alarm.
1 Stator end Shield

2 Hex Plug
3 Level Detector
Fig. 1 Level Detector
BHEL, Haridwar
2.3-5160-10550/1
0209 E
5
Set limit cards for temperature monitoring
6
checking and setting of supervisory
equipment is completed
If seal oil flows from the threaded hole without an

alarm being give, the cause of the level detector malfunction
should be investigated, in such a case, shutoff valve
MKW03 AA501 should then also be opened immediately.
After completion of a successful test, replace hex plug,
making sure that a gas tight seal is obtained.
Set limit cards for temperature monitoring to operating
2.3-5160-10550/2
0209E
Turbogenerators
Measurement of Seal Oil Volume Flows
Operation
Measure volume flows
2
Open shutoff valves for seal oil volume flow
measurement in air side circuit
3
Open shutoff values for seal oil volume flow
measurement in hydrogen side circuit.
MKW71 AA512
(before TE shaft seal)
MKW71 AA522
(before EE shaft seal)
Adjust three-way valves MKW71 AA511 and
MKW71 AA521 so that seal oil flow via volume flow meters.
MKW73 AA512
MKW73 AA522
(before TE shaft seal)

(before EE shaft seal)

MKW73 AA521 so that seal oil flows via volume flow meters.
4
Open shutoff valves for ring relief oil
volume flow measurement
MKW76 AA 512 (for seal ring relief, TE)

MKW76 AA522
(for seal ring relief, EE)
MKW76 AA521 so that relief oil flows via volume flow
meters.
5
Volume flow meters are activated
Start with next settings.
BHEL, Haridwar
2.3-5163-10550/1
0209E
Turbogenerators
Functional Testing of Pumps and
Operation
Exhausters
Perform functional test
2
Check standby seal oil pump for proper
operation
3
Check pumps for automatic operation
4.
When a seal oil temperature more than
400C has been reached, turn on the cooling
water supply to cooler selected for
operation so as to obtain the specified heat
removal capacity.
5
Check bearing vapor exhausters for proper
operation
Measure vacuum in bearing compartments with a U-tube

pressure gauge while the bearing vapor exhauster is in
operation. The vacuum should be between approximately
5 to 10 mbar.
6
Filling and startup procedures are
completed
being normal running routine
BHEL, Haridwar
2.3-5180-10550/1
0209E
Turbogenerators
Startup of Air Side Seal Oil Circuit
Operation
Startup of air side

seal oil circuit
The seal oil system must be in operation when the

generator is :
to be filled with hydrogen.
to be filled with air for leakage testing or
to be operated under load.
Prior to startup, make sure that all indicating devices
are ready for operating and that the Preparations for
Starting have been carried out. The system will normally
be ready for startup when it was shut down in accordance
with the respective instructions.
Place one bearing vapor exhauster in operation.
1.1
Check to ensure that all pressure gauge
shutoff valves are open
1.2
Check if shutoff valves in seal oil circuit are
open
BHEL, Haridwar
Open shutoff valves in specified sequence

MKW01 AA503
(at seal oil storage tank)
MKW11 AA504
(before A1 valves)
MKW11 AA505
(after A1 valve)
MKW31 AA504
(before A2 valve)
MKW31 AA505
(after A2 valve)
MKW11 AA501
MKW21 AA501
MKW31 AA501
(before standby seal oil pump 3)
MKW11 AA003
MKW21 AA002
MKW31 AA003
MKW31 AA004
MKW11 AA004
(after seal oil pumps)
MKW03 AA502
(before float valve, oil inlet)
MKW03 AA501
(after float value, oil drain)
MKW03 AA505
MKW03 AA506
MKW71 BP501
(adjustable orifice)
MKW71 AA512
MKW71 CF511)
MKW71 AA522
MKW76 CF511)
MKW76 AA522
MKW76 CF521)
2.3-5210-10550/1
0209 E
1.3
Verify that shutoff valves in signal lines of
air side circuit are open
1.4
Start air side seal oil pump 1, MKW03
BB001
1.5
Check oil level in seal oil tank MKW03
BB001
2
Air side seal oil circuit is now in operation
2.3-5210-10550/2
0209E
MKW11 AA506
MKW31 AA506
MKW23 AA503
MKW23 AA504
MKW71 AA513
MKW73 AA513
MKW71 AA523
MKW73 AA523

(air side oil signal, TE)
(hydrogen side oil signal, TE)
(air side oil signal, EE)
(hydrogen side oil signal, EE)
Check oil level in seal oil pumps. Place seal oil pump
in operation.
Note : To avoid a temporary excessive pressure build up
in piping system, air in piping must be slowly displaced
with oil. Start and immediately stop seal oil pump several
times until all air is removed from the piping system. Seal
oil pump 1 should then be kept in continuous operation.
During filling of air side circuit, the seal oil tank is

simultaneously filled with seal oil via float valve MKW03
AA002. The float valve closes when the oil level reaches a
predetermined level. Oil will continue to flow from the
hydrogen side of the shaft seal into the seal oil tank,
resulting in a rise of the oil level above the sight glass. This
is caused by the lack of pressure in the generator.
Start with filling of hydrogen side seal oil circuit.
Turbogenerators
Startup of Hydrogen Side Seal Oil
Operation
Circuit
The air side seal oil circuit must be in operation.
Start-up of hydrogen side

seal oil circuit
1.2
Fill seal oil circuit
1.1
Seal oil level is observable at sight glass
of seal oil tank
1.3
Check to assure that shutoff valves in
hydrogen side circuit are open
no
MKW13 AA501
MKW13 AA003
MKW13 AA510
MKW73 AA512
MKW13 AA513
(before hydrogen side seal oil pump)

(after C valve)
MKW73 CF511)
MKW73 CF521)
(before seal oil cooler)
MKW13 AA507
MKW13 AA505
MKW13 AA506
(signal equalization, C valve)

(air side oil signal to C valve)
(hydrogen side oil signal to C valve)
MKW73 AA522
1.4
Verify that shutoff valves in signal lines of
hydrogen side circuit are open
1.5
Start hydrogen side seal oil pump
MKW13 AP001
2
Hydrogen side seal oil circuit is now in
operation
BHEL, Haridwar
Start with venting of seal oil circuits
2.3-5220-10550/1
0209 E
Turbogenerators
Venting of Seal Oil Circuits and
Operation
Checking of Seal Oil Pressures
Vent and check oil pressures
2
Vent coolers and filters
2.1
Vent seal oil coolers (oil side) and seal oil
filters
Keep vent valves of all seal oil coolers and vent plugs
of seal oil filters open until the oil emerges without bubbles.
2.2
Check seal oil filters for contamination and
clean filters, if required
The degree of filter contamination can be seen at the

differential pressure gauge. When the indicator is
completely red. Cleaning will be required.
2.3
Fill service seal oil cooler on water side
and vent cooler
3.1
Vent oil signal lines, Adjust A1, A2, C valves
and pressure equalizing valves.
3.2
Ven pressure gauges
3.3
yes
Is pressure gauge reading correct ?

no
BHEL, Haridwar
2.3-5230-10550/1
0209 E
3
Oil pressures are in agreement with the
previous operating values.
4
Check and, if required, adjust operating
values for seal ring relief
5
Seal oil pressures are set
2.3-5230-10550/2
0209E
no
Note : Final adjustment of the pressure for ring relief can

only be made when the generator has been filled with
hydrogen to rated pressure, when the seal oil is hot and
when the generator operates at rated speed.
Start with functional tests.
Turbogenerators
Checking Automatic Operation of
Operation
Seal Oil Pumps
Perform functional test
2
Check standby seal oil pump for proper
operation
3
Check automatic operation of pumps
4
When a seal oil temperature is more than
400C, turn on the cooling water supply to
cooler selected for operation so as to obtain
the specified heat removal capacity
5
Check bearing vapour exhausters for
proper operation.
6
End of starting procedure. Begin with
normal running routine
BHEL, Haridwar
2.3-5280-10550/1
0209 E
Turbogenerators
Positions of Multi-Way Valves
Operation
in Gas System
BHEL, Haridwar
2.3-6107-10550/1
0209 E
Turbogenerators
Scavenging the Electrical
Operation
Preparatory work
2
Set mechanical zeros
Prior to activating the purity meter system, leak tests

of the generator and its auxiliaries must be finished.
Check gas lines and wiring of the meter system for
correct installation. Transmitter terminals not connected to
an indicator must be connected to the equivalent resistor
(200 or 290 ohm, incorporated in transmitter) by inserting
a jumper (connect negative terminal with terminal (*)).
With the power supply switched off, set output

instruments to their mechanical zeros. In case of indicators,
this should be done by means of the zero setter. In case of
recorders, make setting in accordance with applicable
service instructions.
3
Scavenge measuring gas system
3.1
Prepare to scavenge measuring gas
system
During commissioning make sure that no hydrogen (H2) is

introduced into the air filled generator. Close shutoff valves
and three-way valves.
MKG25 AA519
MKG25 AA518
MKG25 AA502
MKG25 AA512
(H2 filter line)

(CO2 filter line)
(vent gas)
(sampling)
Scavenge piping system with hydrogen prior to

electrical commissioning of the meter system.
Connect one full bottle of H2 to the bottle rack
3.2
Set H2 pressure reducers to minimum lowpressure setting
Loosen the locks for the adjusting screws of H2

pressure reducers.
MKG11 AA001
MKG19 AA001
MKG12 AA001
MKG19 A002
(H2
(H2
(H2
(H2
pressure reducer 1, H2 bottle rack)

pressure reducer 2, H2 unit)
pressure reducer 1, H2 bottle rack)
pressure reducer 2, H2 unit)
Turn adjusting screws counterclockwise to bring

each pressure reducer to lower end of low-pressure range.
BHEL, Haridwar
2.3-6110-10550/1
0209 E
3.3
Set flow path of measuring gas. Open
shutoff valves
3.4
Set H2 pressure reducers to rated gas
pressure.
3.5
Set pressure reducer for measuring gas to
minimum low-pressure setting.
3.6
Three-way valve MKG25 AA507
3.7
Set scavenging gas volume flow
3.8
Terminate scavenging procedure and set
measuring gas volume flow
4
End of scavenging procedure
2.3-6110-10550/2
0209E
To set the flow path, open the following shutoff valves :

MKG11 AA501
(H 2 Bottle)
MKG11 AA531(H2 Bottle rack manifold)
MKG11 AA561(Before H2 pressure reducer-1, H2 bottle rack)
MKG15 AA501
(after H2 pressure reducer-1, H2 bottle
rack)
MKG15 AA504
(for H2 high pressure)
MKG15 AA502
(before H2 pressure reducer-1, H2 unit)
MKG15 AA501
(after H2 pressure reducer, H2 unit)
or
MKG11 AA501(H2 bottle)
MKG11 AA531(H2 bottle rack manifold)
MKG12 AA501
(before H2 pressure reducer- 2, H2 bottle
rack)
MKG16 AA501
(after H2 pressure reducer-2, H2 bottle
rack)
MKG15 AA504
MKG17 AA505
(before H2 pressure reducer-2, H2 unit)
MKG19 AA502
Set H2 pressure reducers 1 and 2 in bottle rack to a gauge

pressure of approximately 8 bar. Set H2 pressure reducers
1 and 2 in H2 unit to rated gas pressure. Subsequently, the
locks for adjusting screws of the pressure reducers must be
retightened firmly. Flow path upstream of three-way valve
MKG25 AA507 is now open.
Loosen the lock for adjusting screw of the pressure

reducer. Turn adjusting screw counterclockwise to being
pressure reducer to low end of low-pressure range.
Switch three-way valve MKG25 AA507 to H2 flow towards

gas purity meter system.
Increase gas volume flow at pressure reducer MKG25

AA003 until float in flow indicator MKG25 CF501 reaches a
scale value of 220 (=20 dm3/h H2 ).
Gas side of meter system is ready for measurement after

a scavenging period of 30-60 Minutes.
Reduce gas volume flow at pressure reducer MKG25
AA003 until in flow indicator MKG25 CF501 reaches a scale
value of 140 (=18dm3/h H2 ). Check and readjust flow rate
several times during the next few minutes.
Start with setting of electrical zero.
Turbogenerators
Setting Electircal Zero of
Operation
Electircal Gas Purity Meter System
Check bridge supply current
2
Set electrical zero
2.1
Close shutoff valves and three-way valve.
3
End of calibration procedure
BHEL, Haridwar
To check bridge supply current, connect an ammeter

with a range of 0 ....... 0.5 A and an internal resistance of
750 milli-ohm between terminal (+) (balancing terminal of
power supply) and the lead run from this terminal to terminal
(+) of the purity transmitter.
Switch on power supply (if required) to amplifier,
regulator or recorder for electrical commissioning of the
purity meter system.
Bridge supply current must be 335 + 1.7 mA.
If another value is obtained, adjust ridge supply current
at potentiometers R3 and R6 in power supply unit.
Set electrical zero after a warm-up period of 30 minutes.

Turn range selector to positing III. Indicator (100-76%
H2 in air) should read 100% H2.
The hydrogen volume flow set prior to checking of the
bridge supply current is used for the setting of the electrical
zero.
Hydrogen is now used as measuring and comparison
gas and therefore the bridge must be balanced. No current
flows between the dividing points of the bridge. The output
voltage of purity transmitter must be 0 mV. and accordingly
a 100% H2 indication should be displayed on the indicators
selected by means of the range selector switch. Any
deviation can be adjusted by miens of zero adjusting
resistor R3.
The H2 volume flow passing through the transmitter is
now set and must not be changed.
De-energize purity meter system and remove ammeter.
MKG11 AA501
MKG11 AA531
MKG11 AA561
MKG15 AA501
MKG15 AA504
MKG15 AA502
MKG19 AA501
MKG25 AA507
or
MKG11 AA501
MKG11 AA531
MKG12 AA501
MKG16 AA501
MKG15 AA504
MKG17 AA505
MKG19 AA502
MKG25 AA507
(H2 bottle)
(H2 bottle rack manifold)
(before H2 pressure reducer 1.
(after H2 pressure reducer 1,
(before H2 pressure reducer 1, H2 unit)
(after H2 pressure reducer 1, H2 unit)
(measuring gas, calibration)
(H2 bottle)
(before H2 pressure reducer 2,
(after H2 pressure reducer 2, H2 unit)
(measuring gas, calibration)
The electrical purity meter system is now calibrated

purity measurements for CO 2 and H2 filling and removal
and for H2 operation can be performed.
2.3-6120-10550/1
0209 E
Turbogenerators
Purity Measurement During CO2 Filling
Operation
Measure purity
during CO2 filling
1.1
Electrical commissioning of meter system
1.2
Turn range selector to position 1
1.3
Observe purity changes during CO2 filling
2
Terminate purity measurement used during
CO2 filling
BHEL, Haridwar
Switch on power supply. After a shortened warm-up

period, the system is ready for measurement during CO2
filling
Turn range selector to position 1 (0 to 100% CO2 in

air).
The indicator should display a reading of 100% CO2 in
air).
The flow path of the measuring gas (extracted before
orifice MKG25 BP502) is as follows :
Flow meter for measuring gas
CO2/ H2 purity transmitter
To atmosphere.
Since the purity meter measures the vent gas purity, it

can be seen from the indicator scale when the generator is
filled with CO2.
CO2 filling can be terminated when the purity amounts
to approximately 95% CO2 in air.
2.3-6130-10550/1
0209E
Turbogenerators
Purity Measurement During H2 Filling
Operation
Measure purity
during H2 filling
1.1
Turn range selector to position II.
H2)
Turn range selector to position II (0 to 100 % CO2 in
The flow path of the measuring gas (extracted before

orifice MKG25 BP502) is as follows :
Shutoff valve for measuring gas (filling)

Flow meter for measuring gas
CO2/H2 purity transmitter
To atmosphere.
1.2
Observe purity changes during H2 filling.
2
Terminate purity measurement used during
H2 filling.
BHEL, Haridwar
H2 filling is terminated when the purity is approximately

98% H2.
2.3-6140-10550/1
0209E
Turbogenerators
Purity Measurement During H2 Operation
Operation
Measure purity
during H2 operation
1.1
Turn range selector to position III.
1.2
Check measuring gas volume flow
Turn range selector to position III (100 to 76% H2 in air)

The meter system measures the purity of the measuring
gas extracted from the generator housing
The measuring has volume flow is to keep the float at

a scale value of 140 in flow indicator ST11 F501. Provide
variations of the volume flow by pressure reducer ST11
N501.
2
The H2 purity meter system is ready for
service. Start with normal running routine
for supervision of purity in generator
housing
BHEL, Haridwar
2.3-6150-10550/1
0209E
Turbogenerators
Gas Filling
Operation
Replacing Air With CO 2
Hints and preparatory work.
2
Fill generator with carbon dioxide (CO2).
Never use fire or an open flame (welding, flame-cutting,

smoking, etc.) in the vicinity of the generator and the
hydrogen system at any time, even when starting with the
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.
CO2 flash evaporator was filled with heat transfer liquid
up to lower edge of the riser.
Ensure that the pose between compressed air filter
MKG25 BT001 and shutoff valve MKG25 AA501 is nor
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.
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.
2.3
Open shutoff and three-way valves.
BHEL, Haridwar
Switch on heater of CO2 flash evaporator. Observe

temperature rise of heat transfer liquid at temperature
gauge. Wait until thermostat switches off the heater at the
preset temperature.
MKG25 AA519
MKG25 AA502
MKG25 AA518
MKG25 AA561
(three-way valve in position H2 vent gas)

(shutoff valve in H 2 vent gas line)
(three-way valve in position CO2 filling)
(shutoff valve for CO2 high pressure)
2.3-6310-10550/1
0209E
Then open shutoff valves at CO2 bottles and at CO2

bottle rack manifold. Replace empty CO2 bottles by full
bottles.
2.4
Turn range selector to position I and
measure CO2 purity
Check zero setting of CO2/H2 purity transmitter.

Set range selector switch in CO2/H2 purity transmitter
to position 1 (0-100% in air)
2.5
Terminate filling with carbon dioxide.
Filling with CO2 may be terminated when a purity in
excess 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
Close shutoff and three-way valves.
MKG25 AA 518
MKG51 AA 561
MKG25 AA 519
(three-way valve in CO2 filler line)

(shut off value for CO2 high pressure)
(three-way valve in H2 filler line)
Close all shutoff values at CO2 bottle rack manifold and

CO2 bottles.
2.7
Check if sufficient CO2 is available for next
generator purge
Prior to starting with H2 filling, check to ensure that a

sufficient amount of CO2 is available for the next generator
purge.
3
The generator is filled with carbon dioxide.
Start with H2 filling.
2.3-6310-10550/2
0209E
Turbogenerators
Gas Filling
Operation
Replacing CO 2 With H 2
Fill generator with H2

to operating pressure

represented by red lines on the mimic diagram of the gas
valve rack.
MKG25 AA518
1.1
Open shutoff and three-way valves
MKG25 AA519
MKG19 AA501
MKG15 AA502
MKG15 AA504
MKG15 AA501
MKG11 AA561
MKG11 AA531
MKG11 AA501
or
MKG25 AA518
(three-way valve in CO2 vent gas

position)
(three-way valve in H2 filling position)
(shutoff valve after the pressure
reducer)
(shutoff valve before H 2 pressure
reducer 1)
(shutoff valve in high-pressure H2 line)
(shutoff valve for low-pressure H2)
(shutoff valve for high-pressure H2)
(H2 bottle)
(three-way valve in CO2 vent gas

position)
MKG25 AA519
(three-way valve in H2 filling position)
MKG19 AA502
(shutoff valve after the pressure
reducer)
MKG17 AA505
(shutoff valve before H 2 pressure
reducer 2)
MKG15 AA504
(shutoff valve in high-pressure H2 line)
MKG16 AA501
(shutoff valve for low-pressure H2)
MKG12 AA501
(shutoff valve for high-pressure H2)
MKG11 AA531
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
Turn range selector to position II
1.3
Observe H2 purity indication and turn
range selector to position III
BHEL, Haridwar
Turn range selector in CO2/H2 purity transmitter to

position II (0 to 100% CO2). The increase in H2 purity can
be seen at the indicator since the purity meter system
continues to measure the vent gas purity. In case of
indicator (position II) shows H2 purity.
In excess of 20% CO2 in H2, turn range selector switch
to position III (100 to 76% H2 in air).
Continue H2 filling until indicator gives a reading of
approximately 98% H2 in air.
Check and, if required, correct measuring gas flow.
2.3-6320-10550/1
0209E
1.4
Close shutoff valve MKG25 AA502
1.5
Set contacts for pump control in seal oil
system.
2
Fill generator with hydrogen to operating
pressure.
The contact settings for control of the seal oil pumps

must be matched to the respective gas pressures. Set
contacts to operating values when rated gas pressure has
been reached.
When shutoff valve MKG55 AA502 is closed, the

generator will be filled to operating pressure.
Filling the generator to operating pressure may also
be performed during operation at rated speed.
Note : Adjust pressure of seal ring relief oil to match
the changed gas pressures during generator runup.
MKG05 AA501
MKG05 AA502
3
Measure H2 purity by means of mechanical
purity meter.
3.1
Open shutoff valves
3.2
Activate mechanical gas purity meter
system
4
The generator is filled with H2.
Start with normal running routine
2.3-6320-10550/2
0209E
(shutoff valve in measuring gas line)

(shutoff valve in measuring gas line)
Activate mechanical gas purity meter system. When

the generator operates at rated speed, the H2 purity can
also be measured by means of the mechanical gas purity
meter system.
The electrical purity meter causes a small gas loss since

the measuring gas is vented to the atmosphere. For this
reason, sufficient H2 must always be available.
Turbogenerators
Operation
Preparatory work
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
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
Q
Q
2
Purging the primary water tank with
nitrogen (N2)
2.1
Open shutoff valves at bottle rack and in
purging gas system
The external primary water circuit was filled with water.

The primary water pumps must be in operation.
A reliable nitrogen supply must be available.
The N2 pressure reducer was set to a gauge pressure
of 0.5 bar.
Note : The nitrogen used for purging must have a purity

of 99.99%.
MKG31 AA501
MKG31 AA502
MKG31 AA503
MKG35 AA501
MKF91 AA502
(at N2 bottle)
(at N2 bottle rack manifold)
(before N2 pressure reducer)
(after N2 pressure reducer)
(in N2 purging gas line)
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 g/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.
10 hours after a refilling procedure during operation.
Note : The primary water must be continuously maintained

in circulation during nitrogen purging
BHEL, Haridwar
2.3-6810-10550/1
0209E
2.4
Terminate nitrogen purging
2.5
Close shutoff valves at bottle rack and in
purging gas system.
3
continue filling or operation of primary water
system.
2.3-6810-10550/2
0209E
MKG31 AA501
MKG31 AA502
MKG31 AA503
MKG35 AA501
MKF91 AA502
(at N2 bottle)
(before N2 pressure reducer)
(for N2 purging gas)
Turbogenerators
Filling and Initial Operation of
Operation
Filling and initial operation

of primary water system
Preparatory Work
Caution : The primary water system may only be filled
with water complying with our specification [1]
Prerequisites for filling the primary water system :
Q
Q
Q
Q
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.
Primary water circuit must have been cleaned [2]
Primary water circuit must have been leak tested [3]
The filter elements of all filters must be installed [4]
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 leakage water 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]
BHEL, Haridwar
2.3-7100-10550/1
0209E
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.
2.9
Ensure that water is available for filling of
the primary water system.
Note : Use only nitrogen complying with our

specification [10]
Make sure that shutoff valves MKF60 AA504 and MKF60

AA520 are closed.
The filler line and make-up line should be carefully
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 ( = 2 to 10 bar,
3
Fill external part of primary water system.
Also refer to following imformations :

[1] 2.1-1885
[2] 2.5-7382
[3] 2.5-0310
[4] 2.4-4740
[5] 2.3-7530
[6] 2.3-7520
[7] 2.3-7510
[8] 2.3-7540
[9] 2.3-4070
[10] 2.1-1883
Primary water specification

Flushing external parts of Primary water circuit
Leakage tests
Maintenance and supervision of Primary water filters
Activating the Primary water conductivity meter system
Activating the Primary water level monitoring system
Activating the Primary water level detector system
Activating the Primary water Volume flow meter system
Operating and setting values
Gas specification
2.3-7100-10550/2
0209E
30 to 145 psig.)
Turbogenerators
Operation
Fill external part of

primary water circuit

Filling External Part of Primary Water Circuit
Prerequisites for filling external part of primary water
circuit :
Preparatory work was completed.
External part of the primary water system consists of
the entire system except for.
Q
Q
Q
Q
2
Close valve
Water treatment system

Terminal bushings and phase connectors
Stator winding
MKF12 AA502
MKF 22 AA502
MKF52 AA521
MKF52 AA522
MKF52 AA523
MKF52 AA544
MKF52 AA581
MKF52 AA591
MKF52 AA593
MKF60 AA502
MKF60 AA504
MKF60 AA519
MKF80 AA506
MKF80 AA507
MKF80 AA509
MKF80 AA512
MKF80 AA513
MKF82 AA501
MKF83 AA501
MKF83 AA502
MKF91 AA502
MKF91 AA506
(drain valve before pump 1)

(drain valve before pump 2)
(primary water drain valve for cooler 1)
(primary water drain valve manifold)
(drain valve at main filter 1)
(drain valve at main filter 2)
(shutoff valve after main filter 2)
(control valve for water treatment
system)
(shutoff valve in makeup line)
(shutoff valve after water treatment
system)
(shutoff valve before water level
indicator, bottom)
(drain valve at water level indicator)
(drain valve at level detectors)
(shutoff valve before level detector 1,
bottom)
(drain valve at level detector 1)
(control valve before stator winding)
(control valve before bushings)
(shutoff valve after bushings)
(shutoff valve for N2 purging gas)
(shutoff valve for vent gas line)
3
Open valve
BHEL, Haridwar
MKF12 AA501
MKF12 AA504
MKF22 AA501
MKF22 AA504
MKF52 AA501
(shutoff valve before pump 1)

(shutoff valve after pump 1)
(shutoff valve before pump 2)
(shutoff valve after pump 2)
(primary water shutoff valve before
cooler 1)
2.3-7110-10550/1
0209E
MKF52 AA502
MKF52 AA503
MKF52 AA511
MKF52 AA512
MKF52 AA513
MKF52 AA531
MKF52 AA532
MKF52 AA533
MKF52 AA545
MKF52 AA580
MKF52 AA582
MKF52 AA583
MKF80 AA503
MKF80 AA504
MKF80 AA505
MKF 80 AA508
MKF 80 AA511
MKF80 AA514
MKF91 AA505
MKF91 AA513

cooler 2)
cooler )
(primary water shutoff valve after
cooler 1)
cooler 2)
cooler 3)
(primary water vent valve for
cooler 1)
cooler 2)
cooler 3)
(primary water vent valve manifold)
(shutoff valve for main filter 1)
(vent valve at main filter 1)
(shutoff valve after main filter 1)
(shutoff valve in main circuit,
delivery pipe)
(shutoff valve in bypass of primary
water tank)
(shutoff valve before water level
indicator, top)
(vent valve at water level indicator)
(shutoff valve before level detector 1, top)
(vent valve at level detector 1)
(drain valve in vent gas line)
(shutoff valve at drain)
4
Filling procedure
Fill circuit slowly with water. Terminate filling when primary
water tank is filled with water up to 3/4 on the sight glass.
Caution : Ensure that water does not enter purging gas
line during filling or addition of makeup water.
4.1
Open shutoff valve MKF60 AA520 in makeup line
4.2
Vent during filling
4.3
Adjust gas pressure in primary water tank
2.3-7110-10550/2
0209E
Note : Water used for filling mist be at the required pressure

before shutoff valve MKF60 AA520.
Vent external circuit through open vent valves.

Close vent valves when water emerges without bubbles.
Throttle filler valve as soon as primary water tank is filled

up to 1/2 on the sight glass.
Open shutoff valve
MKF91 AA506
(shutoff valve for vent gas line)
Turbogenerators
Operation
and close shutoff valve

MKF91 AA505
(drain valve in vent gas line)
Close all vent valves. When air pressure in tank

exceeds 0.2 bar, the compressed air escapes via the
outflow regulator.
4.4
Terminate filling procedure by closing
shutoff valve MKF60 AA520 when tank is
filled up to 3/4 on sight glass.
5
Place external cooling circuit into service
5.1
Carefully vent signal lines to pressure
gauges
Adjust primary water tank level system at the full level

[1].
Caution : Take care to prevent dry running of primary water

pumps, since the sliding ring glands of the pumps must be
continuously supplied with water.
Carefully vent signal lines to pressure gauges via the

test connections at the respective pressure gauge shutoff
valve by filling them with water.
5.2
Place primary water pump 1 in operation
for approximately 10 minutes
5.3
Venting and purging procedure
Vent circuit carefully by opening each vent valve several

times.
Maintain primary water circulation for approximately four
hours to clean the piping, coolers, etc.
5.4
Start pump 2 after pump 1 has been
stopped
5.5
Maintain circulation in external part of
primary water circuit by means of pump 1
or 2
BHEL, Haridwar
Vent circuit several times, as required.
2.3-7110-10550/3
0209E
6
Activate conductivity meter system MKF80
CQ001 [2]
7
External part of primary water circuit is filled
with water; start with filling and placing into
service of water treatment system.
Also refer to following information :

[1] 2.3-7520
Activating the primary water level monitoring

system
[2] 2.3-7350
Activating the primary water conductivity meter

system
2.3-7110-10550/4
0209E
Turbogenerators
Operation

Filling the Water Treatment System
Prerequisites for filling the water treatment system :
Fill water treatment system
External part of primary water circuit was filled with

water.
Water in external part of primary water circuit must have
a conductivity of less than 10 mho/cm.
In the limit of 10 mho/cm is exceeded, the system

must be drained and filled again with water (deionated)
2
Fill ion exchanger with resins
Remove cover of ion exchanger tank after opening the
flanged connection and removing pipe.
Remove upper nozzle tray.
Thoroughly mix cation and anion exchanger resins of
a ratio of 1 : 1 and fill ion exchanger with mixture.
After filling ion exchanger, replace upper nozzle tray
(nozzles facing the resin) and install cover. Make sure
gaskets are properly seated.
Tighten cover flange bolts uniformly at opposite points
to prevent flange distortion.
3
Activate conductivity meter
MKF60 CQ001 [1]
4
Flush ion exchanger resins
Caution : During storage, the resin can decompose. To
prevent products of decomposition from entering the
primary water system, the resins should be flushed.
Filling the ion exchanger with water should be done
slowly to prevent whirling of the resin filling which may result
in separation of resin compounds.
4.1
Close shutoff valves
MKF60 AA510
MKF60 AA517
MKF60 AA511
MKF60 AA522
BHEL, Haridwar
(drain after ion exchanger)

(drain for water treatment system)
(drain at fine filter)
(drain, primary water integrating
flow meter)
2.3-7120-10550/1
0209E
4.2
Open shutoff valves
4.3
Perform flushing procedure
MKF60 AA503
MKF60 AA509
MKF 60 AA512
MKF60 AA513
(vent before ion exchanger)

(shutoff valve after ion exchanger)
(vent at fine filter)
(shutoff valve after filter)
Open shutoff valve MKF60 AA504 in the makeup line so

that water is admitted very slowly. Close vent valves MKF60
AA 503 and MKF60 AA512 as soon as water emerges
without bubbles.
Adjust flushing water volume flow rate to approximately
1 m3/h by means of drain valve MKF60 AA 517 (reading at
flowmeter MKF60 CF502).
Discard flushing water.
Terminate flushing procedure by closing drain valve MKF60
AA517 when conductivity after ion exchanger is 1 mmho/
cm (reading at conductivity transmitter MKF60 CQ001).
Vent the system several times during this procedure.
Close makeup valve MKF60 AA504.
5
Place water treatment system into service
Open control valve MKF60 AA502 slowly. Vent inlet pipe
via vent valve MKF60 AA503. Then open shutoff valve
MKF60 AA519. Adjust a volume flow rate of approximately
1 m3/h by means of control valve MKF60 AA502 (reading
at flow indicator MKF60 CF502)
5.1
Treatment of water in cooling circuit
6
Purge primary water tank with N2 [2]
The flow path through the water treatment system

provides fro treatment of the primary water.
N2 Purging of primary water tank reduces the O2 content

of the water in the external part of the circuit to < 100 ppb
(100 g/dm3)
7
Water in external part of primary water
circuit is subjected to treatment; start with
filling of terminal bushings and phase
connectors

[1] 2.3-7530
Activating the primary water conductivity

meter system
[2] 2.3-6810
2.3-7120-10550/2
0209E
N2 purging after filling of primary water

system
Turbogenerators
Operation
Fill terminal bushings and

phase connectors

Filling Terminal Bushings and Phase
Connectors
Prerequisites for filling the terminal bushings and phase
connectors :
Q
Primary water in external circuit must have a

conductivity of 4 mho/cm.
Primary water in external circuit must have an O 2
content of < 100 g/dm3 (100 ppb). This O2 content is
obtained by proper N2 purging.
Note : Do not add make-up water during filling procedure

Adding makeup 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.
1.1
Open shutoff and control valves
2
Filling procedure
MKF83 AA502
MKF83 AA501
MKF83 AA503
MKF83 AA504
MKF83 AA505
MKF83 AA506
MKF83 AA507
MKF83 AA508
MKF83 AA513
MKF83 AA514
MKF83 AA515
MKF83 AA516
MKF83 AA517
MKF83 AA518
After opening of the above valves, primary water is

admitted to the branch circuit.
Due to the open position of shutoff valve MKF80 AA504
in the bypass, the volume flow rate through the bushings
and phase connectors is low. Therefore venting takes place
slowly.
The volume flow indicators may be placed into service
only after proper venting. Check that water flows through
sight glasses without bubbles.
MKF83 BR501
MKF83 BR502
MKF83 BR503
BHEL, Haridwar
(after bushings)
(before bushings)
(shutoff valve for flow indicator)
(for primary water flow in phase UX

bushings)
(for primary water flow in phase VY
bushings)
(for primary water flow in phase WZ
bushings)
2.3-7150-10550/1
0209E
3
Activate volume flow indicators
Activate volume flow indicators [1] :

MKF83 CF001A
MKF83 CF001B
MKF83 CF011A
MKF83 CF011B
MKF83 CF021A
MKF83 CF021B
4
Close control valves
(for volume flow in phase R bushings)

(for volume flow in phase R bushings)
(for volume flow in phase S bushings)
(for volume flow in phase S bushings)
(for volume flow in phase T bushings)
(for volume flow in phase T bushings)
Carefully vent transmission lines and flow indicators

via the shutoff and equalizing valve assemblies.
Check parallel connected flow indicators for identical
volume flow readings.
MKF83 AA502
MKF83 AA501
(before terminal bushings)

(after terminal bushings)
5
Terminal bushings and phase connectors
are filled; start with filling of stator winding
Terminal bushings can be placed into service again by

opening the above control valves after the addition of
makeup water to the primary water tank following filling of
the stator winding and subsequent N2 purging.

[1] 2.3-7540
Activating the primary water volume flow

meter system
2.3-7150-10550/2
0209E
Turbogenerators
Operation

of Primary Water System
Filling the Stator Winding
Prerequisites for filling the stator winding :
Fill stator winding
Drain valves of primary water manifolds were closed

and secured against opening.
Primary water in external circuit must have a
conductivity of < 4 mho/cm.
Primary water in external circuit must have an O 2
content of < 100 g/dm3 (100 ppb). This O2 content is
obtained by proper N2 purging.
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
3
Filling procedure
4
Activate volume flow indicators
MKF82 AA502
MKF82 AA503
MKF82 AA504
MKF82 AA505
MKF82 AA507
MKF82 AA508
(vent before stator winding)

(vent after stator winding)
Slowly open control valve MKF82 AA501 (stator winding

inlet).
Close vent valves as soon as water emerge without
bubbles.
Activate volume flow indicators [1]
MKF82 CF001A
MKF82 CF001B
(flow indicator for primary water volume

flow, stator outlet)
(flow indicator for primary water volume
flow, stator outlet)
Carefully vent transmission lines and flow indicators

via the shutoff and equalizing valve assemblies.
Check parallel connected flow indicators for identical
flow readings.
5
Flush and vent stator winding
BHEL, Haridwar
Increase volume flow rate through stator winding by

slowly opening control valve MKF82 AA501. Simultaneously
throttle shutoff valve MKF80 AA504 in bypass to obtain
higher volume flow rate through stator winding.Briefly open
vents on inlet and outlet pipe at reasonable intervals.
Stator winding should be completely vented after a
flushing period of approximately two hours.
2.3-7160-10550/1
0209E
6
Carefully vent all signal lines to pressure
gauges
Carefully vent signal lines to pressure gauges via the

test connections at the respective pressure gauge shutoff
valve.
7
Isolate stator winding from external part
of primary water circuit
Isolate filled stator winding from external part of primary

water circuit prior to restoring the required water level in
the primary water tank by the addition of makeup water.
To do this, fully reopen shutoff valve.
MKF80 AA504
(in bypass)
and then close control valve

8
Adjust nominal water level in primary water
tank
MKF82 AA501
(before stator winding)
After the stator winding and terminal bushing with phase

connectors were isolated from the external part of the
circuit, close shutoff valve.
MKF60 AA502
(before ion exchanger)
and slowly open shutoff valve

MKF50 AA504
(in makeup line)
Slowly raise water level in primary water tank to 75%

of nominal value. Read nominal level at indicator of level
detector MKF80 CL501.
Then close shutoff valve.
MKF60 AA504
(in makeup line)
and reopen control valve

9
Purge primary water tank with nitrogen [2]
10
Open control and shutoff valves
11
Close shutoff valve MKF80 AA504 in
bypass
MKF60 AA502
(before ion exchanger).
N2 purging of primary water tank reduces the O2 content

of the water in the external part of the circuit to 100g/
dm3 (100 ppb).
As soon as the water in the external part of the circuit
has reached an O2 content of 100 ppb, open control and
shutoff valves.
MKF82 AA501
(before stator windings)
MKF83 AA501
(before terminal bushings)
MKF83 AA502
(after terminal bushings)
Slowly close shutoff valve MKF80 AA504 in bypass.
Adjust volume flow rate [3] by means of the above control
valves.
12
Stator winding is filled; start with filling of
primary water coolers on cooling water
side.
2.3-7160-10550/2
0209E

[1] 2.3-7540 Activating the primary water volume flow meter system
[2] 2.3-6810 Nitrogen purging after filling primary water system
[3] 2.3-4070 Operating and setting values
Turbogenerators
Operation
Fill and vent coolers

on cooling water side

Filling Primary Water Coolers on Cooling
Water Side
Note: Fill coolers with water on cooling water side only
one day before start-up and loading of generator.
2
Check and activate primary water
temperature control system.
3
Close shutoff valves before and after cooler

MKF52 BC003
MKF52 AA551
MKF52 AA552
4
Open shutoff valves
(and shutoff valves)

(drain valve at cooler 1)
(drain valve at cooler 2).
Open shutoff valves before and after coolers.

MKF52 BC001
MKF52 BC002
(cooler 1)
(cooler 2)
and shutoff valves

MKF52 AA553
MKF52 AA561
MKF52 AA562
MKF52 AA563
5
Filling procedure
6
Primary water circuit is ready for operation; start with necessary checks prior to
startup.
BHEL, Haridwar
(drain valve at cooler 3)

(vent valve at cooler 1)
(vent valve at cooler 2)
(vent valve at cooler 3).
Fill primary water coolers with water after opening

shutoff valves.
Close vent valves as soon as water emerges without
bubbles.
Note: Fill and vent only two of three primary water
coolers on their cooling water sides 100% of the maximum
cooler capacity required (at maximum cooling water
temperature and maximum generator output) will then be
in service.
The third primary water cooler should not be filled on
its cooling water side but left in a clean and dry condition
with closed inlet and outlet valves and open drain and vent
valves.
2.3-7180-10550/1
0209E
Turbogenerators
Activating Primary Water System

After a Shutdown of Less Than 48
Hours
Operation
The primary water must still be in the system.

For activating the primary water system after a
shutdown in which the system or a branch circuit was
drained, follow the corresponding instruction [1].
Activate primary water system

after a shutdown of less than 48 hours
2.1
Start one primary water pump and be sure
the other pump is ready for starting
2
Are primary water pumps in operation ?
no
yes
3.3
Activate stator winding branch circuit by
slowly opening control valve MKF82 AA501.
Note : Close shutoff valve MKF80

AA504 after reactivation of stator
winding branch circuit
3.2
Activate bushing and phase connector
branch circuit by slowly opening control
valves MKF83 AA502 and MKF83 AA501
3.1
Place water treatment system into service
by slowly opening valves MKF60 AA502
and MKF60 AA519
3
Are all primary water branch circuits in
service
no
4
Check primary water circuit prior to startup[2]
5
Primary water system is now in service.
Start with normal running routine

[1]
[2]
BHEL, Haridwar
2.3-7100
to 2.3-7180
Primary water System
2.3-7610
Checks Prior to Startup
2.3-7210-10550/1
0209E
Turbogenerators
Activating Primary Water System

After a Shutdown of More Than 48
Hours
Operation
Activate primary
water system after a shutdown
of more than 48 hours
2.1
Fill and activate primary water system or
any branch circuits [1]
2
Primary water circuit is completely filled
no
3
Perform checks necessary prior to startup
4
Primary water system is now in service;
start with normal running routine

[1]
2.3-7100
.. to ..

2.3-7180
[2]
BHEL, Haridwar
2.3-7610

2.3-7220-10550/1
0209E
Turbogenerators
Operation
Activating the Primary Water

Activate conductivity meter system
Prior to initial operation of the conductivity meter

system, check the wiring for compliance with circuit and
connection diagrams.
2
Check mechanical zero of conductivity
indicator
Set and check mechanical zero by adjusting zero

setting screw on the indicator.
3
Check electrical zero
Note : This check can only be performed if conductivity

transmitter is completely dry and therefore should be
performed prior to filling the primary water system.
Select the range 0 to 2 mho/cm by means of jumper
on printed circuit board of transmitter module.
Switch on the power supply.
Check conductivity indication after a warm-up period
of approximately 15 minutes. If the indication is not zero, a
correction can be made at potentiometer P-O of transmitter
module.
4
Check complete conductivity meter
system by means of test switching unit
This check may be performed either before or after

filling primary water system.
Turn associated test selector switch to zero position.
With switch in this position, a zero indication is given at the
conductivity indicator.
Turn associated test selector switch to test value 1.5
mho/cm position. With switch in this position, instrument
should indicate a value of 1.5 mho/cm.
Turn test selector switch to the operation position. With
switch in this position, conductivity indicator indicates
conductivity of primary water, provided that primary water
system is filled and that water flows through the measuring
device.
If conductivity of the primary water is still beyond the
selected range, use jumper in transmitter module to select
one of the higher ranges:
0 to 5 mho/cm
0 to 10 mho/cm
0 to 25 mho/cm
BHEL, Haridwar
2.3-7530-10550/1
0209E
5
Check conductivity meter system at
transmitter module by use of test resistor
If the checks of conductivity meter system do not yield

result as given in step 4, perform the following checks at
the transmitter module by using the furnished test resistor.
Note : During generator operation, make sure that the
connections are disconnected and reconnected in the
correct sequence. This prevents a full-scale deflection
of the conductivity indicator which would result in
initiation of an alarm during normal operation. The test
resistor can be used to check the transmitter module
and the conductivity indicator.
When using test resistor, be sure to only disconnect
the leads to terminals 2 and 3 of transmitter module. Lead
to terminal 1 should not be disconnected.
The test procedure is as follows :
Q
6
Conductivity meter system is ready for
continuous monitoring of the primary
water conductivity
2.3-7530-10550/2
0209E
Disconnect lead to terminal 2 of transmitter module.

Conductivity indicator should indicate zero.
Disconnect lead to terminal 3 of transmitter module.
Conductivity indicator should indicate 30% of maximum
deflection.
Connect test resistor terminal 1 to terminal 1 of
transmitter module. Be sure that the lead from
measuring device also remains connected to the
terminal. Conductivity indicator should indicate 30% of
maximum deflection.
transmitter module. Conductivity indicator should
indicate zero.
transmitter module. Conductivity indicator would
indicate value given on test resistor.
Disconnect test resistor from terminal 3 of the
indicate zero.
Disconnect test resistor from terminal 1 of transmitter
module. Conductivity indicator should indicate 30% of
maximum deflection.
Reconnect leads to terminal 3, then terminal 2 of
indicate conductivity of the primary water.
A deviation between the results described above and

the actual test results using the test selector switch and
test resistor can be due to an influence of the leads between
the conductivity measuring device and the transmitter
module. These deviations can be corrected by P-X or P-Y.
Since these potentiometer settings influence each other,
the correction may have to be repeated several times until
the required accuracy is obtained for all scale points
included in the check.
Turbogenerators
Activating the Primary Water

Operation
Prior to activating the flow meter system check wiring

for compliance with circuit arrangement and connection
diagrams.
Check power supply voltage.
Activate volume flow meter system
2
3
4
5
1
2
3
4
5
Fig.1
Span Potentiometer
Zero indicator
Zero switch
Test jack
Zero Potentiometer
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.
BHEL, Haridwar
2.3-7540-10550/1
0209 E
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
measuring mechanism
To do this, open equalizing valve of the equalizing valve

assembly.
4.3
Check indication of zero indicator
The electrical zero setting is indicated by the zero

indicator.
4.4
Correct zero setting
4.5
Set zero to N (normal) position
4.6
Apply upper range differential pressure to
meausring mechanism (upper range value
< orifice design)
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).
After checking or correction of zero setting, reset zero

switch to its N (normal) operating position.
Note : Check to ensure that no impurities are introduced

into the primary water circuit (apply upper range pressure
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
[2]
2.1-8412
Primary Water Volume flow

Meter System
2.3-7540-10550/2
0209E
Pressure Transmitters
Turbogenerators
Operation
Initial Operation of Primary Water

System
Perform necessary checks

prior to startup
2
All primary water coolers are filled on their
primary water side.
3
Check or adjust vent and drain valves at
primary water coolers
Ensure that all three coolers are filled on their primary

water sides.
Make sure to open valves

MKF52 AA521
MKF52 AA522
MKF52 AA523
MKF52 AA531
MKF52 AA532
MKF52 AA533
(shell side drain at primary water cooler1)

(shell side vent at primary water cooler1)
and close valves

MKF52 AA544
MKF52 AA545
4
All units of primary water system are
properly vented.
Perform check by briefly opening shutoff valves

MKF52 AA541
MKF52 AA578
MKF82 AA502
MKF82 AA503
MKF60 AA512
MKF60 AA503
MKF52 AA582
MKF52 AA545
5
All pressure gauges and pressure
transmitters are properly vented.
BHEL, Haridwar
(shell side drain manifold of primary water

coolers)
(shell side vent manifold of primary water
coolers)
(vent before primary water cooler)

(vent after primary water cooler)
(vent before stator winding)
(vent after stator winding)
(vent at ion exchanger)
(vent at main filter)
(shell side vent manifold of
primary water cooler)
Perform check by briefly opening vent plug at each

respective pressure gauge shutoff valve.
2.3-7610-10550/1
0209E
6
Two primary water coolers are filled and
vented on their cooling water sides
7
Primary Water Temperature control system
is ready for operation
8
Primary water circuit is ready for operation;
start with regular monitoring of operation
2.3-7610-10550/2
0209E
Check that primary water coolers are filled on their cooling

water sides and properly vented.
Turbogenerators
Operation
1
General
The generator should be operated on the turning gear
and brought up to speed in accordance with the turbine
startup diagrams.
2
Turning Gear Operation

Prior to operating the generator on turning gear, the
shaft lift oil pump and the bearing oil system must be placed
into operation.
The seal oil system for lubrication and sealing of that
shaft seals and the primary water system must be placed
into operation.
The oil flow to the bearings and shaft seals should be
checked prior to turning gear operation to ensure an
adequate flow. In addition, drains should be inspected for
proper operation.
The generator may be filled with hydrogen prior to or
during turning gear operation provided that leakage tests
have been performed and the seal oil system is in operation.
3
Generator Cooling Gas Temperatures

The hydrogen coolers should be placed into service
on their cooling, water sides as soon as the generator is
filled with hydrogen and on turning gear. The H2 coolant
temperature control system should be changed over from
the Automatic to the Manual mode. Use manual mode to
adjust a cooling water volume flow through the hydrogen
coolers of approximately 5 to 10% of the nominal 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 the cooler tubes and fins.
The cooling water volume flow through the hydrogen
coolers should not be increased as long as the H2 cold gas
temperature is not at rated value.
During runup, the cooling water volume flow through
the hydrogen coolers should be increased by manual
adjustment to maintain the cold gas temperature at least
5 K below the primary water inlet temperature. Changing
over the H2 coolant temperature control system from the
Manual to the Automatic mode is permissible as soon as
the primary water temperature control system, set for the
automatic mode, opens the final control element for the
cooling water downstream of the primary water coolers.
4
Exciter Temperatures
The exciter coolers must be filled with water and vented.
The shutoff valves in the lines upstream of the coolers are
open, and the control valves in the lines downstream of
the coolers are closed.
Turning Gear Operation and

Runup of Generator
During runup of the turbine-generator, the cold air
temperature requires particular attention. Open control
valves in cooling water outlet lines as soon as the cold air
temperature has risen to > 400C. Open control valves only
to the extent required to adjust a cold air temperature of <
400C in the exciter. In addition, adjust the two control valves
so that equal cooling water outlet temperatures are obtained
downstream of the cooler sections (measured by means
of the thermometers in the outlet lines).
After load pickup, adjust control valves for a cold air
temperature of < 400C.
5
Runup
During runup to rated speed, the bearing oil inlet
temperature should not be less than 350C but not higher
than 450C. The oil inlet temperature at the shaft seals should
not be less than 380C.
Note : Do not run up generator to rated speed and
voltage as long as generator casing pressure [1] is not
at rated value.
During runup, the critical speed ranges should be
passed through quickly and at a uniform rate.
Smooth running depends on several factors. Even
minor temperature differences of 1-2 deg C between
opposite sides of the rotor may result in rotor distortion
which could lead to inadmissible vibrations due to
unbalance.
During runup, the bearing and oil temperatures should
be read and recorded at short intervals.
To prevent these thermal unbalances during runup, the
turbine-generator should be run on turning gear. If the
generator is run up following prolonged turning gear
operation, no restriction regarding the rate of runup need
be observed other than those required for the turbine.
6
Generator Air Operation

Besides the above mentioned operating conditions. It
may be necessary in certain exceptional cases to operate
the generator without hydrogen. i.e. during initial runup of
the unit to check the bearings and vibrations and for cleanup. In view of the high windage losses and the resulting
high temperature rise of the air such air operation is only
permissible for brief periods and only with generator nonexcited.
The cold air temperature downstream of the coolers
should not exceed 400C. At higher cold air temperatures,
the hydrogen coolers should be placed into service.
During generator air operation, the supply of seal oil to
the shaft seals must be ensured as well.
[1]
BHEL, Haridwar
2.1-1850
Reactive capability curve

2.3-8010-10550/1
0209E
Turbogenerators
Generator Startup Diagram
Operation
1
Command : Start up generator
Actual condition
Bearing vapour exhausters

Exciter drying system
in operation
in operation
in operation
Seal oil system
in operation
Seal oil inlet temperature
t = approx. 380C.
Generator hydrogen pressure

Hydrogen purity
p = rated gas pressure

> 96%
Measuring devices and supervisory equipment
in operation
Gas drying system
in operation
Hydrogen coolers
Primary water coolers
Exciter cooler
in service with reduced flow (approx. 10% of norminal flow)

in operation and vented
filled with water and vented, control valves closed
Coolant temperature control
in operation
ready for operation
Command : Run up generator
Drying system
Heating system
n >= 4 s1 out of service

n >= 4 s1 out of service
Bearing vibration
Bearing metal temperature
normal
normal
Exciter cooler
at r cold air > 400C, adjust cooling water flow required for
removal of loss heat.
Speed
n= approximately 90%
BHEL, Haridwar
2.3-8011-10550/1
0209E
Differential temperature between H2 cooling gas

and cold primary water
>5K
Field circuit breaker
closed
Set point for rated voltage
set
Speed
Primary water volume flows
n = rated speed
set
Bearing vibrations
set seal ring relief oil pressure for shaft seals
Synchronizing, parallelling and loading
Synchronizing
Paralleling
Loading
2.3-8011-10550/2
0209E
to required load, only within the region of the capability

curve
Turbogenerator
Permissible Synchronizing Criteria
Operation
BHEL, Haridwar
2.3-8081-10550/1
0209 E
Turbogenerators
Operation
1
Load Limits
For permissible generator loading, refer to the reactive

capability curve [1]. The following conditions are required
:
Q
Q
Q
Q
Primary water cooling system is fully operational.

Generator is filled with hydrogen at the rated pressure
and all four hydrogen cooler sections are in operation.
Generator is operated at rated frequency
Generator is operated at rated voltage.
Any desired load setting is possible within the limits

indicated on the Reactive Capability Curve.
Load operation for long periods of time at reduced H2
pressure is, however, not permissible, since the stator
primary water pressure may then exceed the hydrogen
pressure. This results in the possibility of primary water
escaping into the hydrogen atmosphere, should a leak be
present in the primary water system within the stator.
2
Rate of Loading
During operation load variation is permissible within

the limits or the reactive capability curve. The permissible
rate of loading depends on the condition of the winding
insulation Generators with a Micalastic stator winding
insulation and a rotor winding of silver-alloyed copper with
glass laminate insulation can be suddenly loaded and
unloaded if an automatic coolant control system is
provided and fully operational. The actual rate of loading
should be matched to the permissible limits of the turbine.
3
Unbalanced Load
The continuously permissible unbalanced load as

specified [2] must not be exceeded under any operating
condition. Unbalanced load is defined as the ratio of
negative sequence current to rated current, with the rated
current [2] not being exceeded in any of the three phases.
4
Load Restrictions
During the service life of the generator, operating

conditions may arise at the generator which require the
generator to be operated at reduced load in order to avoid
damage to the unit. The following restrictions should be

observed for the conditions indicated :
4.1 Operation With Hydrogen Coolers Out of Service
If one of the four hydrogen cooler sections is out of
service, operation of the generator is permissible at not
more than 67% of rated load.
Operation at reduced load presupposes, however,
that
Q
Primary water cooling system of generator is fully

operational.
Dew point temperature of hydrogen atmosphere in
generator is sufficiently below cold gas temperature.
This condition is normally obtained by drying the

closed generator with the gas drying system for not less
than four weeks, with no leak developing in the generator
interior during this period.
Note : The actual-value transmitter for the hydrogen
temperature control is located after cooler a, In the
event of a failure of this cooler, change over control
system from Automatic to Manual. The necessary
corrections should be performed manually.
4.2 Deviation of Rated Hydrogen Pressure
If the specified hydrogen pressure [1] cannot be
maintained for unforeseeable reasons (e.g. lack of gas,
high gas losses), the generator must be unloaded and
de-excited when the rated pressure has dropped by 0.4
kg/cm 2. The cause of the gas loss should be identified
and corrected.
4.3 Loss of Primary Water Supply
If loss of primary water supply occurs, the generator
is disconnected from the system by the generator
mechanical equipment protection and de-excited.
Operation of the generator without full primary water
service is not permissible.
4.4 Deviation of Rated Voltage and Rated Frequency
Loading of the generator with deviations from the
rated generator voltage and/or frequency is only
permissible up to the limits shown in the attached
diagram [3].

[1]
[2]
[3]
BHEL, Haridwar
2.1 - 1850 Reactive Capability curve

2.1 - 1810 General and Electrical Data
2.3 - 8181 Permissible Loading at Rated P.F.
during voltage and frequency deviations
2.3-8170-10550/1
0209 E
Permissible Loading at Rated P.F.

During Voltage and Frequency
Deviations
Turbogenerators
Operation
40
30
PERMISSIBLE SHORT TIME

OPERATION (IN MINUTES) WITH
RATED MVA AT RATED PF WITH
10% VOLTAGE DEVIATION
20
10
10
9
8
7
6
VOLTAGE DEVIATION (%)
5
4
3
2
1
0
-12 -11 -10 -9 -8
-7 -6 -5
-4 -3
-2
-1
-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 (%)
BHEL, Haridwar
2.3-8181-10550/1
0209 E
Turbogenerators
Operation
Continuous
Operatopn
Generator Capability With Hydrogen

Coolers Out of Service on Water Side
Short time operation

Only permissible for cooler cleaning
100 %
MVA
66.6 %
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
BHEL, Haridwar
2.3-8184-10550/1
0209 E
Turbogenerators
Unbalanced Load-Time Curve
Operation
=
=
=
=
=
=
=
588.000
21.000
16.166
50.000
0.850
3.500
45.000
MVA (500 MW)

kV
kA
Hz
bar (G)
Cel
6
4
TIME T IN SECONDS
3
2
8 101
3
8
6
10
-1
10
10
8
8 100
i22 t =10.00
i22 t =0.08 , CONTINUOUS
8 102
8 103
RATED GENERATOR OUTPUT SN

RATED ARMATURE VOLTAGE UN
RATED ARMATURE CURRENT I N
RATED FREQUENCY
FN
POWER FACTOR
PF
PE
RATED H2 PRESSURE
COLD GAS TEMPERATURE
TK
PER UNIT NEGATIVE SEQUENCE CURRENT
BHEL, Haridwar
2.3-8187-10550/1
0209 E
BHEL, Haridwar
1.2
1.4
1.6
1.8
2.2
2.4
10
TIME IN SEC
100
2. FIELD WINDING SHORT-TIME THERMAL

REQUIREMENTS (FIELD VOLTAGE VS TIME)
1. ARMATURE WINDING SHORT TIME THERMAL

REQUIREMENTS (STATOR CURRENT VS TIME)
OVERLOAD CAPABILITY
1000
Turbogenerators
Current Overload Capability
Operation
2.3-8188-10550/1
0209E
STATOR CURRENT (P.U.)

FIELD
VOLTAGE (P.U.)
Turbogenerators
Runback for Loss of Stator coolant
Operation
50
CAUTION
49
IF STATOR COOLANT IS NOT

RESTORED WITHIN 50 MINUTES OF INITIATION OF
RUNBACK, THE TURBINEGENERATOR MUST B E
TRIPPED.
TIME IN MINUTES
48
47
5
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
CURRENT PER UNIT AMPERE
BHEL, Haridwar
2.3-8190-10550/1
0209E
BHEL, Haridwar
100
200
300
400
500
600
42
47
40
45
Generator type THDF 115/59
49
44
51
53
48
COLD PW TEMPERATURE (Deg.C)
46
COLD GAS TEMPERATURE (Deg.C)
588.00 MVA, 500.000 MW, 50 Hz, 0.85 PF
55
50
60
52
62
54
Turbogenerators
Unloading Schedule For Increased
Operation
Cooling Water Inlet Temperature
2.3-8191-10550/1
0209 E
PERMISSIBLE LOAD OUTPUT (MW)
Turbogenerators
Shutdown of Generator
Operation
During shutdown of the generator, the shaft lift
oil pump must be started as soon as the unit reaches
the speed specified in the Turbine Instruction Manual.
To prevent any difficulties during a subsequent
runup due to thermal unbalances and the resulting
rotor distortion, the turning gear must be started as
soon as the turbine-generator coasts down to the
speed (turning gear speed) specified for the turbine
(normally automatic) and maintained in operation
without interruption until the rotor has cooled down
to nearly room temperature.
BHEL, Haridwar
Before the unit reaches turning gear speed, the

H 2 coolant temperature control system (if provided)
should be changed over from the automatic to the
manual mode. Use manual control to adjust a cooling
water volume flow through the H2 coolers of
approximately 5 to 10% of the nominal 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 the cooler tubes and fins. The
coolers should be operated with this cooling water
volume flow for approximately 15 hours.
2.3-8310-10550/1
0209 E
Turbogenerators
Generator Shutdown Diagram
Operation
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
Anticondensation heating system
n<3.5s1 inoperation
n<3.5s1 inoperation
Turning gear operation
see Turbine Instruciton Maual
Seal oil system
in operation
Gas system
in operation
in operation
Speed
n = 0 s1; at room temperature
Shutdown procedures
completed
BHEL, Haridwar
2.3-8311-10550/1
0209E
Turbogenerators
Operation
1
Generator at Standstill With Seal Oil, Gas and

Primary Water System in Operation
Due to operational conditions, it may become

necessary to shut down the generator for a short
period. With the unit at rest or on turning gear, the
mechanical hydrogen purity meter cannot give an
indication due to the lack of differential fan pressure.
When the unit at standstill, the bearing oil system can
be taken out of service. In the absence of any
o p e r a t i o n a l n e e d s . e . g . i n s p e c t i o n o r f a u l ts o n
generator, the water and hydrogen should remain in
the generator in order to retain the most favorable
prerequisites for a dry condition. All observation
required for a generator partly taken into service
should be performed, such observations being
essentially limited to the seal oil, gas and primary
water systems.
Normally it can be assumed that the generator was
operated with the gas dryer during the preceding
service period. The generator interior will thus be in
dry condition provided that the cooling gas was not
replaced.
Special measures should be taken to prevent
corrosion damage to the tubes of the hydrogen,
primary water and exciter coolers during idle periods.
During a brief outage, the coolers should be supplied
with a small water flow. In addition, the coolers should
be flushed with the full water flow twice weekly.
In the case of prolonged outages, the coolers
should be drained on their water sides and dried.
To prevent the formation of a moisture film due to
condensation on the exciter coolers., the cooling
water supply should be isolated immediately after
shutdown of the unit, making sure that the exciter
drying system is functioning properly. In the case of
prolonged outages, the coolers should be drained on
BHEL, Haridwar
Supervision of Generator During

Standstill
General
t h e i r w a t e r s i d e s , d r i e d a n d m a i n ta i n e d i n d r y
condition to prevent standstill corrosion in the cooler
tubes.
2
Generator at Standstill With Seal Oil, Gas and

Primary Water System Out of Operation
Preservation measures will have to be taken when

the generator is to be shut down for a period
exceeding two months with the seal oil, gas and
primary water systems to be taken out of operation.
The scope of the preservation work required depends
on the duration of the shutdown, on the overall
conditions in the vicinity of the unit and on the extent
to which checks and inspections are possible during
such period.
After removal of the hydrogen from the generator,
it is recommended to open the generator by removing
two manhole covers and to connect a dryer or hot air
blower for continuous drying or circulation of the air
in the generator. Care should be taken to ensure that
this equipment is connected in such a way that a
circulation through the entire generator interior will
be accomplished.
To maintain the generator in satisfactory dry
condition, the exciter enclosure must be kept closed
and the exciter drying system must remain in
operation.
The hydrogen, primary water, exciter and seal oil
coolers should be drained to their water sides and
dried by suitable measures.
These measures are intended to prevent any
condensation in the generator interior even under
varying environmental conditions to minimize the risk
of stress corrosion cracking of the austenitic rotor
retaining rings.
2.3-8400-10550/1
0209E
Turbogenerators
Operation
Suitable measures will have to be taken on all coolers
taken out of service to prevent standstill corrosion in the
cooler tubes.
In the case of a brief outage, it will mostly be sufficient
BHEL, Haridwar
During Standatill
Coolers
to supply the coolers with a small water flow and to flush
them with the full water flow twice weekly.
In the case of a prolonged outage, the coolers should
however, be drained on their cooling water sides and
dried.
2.3-8440-10550/1
0209 E
Turbogenerators
Operation
After gas removal from the generator, the seal oil
system can be taken out of operation, and monitoring of
the generator is no longer required.
However, if the seal oil system remains activated,
BHEL, Haridwar
During Standstill
Seal Oil System
monitoring of the generator must be continued. All seal
oil pressure and temperature should be recorded at the
previous intervals, and attention should be given to all
special occurrences.
2.3-8500-10550/1
0209E
Turbogenerators
Shutdown of Seal Oil System
Operation
Shutdown of seal oil

system
2
Shut down turbine-generator
The system should be taken out of service only for a

prolonged shutdown of the generator requiring removal
of the gas due to a major fault in the seal oil system.
The turbine-generator should be shut down and the

generator rotor should be at standstill (n = 0 s1)
3
Remove H2 gas from generator
4
Stop seal oil pumps
Deactivate controls of seal oil pumps and bearing

vapor exhausters.
5
Terminate normal running routine
6
Remove all faults, e.g. replace any defective
shutoff valves or temperature gauges
BHEL, Haridwar
If new shutoff valves or temperatures gauges must

be installed, drain seal oil from respective pipe. Remove
defective component and install a new part.
Draining of the seal oil circuit will not be required for
other work. In the event of a longer shutdown of the
turbine-generator, water must be drained completely
from the seal oil cooler or a small amount of water must
pass through the coolers continuously in order to prevent
standstill corrosion.
To restart seal oil system if oil has been drained from
part of the circuit, the branch circuits should be refilled
with seal oil and placed in operation.
2.3-8510-10550/1
0209 E
Turbogenerators
Operation
Preparatory work for draining

seal oil circuit
Draining the Air Side

Seal Oil Circuit
The turbine-generator must have been shut down,

and the generator rotor must be at standstill (n = 0 s1).
The hydrogen must have been removed from the
generator, and all seal oil pumps should be out of
operation.
2
Drain air side seal oil circuit
2.1
2.2
Open cooler drain and vent valves on oil
side
MKW01 AA503
MKW11 AA505
MKW31 AA505
MKW11 AA501
MKW21 AA501
MKW31 AA501
(after seal oil storage tank)

(after A1 valve)
(after A2 valve)
(before seal oil pump1)
(before standby seal oil pump 3)
MKW51 AA505
MKW51 AA511
MKW51 AA504
MKW51 AA510
(drain, seal oil cooler 1)

(vent, seal oil cooler 1)
Air side seal oil circuit is now drained via the two
drain valves.
2.3
Open cooler drain and vent valves on water
side
Before opening cooler drain and vent valves on water

side, close cooling water inlet valves.
MKW51 AA507
MKW51 AA509
MKW51 AA506
MKW51 AA508

After draining on their water sides, the coolers should

be dried to prevent standstill corrosion of the cooler
tubes.
3
Draining of air side seal oil circuit is
complete
BHEL, Haridwar
Start with draining of hydrogen side seal oil circuit.

2.3-8520-10550/1
0209E
Turbogenerators
Operation
Preparatory work for draining

seal oil circuit
Draining the Hydrogen Side

Seal Oil circuit
The turbine-generator must have been shut down,

and the generator rotor must be at standstill (n = 0 s1).
The hydrogen must have been removed from the
generator, and all seal oil pumps should be out of
operation.
2
Drain hydrogen side seal oil circuit
2.1
Close shutoff valves at seal oil unit
MKW03 AA501
MKW13 AA503
MKW03 AA502
MKW13 AA510
pump)
(after seal oil tank)

(before seal oil tank)
(bypass of hydrogen side seal oil
MKW13 AA504
MKW13 AA511
(hydrogen side seal oil drain)

(hydrogen side seal oil drain)
2.2
Open shutoff valves at seal oil unit.
2.3
Start seal oil pump
Start hydrogen side seal oil pump. The seal oil pump
should be kept in operation only until the seal oil has
been removed from the seal oil tank MKW93 BB001. Stop
seal oil pump immediately afterwards.
The remaining seal oil can be drained through the
drain plug in bottom of seal oil tank.
2.4
Open shutoff valve MKW113 AA503
2.5
Open cooler drain and vent valves on oil
side
MKW53 AA505
MKW53 AA511
MKW53 AA504
MKW53 AA510

Hydrogen side seal oil circuit is now drained via the

two drain valves.
BHEL, Haridwar
2.3-8521-10550/1
0209E
2.6
Open cooler drain and vent valves on water
side
Close cooling water inlet valves :

MKW53 AA507
MKW53 AA509
MKW53 AA506
MKW53 AA508

After draining on their water sides, the coolers should

be dried to prevent standstill corrosion of the cooler
tubes.
3
Draining of hydrogen side seal oil circuit is
complete
2.3-8521-10550/2
0209E
Start with draining of signal lines.
Turbogenerators
Operation
Draining the Seal Oil Signal Lines

and Seal Ring Relief Piping
Draining seal oil signal lines and

seal ring relief piping
2
Drain signal pipes
2.1
Open drain valves in signal pipes
2.2
Open vent valves in seal oil valve rack
3
Drain seal oil filters
MKW11 AA507
MKW31 AA507
MKW13 AA508
MKW13 AA509
(oil
(oil
(oil
(oil
signal
signal
signal
signal
to A1 valve)
to A2 valve)
to C valve)
to C valve)
MKW71 AA514
MKW73 AA514
MKW71 AA524
MKW73 AA524
(air side vent valve, TE)

(hydrogen side vent valve, TE)
(air side vent valve, EE)
(hydrogen side vent valve, EE)
Drain seal oil filters through drain plugs in filter

housings.
4
Drain seal ring relief piping
4.1
Close shutoff valves in seal oil valve rack
MKW76 AA513
MKW76 AA523
(TE seal ring relief)

(EE seal ring relief)
Loosen flanges at shutoff valves and drain seal oil

from pipes for seal ring relief.
5
Draining of seal oil circuit is complete
BHEL, Haridwar
When restarting the system, ensure that all flanges

are bolted to the shutoff valves, that all vent and drain
valves are closed and that valves closed for seal oil
draining are reopened.
2.3-8522-10550/1
0209E
Turbogenerators
Operation
It is recommended to leave the hydrogen in the
generator and to reduce the hydrogen pressure if the
generator is to be shut down for a period up to two
months.
It should, however, be observed that all alarm
devices must be set to the new operating values.
Monitoring of the gas system must be continued as during
BHEL, Haridwar
Supervision of Generator During

Standstill
Gas System
normal operation.
The gas must, however, be removed from the generator
if the seal oil system is taken out of service or for carrying
out welding work within the range of the gas supply
system or work on the generator. If the generator is filled
with air, the seal oil system can be taken out of service.
2.3-8600-10550/1
0209E
Turbogenerators
Operation
Preparatory work
Gas Removal
Lowering Hydrogen Gas Pressure
in Generator
Prior to removing hydrogen (H 2) from the generator

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 CO 2 /H 2 purity
transmitter
1.2
Close shutoff valves and three-way valves
MKG25 AA519
MKG19 AA501
MKG19 AA502
MKG15 AA502
MKG17 AA505
MKG15 AA504
MKG15 AA501
MKG11 AA561
MKG16 AA501
MKG12 AA501
(H2 filler line)

H2 bottle rack)
(before H 2 pressure reducer 1,
H2 bottle rack)
H2 bottle rack)
(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 gas pressure in the generator
2
Generator is ready for filling with CO 2
BHEL, Haridwar
Lower the gas pressure in the generator to

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.
2.3-8610-10550/1
0209 E
Turbogenerators
Operation
Gas Removal
Replacing H2 With CO2
Fill generator with carbon dioxide

represented by yellow lines on the mimic diagram on
the gas valve rack.
1.1
Set range selector switch to position II

to position II (0 to 100% CO2 in H 2)
1.2
Switch on heater of CO2 flash evaporator
1.3
Open shutoff valves and three-way valves
1.4
Close three-way valve MKG25 AA507
1.5
Measure CO2 purity
1.6
Terminate filling with CO2
2
Generator is filled with CO2
BHEL, Haridwar
Switch on heater of CO2 flash evaporator. Observe

temperature rise of heat transmitting liquid at the
temperature gauge. Wait until the thermostat switches
off the heater.
MKG25 AA502
MKG25 AA518
MKG59 AA507
evaporator)
MKG51 AA561
MKG25 AA519
Gas)
(shutoff valve in H 2 vent gas line)

(three-way valve in position CO2 Filling)
(shutoff valve after CO 2 f l a s h
(shutoff valve for high-pressure CO 2)
(three-way valve in position H 2 Vent
Then open shutoff valves at CO 2 bottles and CO2

bottle rack manifold. Replace empty CO2 bottles by full
bottles.
The CO2/H2 purity system measures the purity of the

vent gas.
The generator is filled with CO 2 when the indicator

shows a purity reading in excess of 95% CO2 in H2 Filling
with CO2 can be terminated.
Then close shutoff valves :
MKG25 AA518 (three-way valve in CO2 filler line)
MKG25 AA519 (three-way valve for measuring gas)
MKG51 AA561 (shutoff valve or high-pressure CO 2)
MKG59 AA507 (shutoff valve after CO 2 f l a s h
evaporator)and all shutoff valves at CO2 bottles and CO2
bottle rack manifold.
Switch off heater of CO2 flash evaporator.
Start with air filling.
2.3-8620-10550/1
0209E
Turbogenerators
Operation
Fill generator with

air
1.1
Set range selector switch to position I
1.2
Establish hose connection
1.3
Open shutoff valves
Gas Removal
Replacing CO2 With Air

represented by blue lines on the mimic diagram of the gas
valve rack.

to position I (0 to 100% CO2 in air).
Establish hose connection between compressed air

filter MKG25 BT001 and shutoff valve MKG25 AA501.
MKG25 AA501 (shutoff valve in compressed air line)

MKG25 AA509 (shutoff valve in compressed air line)
MKG25 AA518 (three-way valve in position CO2 Vent Gas)
Ensure that compressed air is clean and dry, i.e. neither
oil nor water should be entrained in the air. Adjust the
compressed air pressure by means of shutoff valve MKG25
AA509 so that the pressure in the generator will not exceed
1 bar.
1.4
Terminate filling with air
1.5
Remove hose connection
1.6
Close shutoff valves and three-way valves
When the indicator gives a reading of 0% in air, the

carbon dioxide has been driven out of the generator.
Open shutoff valves downstream of the liquid level
detectors and close three-way valve MKG25 AA518 for
purging the terminal box and the pipes to the level
detectors. After purging, switch three-way valve MKG25
AA518 to position CO2 Vent Gas and close shutoff valves
downstream of liquid level detectors.
Close shutoff valves MKG25 AA501 and MKG25 AA509.
Disconnect hose connection between compressed air
filter MKG25 BT001 and shutoff valve MKG25 AA501 at
bayonet fitting.
After approximately 15 minutes, close all shutoff valves

and three-way valves of the gas supply that are still open,
except for the pressure gauge shutoff valves.
With the generator rotor at standstill (n = 0s1), the seal
oil supply to the shaft seals may also be shut down.
Stop normal running routine of gas system
BHEL, Haridwar
2.3-8630-10550/1
0209E
Turbogenerators
Operation
Preparatory work
N2 Purging Before Draining

of Primary Water System
Primary water tank must be purged with nitrogen prior

to complete or partial draining of primary water circuit to
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.
Q
Q
2
Purge primary water tank with nitrogen
2.1
Open shutoff valves in N2 bottle rack and
purging gas system
2.2
Check nitrogen purging gas volume flow
2.3
Perform nitrogen purging procedure
Primary water pumps must be in operation.

A reliable nitrogen supply must be available.
Note : The nitrogen used for purging must have a purity

of 99.99%.
MKG31 AA501
MKG31 AA502
MKG31 AA503
MKG35 AA501
MKG91 AA502
(at N2 bottle)
(before N 2 pressure reducer)
(after nitrogen pressure reducer)
(in N 2 purging gas line)
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.
After a purging period of 12 hours, there will be no

potential hazards due to hydrogen atmosphere.
2.4
Terminate nitrogen purging
2.5
Close shutoff valves in N2 bottle rack and
purging gas system
MKG31 AA501
MKG31 AA502
MKG31 AA503
MKG35 AA501
MKG91 AA502
(at N2 bottle)
(before N 2 pressure reducer)
(in N2 purging gas line)
3
Continue shutdown of primary water system
BHEL, Haridwar
2.3-8650-10550/1
0209E
Turbogenerators
Operation
After shutdown of the turbine-generator, the primary
water supply to the generator is maintained by keeping
the primary water pumps in service. This condition is
permissible for a prolonged period of time. Monitoring
of the primary water system must be continued as during
normal operation.
BHEL, Haridwar
Supervision of Generator During Standstill

Water circulation in the primary water circuit or in

individual branch circuits can be stopped for shutdowns
up to 48 hours if work must be performed on the primary
water system. If the water circulation is to be stopped
for longer periods of time, complete or partial draining
of the primary water circuit will be required.
2.3-8700-10550/1
0209E
Turbogenerators
Shutdown of Primary Water System

for Less Than 48 Hours
Operation
Caution : The primary water system may only be shut

down when generator is carrying no load and has been
taken out of operation (n = 0s1).
Shutdown is defined as any of the following.
Shut down primary

water system for less
than 48 hours
2
Will entire primary water cooling circuit
be deactivated?
Yes
2.1
Stop primary water circulation
No
Stopping water circulation in branch circuits by

closing respective valves.
Completely or partially draining primary water system.
If primary water circulation cannot be maintained

because of faults in the primary water cooling circuit,
the entire cooling circuit may be shut down for a period
up to 48 hours.
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
Take branch circuits out of service
3.1
Take stator winding branch circuit out
service
3.2
Take bushing and phase connector branch
circuit out of service
When taking branch circuits out of service, the

primary water pumps can be maintained in operation.
Temporary drinking of individual branch circuits
should be performed in accordance with the following
instructions.
Close control valve MKF82 AA501. When this valve

is closed, primary water remains in stator winding branch
circuit.
Caution : Open shutoff valve MKF80 AA504 prior to
taking stator winding branch circuit out of service.
Take bushing and phase connector branch circuit out

of service by closing valves.
MKF83 AA501
MKF83 AA502
BHEL, Haridwar
(control valve before bushings)

(shutoff valve after bushings)
2.3-8720-10550/1
0209E
3.3
Take water treatment system out of
service
Isolate the water treatment system by slowly closing

valves.
MKF60 AA502 (control valve for water treatment
system)
MKF60 AA519 (shoutoff valve after water treatment system)
4
Primary water can be left in individual
branch circuits for periods up to 48 hours
2.3-8720-10550/2
0209E
Turbogenerators
Operation
Shut down primary water

system for more than
48 hours
2
Purge primary water tank with nitrogen
(N2)[1]
3
Reduce pressure in primary water tank
Shutdown of Primary Water System

for More Than 48 Hours
Caution : The primary water system may only be shut

down when generator is carrying no load and has been
shut down (n = 0s1).
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.
Caution : Primary water contains dissolved hydrogen.

Primary water tank must be purged with nitrogen prior
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 cooling circuit.
Reduce pressure in primary water tank to

atmospheric level by adjusting overflow regulator MKF91
AA003.
4
De-energize electrical equipment in
primary water system
De-energize :
Conductivity transmitters
Level detector system at primary water tank
Q
Volume flow indicators for stator winding and
bushings
Q
Q
Coolant temperature control system
Q
Power circuits of pumps
Q
Q
5
Drain compeleteprimary water circuit or
branch circuits
BHEL, Haridwar
Complete of partial draining of primary water circuit

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 provided that
Q
Electrical measuring devices in remaining branch
2.3-8730-10550/1
0209E
circuits remain activated.

Q
Q
Q
Nitrogen purging of primary watertank is continued.

Primary water is treated.
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 normal running routine of branch
circuits taken out of service
2.3-8730-10550/2
0209E
Turbogenerators
Operation
Drain primary water coolers

on cooling water side
2
Close shutoff valves before and after
coolers
3
Open drain and vent valves at coolers
Draining the Primary Water System

Primary Water Coolers (Cooling Water Side)
If the coling qwater cirvulation is stopped for maore
than three days, the coolers shoud be drained and dried.
If operation can presumably be resyume within theee
days, the coolerw may remain filled with cooling water
provided that the cooler tubes are free from deposits. With
deposti fuild-up, the cooling water should be drained and
the tubescleaned and flushed with clean water. Teh water
channels whould be kept open untill the unit is restarted.
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.
Close shutoff valve before and after coolers filled on

their cooling water sides. Check shutoff valves of standby
cooler for closed position.
Close drain valve of standby cooler not filled on its

cooling water side. Ten open drain and vent valves of
coolers filled on their cooling water sides.
After opening of the valves, the water is drained from
the coolers filled on their cooling water sides. Reopen drain
valve of standby cooler as soon as water has been drained
from coolers.
4
Dry coolers with compressed air
Establish a compressed air connection at vent manifold

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
BHEL, Haridwar
2.3-8732-10550/1
0209E
Turbogenerators
Operation

Stator Winding
Prerequisites for draining :
Drain stator winding
Q
Q
2
Preparatory work prior to draining
3
Blow out stator winding with compressed
air
4
Purge stato winding with N2
Primary water tank was purged with N 2 [1].

Measuring devices and supervisory equipement in
this primary water branck cirvuit nust have been
deactivated.
Close control valve before stator winding.

Remove inlet and outlet pipes, If required, clean the
two strainers inthe sttor winding inlet and outlet. Establish
hose connections between waste water wywtem and
drain, valves of primary water manifolds.
Stator winding is drained by blowing out winding with

compressed air.
Make sure that the compressed air is free from oil,
dust and other contaminants.
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.
Open compressed air valve briefly at reasonable
intervals, permitting water to be driven out via the drain
valve at the turbine end primary water manifold.
Open compressed air valve fully when only a small
amount of water accumulates.
Shut off compressed air supply at times during this
procedure to allow water to accumulate.
Open drain valve at exciter end primary water
manifold briefly several times during blowing-out
procedure to drain accumulated water.
Blowing out stator winding may be terminated when
air leaving the system is free of atomized air.
Slowly empty one nitrogen bottle through the stator

winding. connect nitrogen supply to primary water inlet
flange of exciter end manifold. Purging period should
amount to approximately two hours. Carefully close inlet
and outlet after purging. N2 purging should be performed
daily.
BHEL, Haridwar
2.3-8734-10550/1
0209E
5
Pressure stator winding
If the stator winding is to be preserved for a prolonged

shutdown, obtain the help of manufactures product service
personnel.
6
Stator winding is drained and preserved
After refer to the following information

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

Water System
2.3-8734-10550/2
0209E
Turbogenerators
Operation

Terminal Bushings and Phase Connectors

1
Drain terminal bushings

and phase connectors
Q
Q
2
Preparatory work prior to draining
Primary water tank was purged with N2 [1].

Measuring devices and supervisory equipement in this
primary water branch circuit have been deactivated.
Close valves:
MAKF83 AA501
MAKF83 AA501
(before bushings)
(after bushings)
Remove inlet pipe near the neutral point.
3
Blow out phase conectors and bushings
with compressed air
Phase connectors and bushings are drained by blowing

them out with compressed air.
Make sure that the compressed air is free from oil, dust
Connect a compressed air source to inlet flange.
Establish a hose connection between the waste water
system and the outlet fkange.
Deactivate voulume flow indicators
MKF83 CF001A
MKF83 CF001B
MKF83 CF011A
MKF83 CF0011B
MKF83 CF021A
MKF83 CF021B
(phase A bushings)
(phase A bushings)
(phase B bushings)
(phase B bushings)
(phase C bushings)
(phase C bushings)
by closing shutoff valves at valve assemblies.

Open compressed air valve, and blow out phase
connectors and bushings for several hours.
Intermittetly shut off compressed air supply during this
procedure, allowing water to accumulate.
Blowing out can be terminated when air leaving the
system is free of atomized air.
4
Purge phase conectors and bushings
with N2
BHEL, Haridwar
To prevent oxidation, purge phase connectors and

bushings with nitrogen. Connect nitrogen supply to 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 ourging. N2 purging should be performed daily.
2.3-8738-10550/1
0209 E
If the phase connectors and busings are to be preserved

for a polonged shutdown. Obtain the help of
manufacturerers product service personel.
Pressure phase conectors and bushings
6
Phase conectors and bushings are
drained and preserved
After refer to the following information

[1] 2.3-8650

Water System
2.3-8738-10550/2
0209E
Turbogenerators
Operation

Water Treatment System

1
Drain water treatemnt system
Q
Q
2
Take ion exchanger out of service

Measuring devices and supervisory equipement in this
primary water branch circuit have been deactivated.
Note: When draining primary water treatment system,

make sure that ion exchanger resins remain immersed
in water.
To do this, isolate ion exchanger by closing valves:
MKF60 AA502
MKF60 AA509
3
Drain water treatment system
(control valve before ion exchanger)

(shutoff valve after ion exchanger).
Drain water treatment system by closing shutoff valve

MKF60 AA519
(shutoff valve for primary water

treatment system)
and opening shutoff valves:

MKF60 AA503
MKF60 AA511
MKF60 AA512
MKF60 AA510
MKF60 AA517
4
Drain and dry piping system with
compressed air
(vent before ion exchanger)

(drain,fine filter)
(vent, fine filter)
(drain, primary water treatment system)
(drain, water treatment system).
Connect vent valve MKF60 AA503 to compressed air

system.
drain valve is free of atomized air.
5
Water treatment system is drained and
dry

[1] 2.3-8650

Water System
BHEL, Haridwar
2.3-8746-10550/1
0209E
Turbogenerators
Operation

External Part of Primary Water Circuit

Q
Drain external part of

primary water circuit

All branch circuits were drained or isolated from external
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.
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
Dry piping system with compressed air
Establish a connection to the compressed air system at a

suitable point (high static head of the external primary water
circuit.
vent and drain valves is free of atomized air.
3
External part of primary water circuit is
drained and dry

[1] 2.3-8650

Water System
BHEL, Haridwar
2.3-8748-10550/1
0209E
Turbogenerators
Operation
With the generator on turning gear or at standstill,
the dryer and the space heaters must be in operation.
The filter pads installed at the dryer inlet should
be carefully checked for contamination at regular
intervals and cleaned or replaced in due time.
Caution : Never place dryer into operation without
BHEL, Haridwar
During Standstill
Exciter
make-up air filter.
The brushes of the ground fault detection system
should be lifted off the measuring sliprings to prevent
the formation of rust on the sliprings. In the case of a
prolonged outage, a protective coating should be
applied to the measuring sliprings.
2.3-8900-10550/1
0209 E
Turbogenerators
Operation
The details given herein on faults, their possible causes
and the corrective measures cannot be considered
complete in every respect, since all possible troubles cannot
be covered in advance. In most cases, the operator will
have to decide on the measures to be taken. The individual
measures required depend on the mode of operation.
BHEL, Haridwar
Fault Tracing
General
Unless corrective measures can be taken in accordance

with the following instruction. The turbine-generator should
be shout down and the hydrogen should be replaced with
carbon dioxide. If required, the services of the manufacturer
should be requested. In most cases, however, sufficient
details will be found in the Turbogenerator Manual.
2.3-9000-10550/1
0209E
Turbogenerators
Operation
Fault/Cause
Differences in slot temperatures between individual
phases of stator winding
High hot gas temperature

and/or
High cold gas temperature
Fault Tracing
Stator and Generator Supervisory
Equipment
Remedy
The embedded RTD's should be checked when
different slot temperatures are indicated while stator
currents are of equal magnitude in all the three phases.
Such a check should only be made with the generator at
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.
Note: If cold gas temperature continues to rise, a
turbine trip is activated via the generator mechanical
equipment protection.
Hydrogen temperature control is disturbed. Insufficient

cooling water flow volume through hydrogen coolers.
Verify cause of disturbance by checking analog

indicators (uniform rise of temperatures at all coolers).
Set temperature control from Automatic to manual
mode and increase cooling water volume flow by opening
the final control element. If necessary, the final control
element should be manually opened.
Insufficient cooling water volume flow through a

single hydrogen cooler.
Verify cause of disturbance by checking analog

indicators (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

the system connected to generator
If the generator is operated with unbalanced load due

to particular system conditions, care must be taken that
the continuously permissible unbalanced load is not
exceeded [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
BHEL, Haridwar
2.3-9200-10550/1
0209 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.
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.
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].
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.
Oil
Oil level control in seal oil tank is disturbed.

Prechambers in generator are overflowing.
Take corrective actions as described in [ 4 ]
immediately.
2.3-9200-10550/2
0209E
[1]
[2]
[3]
[4]
2.1-1810
2.3-8170
2.3-9440
2.3-9561

Fault Tracing-Coolers
Fault Tracing- Oil Level in Seal Oil System
Turbogenerators
Operation
Fault/Cause
Fault Tracing
Generator Supervisory Equipment
Coolant Temperature Control
Remedy
Low coolant differential temperature

The temperature difference between the cold primary
water and the cold gas amounts to 3 K only.
Hydrogen temperature control is disturbed. Cooling

water volume flow through hydrogen coolers is
insufficient.
Verify cause of disturbance at analog indicators.

Change over control to manual mode and increase
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.
Primary water temperature control is disturbed. Cooling

water volume flow through primary water coolers is
excessive.
Verify cause of disturbance at analog indicators.

Change over control to manual mode and increase
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

disturbed.
BHEL, Haridwar
If the temperature difference between the cold

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.
2.3-9280-10550/1
0209 E
Turbogenerators
Operation
Fault/Cause
Sudden deterioration of rotor running condition.
BHEL, Haridwar
Fault Tracing
Rotor
Remedy
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.
2.3-9310-10550/1
0209 E
Turbogenerators
Operation
Fault/Cause
Fault Tracing
Coolers
Remedy
Liquid in Generator
Q
This fault is due to a leaking or defective H2 cooler
tube.
Identify the defective cooler section. First, close cooling

water outlet of this cooler section and then the cooling water
inlet.
Close shutoff valve before the level detectors that have
initiated the alarm. Drain the liquid by means of shutoff
valves after the level detectors. Repeat this procedure until
no liquid is drained through the shutoff valves. This
procedure ensures that no hydrogen can escape form the
generator through the shutoff valves.
4
1
2
3
4
Shutoff valve before level detector

Level detector
Sight glass
Shutoff valve after level detector
Fig. 1
Arrangement of Level Detectors
Shut down generator and remove the hydrogen with

carbon dioxide. Fill generator with air to a gauge pressure
of approximately 0.5 bar (7 psig). Remove the return
water channel. Ensure that gaskets are not damaged.
After removal of the cover of the return water channel,
the defective tube can be easily identified since air bubbles
emerge from this tube. Mark defective tube and drain cooling
water. Detach cooling water lines, seal cap and inlet/outlet
water channel. Ensure that gaskets are not damaged. Plug
the defective tube at both ends. Insert plugs by light hammer
blows into upper and lower tube sheets. To reassemble the
components, follow disassembly procedure in reverse order.
The cooler section should be filled with water and
BHEL, Haridwar
2.3-9440-10550/1
0209 E
Fault/Cause
1
2
3
1
2
3
4
Plug
Upper tubesheet
Cooler tube
Lower tubesheet
Fig. 2
Plugging a Defective Cooler Tube
vented. Check water channels to ensure there is no leakage.

The generator should be filled with gas, run up,
synchronized and loaded.
This temporarily repaired cooler may be maintained in
operation until next inspection or outage, at which time the
tube bundle or defective cooler tube should be replaced.
2.3-9440-10550/2
0209
Turbogenerators
Operation
Fault Tracing
Bearings
Fault/Cause
Remedy
Generator bearing temperatures vary.
Temperature variations at the generator bearings

may be due to different causes. Turbogenerator can
be kept in operation as long as permissible bearing
temperature is not exceeded. When a variation is
noted, the operating 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.
BHEL, Haridwar
2.3-9450-10550/1
0209 E
Turbogenerators
Operation
Fault/Cause
Fault Tracing
Bearing Vapour Exhausters
Remedy
Bearing vapour exhauster 1 failed.

Q
Fuses or thermal overload device have tripped main

contactor, resulting in failure of bearing vapour
exhauster 1.
Bearing vapor exhauster 2 automatically takes over

venting of generator bearing compartments. Verify that
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

contactor, resulting in failure of bearing vapour
exhauster.
Bearing vapor exhauster 1 automatically takes over

venting of generator bearing compartments. Verify that
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
BHEL, Haridwar

cable). Replace defective fuse and restart bearing vapor
exhauster 2.
2.3-9521-10550/1
0209 E
Turbogenerators
Operation
Fault/Cause
Seal oil pump 1 failed
contactor, resulting in failure of seal oil pump 1.

contactor, resulting in failure of seal oil pump 2.

Fuses or thermal overload device have tripped the
main contactor, resulting in failure of seal oil pump 3
(stand by seal oil pump). Hydrogen side seal oil pump is
stopped simultaneously.
Seal oil pump 1, loss of control voltage



BHEL, Haridwar
Fault Tracing
Seal Oil Pumps
Remedy
In the event of a failure of seal oil pump 1, seal oil pump

2 automatically takes over the seal oil supply to the shaft
seals.
Check if voltage is available. Check fuses and thermal
overload device. Examine seal oil pump for proper
mechanical and electrical condition.
Start seal oil pump 1 after fault is corrected.
In the event of a failure of seal oil pump 2, seal oil pump

3 (stand-by seal oil pump) automatically takes over the seal
oil supply to the shaft seals if seal oil pump 1 has failed
too.
Caution: If one of the two failed seal oil pumps cannot
take over the seal oil supply to the shaft seals immediately,
make all preparations for shutdown of generator and gas
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 pump can be
promptly restarted.
Sealing and lubrication of shaft seals with seal oil can

no longer be maintained.
Caution: Hydrogen glows into generator bearing
compartments via sealing gap and is extracted by
bearing vapour exhauster in service.
If another seal oil pump cannot be started immediately,
de-excite and shut down generator and remove hydrogen
gas promptly.
Isolate H 2 supply to generator by means of the
respective shutoff valves. Bring three-way valve MKG19
AA519 to H 2 vent gas position and place CO2 flash
evaporator in operation.
Displace hydrogen with carbon dioxide.

cable). Replace defective fuse and ensure that seal oil
pump 1 can be restarted.
2.3-9523-10550/1
0209E
Fault/Cause
Remedy
Hydrogen side seal oil pump failed

contactor due to loss of control voltage.
2.3-9523-10550/2
0209E
Shaft seals are now supplied with seal oil from the air
side seal oil circuit only. Seal oil drained towards the
hydrogen side of the shaft seals is returned to the seal oil
storage tank via seal oil tank MKW03 BB001 and float valve
MKW03 AA001.
Note: Seal oil saturated with air is now also supplied to
hydrogen side shaft seals. Air entrained in seal oil escapes
into generator, resulting in a deterioration of H2 purity.
Verify that voltage is available. Check fuses and thermal
overload device.
Visually examine pump to determine condition of
mechanical parts. Start pump immediately after the fault is
corrected. Verify that pressure gauges indicate previous
operating values.
Turbogenerators
Operation
Fault/Cause
Low seal oil pressure after air side oil filter
Seal oil filter in service is contaminated.
High differential pressure across air side oil filter

High differential pressure across hydrogen side oil

filter
Low air side seal oil pressure, TE/EE

A1 or A2 valve no longer controls to operating value.
Air side seal oil pump MKW11 AP001 or MKW21
AP001 is disturbed.
Seal oil filter MKW51 BT002 is contaminated.
Low hydrogen side seal oil pressure, TE/EE
C valve no longer controls to operating value.
Hydrogen side seal oil pump MKW13 AP001 is disturbed.
Seal oil filter MKW53 BT002 is contaminated.
Fault Tracing
Seal Oil Pressures and Temperatures
Remedy
Place stand by filter into service in order to determine

whether pressure drop is due to a contaminated filter.
Change over to stand by filter with changeover valve

assembly. Deactivate contaminated filter.
Remove filter cover and screen filter. Thoroughly clean
screen filter and reassemble filter. Fill filter housing with
turbine oil prior to reassembly.
Change over to stand by filter with changeover valve

assembly. Deactivate contaminated filter.
Remove filter cover and screen filter. Thoroughly clean
screen filter and reassemble filter. Fill filter housing with
turbine oil prior to reassembly.
Check settings of A1 and A2 valves. Check air side

seal oil pump in service. Check and, if required, clean air
side seal oil filter.
Alarm is activated through pressure gauge with contact.

Check setting of C valve. Check hydrogen side seal oil
pump. Check and, if required, clean hydrogen side seal oil
filter.
Low differential seal oil pressure, TE

Preset differential pressure between air side and
hydrogen side seal oil systems no longer exists.
Vent pressure equalizing valve.
Low differential seal oil pressure, EE

Preset differential pressure between air side and
hydrogen side seal oil systems no longer exists.
Vent pressure equalizing valve.
High seal oil temperature after air side / Hydrogen

side cooler
Cooling water flow is too low or cooler is contaminated.
BHEL, Haridwar
Verify that correct relationship exists between cooling

water flow and seal oil temperature. If cooling water flow is
too low, increase the cooling water flow by opening the
shutoff valves in cooling water outlet pipes. Failure of seal
oil temperature to decrease is indicative of a dirty cooler.
Place stand by cooler in operation by means of rotary
valve set.
Ensure that other cooler is properly vented on its oil
and water sides. Thoroughly clean cooler taken out of
operation on its water side.
2.3-9531-10550/1
0209 E
Fault/Cause
Varying pressure gauge indications

Q
Entrapped air in pipes.
Remedy
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

movements are due to lines or foundation.
Insufficient control range of differential pressure

regulating valves
Insufficient control range of A1 valve:

Keep shutoff valve MKW11 AA505 closed until pressure
gauge readings remain constant.
Insufficient control range of A2 valve:
Insufficient control range of C valve:
2.3-9531-10550/2
0209E
Turbogenerators
Operation
Fault/Cause
Relief valve of seal oil pump in service operates
during operation with A1 valve
Shutoff valves MKW11 AA505 and MKW11 AA504
are closed.
Main bellows in A1 valve is defective, resulting in a
rise of seal oil pressure before the shaft seals. A1 valve
may only be taken out of service when operation with
A2 valve is ensured.
Relief valve of seal oil pump in service operates

during operation with A2 valve
Shutoff valves MKW31 AA505 and MKW31 AA504
are closed.
Fault Tracing
Relief Valves in Seal Oil System
Remedy
Open shutoff valves MKW11 AA505 and MKW11

AA504.
Open shutoff valve MKW11 AA508.
Check that A2 valve regulates to operating pressure.
Close shutoff valve MKA23 AA504 in gas signal line
and shutoff valve MKW11 AA506 in oil signal line.
Close shutoff valves MKW11 AA504 and MKW11
AA505.
Disconnect gas signal line from valve head.
Dismantle valve head and replace main bellows.
Refit valve head and gas signal line.
Slowly open shutoff valve MKA23 AA504 and
afterwards shutoff valve MKW11 AA506. Vent oil signal
line through vent plug.
Open shutoff valves MKW11 AA504 and MKW11
AA505 and close shutoff valve MKW11 AA508.
Ensure that previous operating values are restored
during operation with A1 valve. If required, readjust A1
valve.
Open shutoff valve MKW31 AA505, MKW31 AA504

and MKW11 AA508.
Main bellows in A2 valve is defective, resulting in a

rise of seal oil pressure before the shaft seals. A2 valve
may only be taken out of service when operation with
A1 valve is ensured.
Open shutoff valve MKA23 AA504, MKW11 AA506

and MKW11 AA504 and MKW11 AA505 and check that
A1 valve regulates to operating pressure.
Close shutoff valve MKW23 AA503 in gas signal line
and shutoff valve MKW31 AA506 in oil signal line.
Close shutoff valves MKW31 AA504 and MKW31
AA505.
Disconnect gas signal line from valve head.
Dismantle valve head and replace main bellows.
Refit valve head and gas signal line.
Slowly open shutoff valve MKA23 AA503 and
afterwards shutoff valve MKA31 AA506. Vent oil signal
line through vent Valve MKW31 AA507. Open shutoff
valves MKW31 AA504 and MKW31 AA505 and close
shutoff valve MKA23 AA504, MKW11 AA506, MKW11
AA504 AND MKW11 AA505.
Ensure that previous operating values are restored
during operation with A1 valve.
Relief valve MKW13 AA001 operates.

Shutoff valve MKW13 AA510 is closed.
Main bellows in C valve is defective, resulting in a rise
of seal oil pressure before the shaft seals.
Open shutoff valve MKW13 AA510.

Take hydrogen side seal oil pump out of service. The
shaft seal are now supplied with seal oil from the air
side seal oil circuit only.
BHEL, Haridwar
2.3-9551-10550/1
0209E
Fault/Cause
Remedy
Close shutoff valve MKW13 AA510.
Close shutoff valve MKW13 AA505 in air side seal
oil signal line and shutoff valve MKW13 AA506 in
hydrogen side seal oil signal line.
Disconnect air side seal oil signal line from valve
head. Dismantle valve head and replace main bellows.
Refit valve head and air side seal oil signal line.
Open shutoff valve MKW13 AA507. Then open
shutoff valves MKW13 AA505, MKW13 AA506 and
MKW13 AA510.
Place hydrogen side seal oil pump in operation.
Close shutoff valve MKW13 AA507.
Vent hydrogen side and air side seal oil signal lines
through vent plugs. Ensure that previous operating
values are restored. If required, readjust C valve.
2.3-9551-10550/2
0209E
Turbogenerators
Operation
Fault/Cause
High oil level in TE/EE prechambers
Oil level in generator prechambers has risen to such
a height that one level detector is immersed in oil. Oil
level control is malfunctioning.
Low oil level in seal oil storage tank

Level detector is malfunctioning
Fault Tracing
Oil Level in Seal Oil System
Remedy
Make sure that valve MKW03 AA501 is fully open.

With valve open, oil level control should maintain in a
constant level of oil in seal oil tank. If unsatisfactory,
control valve MKW03 AA001 is not functioning properly.
Determine cause of trouble and correct it. Corrective
action is only practicable following shutdown and
emptying of generator and lowering of oil level in seal
oil tank. Emergency operation is possible with manual
control of valve MKW03 AA504. Make sure that oil level
remains visible in oil sight glass.
Cautiously open shutoff valve MKW03 AA504 by a small
amount. Seal oil is forced into the seal oil storage tank by
the H2 casing pressure acting on the oil in the tank.
Close shutoff valve MKW03 AA504 immediately when
oil level is visible in oil sight glass.
Caution: If the shutoff valve is left open, the complete
oil volume contained in the seal oil tank is forced into
the seal oil storage tank. Hydrogen flows into the seal
oil storage tank via the seal oil tank.
Check level detector and probe.
Leak in seal oil storage tank

In the event of a leak in the seal oil storage tank, the
seal oil pumps can no longer draw oil for supply to the
shaft seals. Shut down generator and remove gas
immediately.
Low oil level in seal oil tank
Low oil level in seal oil tank has dropped to such an
extent that level detector is no longer immersed in oil.
BHEL, Haridwar
Make sure that shutoff valve MKW03 AA504 is closed,

and shutoff valve MKW 03 AA501 OPEN.
If the level detector is no longer immersed in seal oil,
the level detector stops the hydrogen side seal oil pump to
prevent dry running of the pump.
Correct fault immediately.
2.3-9561-10550/1
0209 E
Turbogenerators
Operation
Fault/Cause
Fault Tracing
Gas Pressures
Remedy
Low H2 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.
Setting of pressure reducers incorrect.
Set H2 pressure reducers to operating pressure.
BHEL, Haridwar
2.3-9640-10550/1
0209E
Turbogenerators
Operation
Fault/Cause
Low H2 purity
Seal oil pump MKW13 AP001 supplying the hydrogen
side of the shaft seal has failed. In this case, the air
entrained in the air side seal oil circuit will escape into
the generator, resulting in deterioration of the H2 purity.
The supply of measuring gas to CO2 /H2 purity transmitter

MKG25 CQ001 has been interrupted, resulting in faulty
indication of the instrument.
No indication at indicators of purity meter system.
Fault Tracing
Remedy
The H 2 purity should be re-established through

scavenging with Hydrogen. Momentarily bring three-way
valve MKG25 AA518 to CO 2 vent gas position. Pressure
in generator will decrease. Pure hydrogen is
automatically replenished via the pressure reducers.
Check the complete meter system for CO2/H2 purity
transmitter MKG25 CQ001. To do this, interrupt
measuring gas flow to meter system by means of threeway valve MKG25 AA519. Bring three-way valve MKG25
AA507 in H 2 calibration position and re-calibrate meter
system with pure hydrogen.
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.
Gas flow decreases in spite of constant operating

pressure.
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% H 2 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
inserted.
Isolate measuring gas supply to meter system by
means of three-way valve MKG25 AA519 and remove
BHEL, Haridwar
2.3-9680-10550/1
0209 E
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.
2.3-9680-10550/2
0209E
Turbogenerators
Operation
Fault/Cause
Fault Tracing
Primary Water Pumps
Remedy
Primary water pump 1 failed

or
Primary water pump 2 failed
Q
The fuses or thermal overload devices have

operated.
The starting contactor has dropped out due to loss
of voltage
Check whether voltage is available. Check fuses or

miniature automatic circuit breakers and thermal
overload devices. Check pump for mechanical defect.
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

dropped out due to loss of voltage.
BHEL, Haridwar
Take corrective actions as described for the above fault.
2.3-9720-10550/1
0209E
Turbogenerators
Operation
Fault/Cause
Low pressure after primary water pump 1
or
Low pressure after primary water pump 2
Primary water circulation disturbed.
Fault Tracing
Water Pressures and Temperatures
in Primary Water System
Remedy
Correct disturbance and/or identify cause

immediately. Generator operation with insufficient cooling
water pressure will impair cooling of the unit and is thus
not permissible.
The standby pump is automatically started and takes
over the water circulation.
High pressure in primary water tank

Q
Gas in primary water tank is compressed due to

primary water being added at an excessive rate, the
outflow regulator being unable to release
corresponding gas quantities.
Reduce rate of make-up primary water.
Excessive hydrogen leakage, with the outflow

regulator being unable to handle leakage gas flow.
Check system for hydrogen leakage by determining

hydrogen losses of generator. In the event of a leak being
detected, reduce outflowing gas quantity by reducing
hydrogen pressure in generator; if necessary shut down
generator.
High differential pressure across fine filter

Fine filter is contaminated.
High differential pressure across main filter

Main filter is contaminated.
Low pressure in stator winding

BHEL, Haridwar
Take water treatment system out of service and

replace filter inserts in fine filter [1].
External part of primary water circuit is 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 circuit are possible due to resins in
the water treatment branch circuits 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,
place main filter 2 into operation and take main filter 1
out of service by filter changeover [2].
After changeover to the stand by main filter, make
sure that specified operating data have been restored.
After filter cleaning, operation of the primary water
system can be continued either with the cleaned filter of
with the filter placed into operation by filter changeover.
Cleaning the main filter during operation is possible
as described above.
2.3-9730-10550/1
0209E
Fault/Cause
High temperature after primary water cooler
Q
Cooler fouling (cooling water side).
Remedy
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.
Primary water temperature control disturbed.
Check the primary water temperature control system

and, if required, change over to manual control.
Insufficient venting of coolers.
Open vent values (primary water side and cooling

water side) until only water emerges.

[1] 2.4-4740
[2] 2.3-9740
2.3-9730-10550/2
0209E
Maintenance and Supervision of Primary Water

Filters
Filters in Primary Water System
Turbogenerators
Operation
Fault/Cause
High differential pressure across fine filter
Fine filter is contaminated.
Fault Tracing
Remedy
Take fine filter out of service by closing shutoff valves:

MKF60 AA509
(after ion exchange).
MKF60 AA513
(after fine filter).
Open shutoff valves:
MKF60 AA512
MKF60 AA511

(drain at fine filter)
to drain the primary water from the filter. Discard

water.
Open filter housing and replace filter element [1].
Recommissioning the fine filter:
Close shutoff valve
MKF60 AA511
(drain at fine filter).
Open shutoff valve

MKF60 AA509
(after ion exchange)
to admit primary water into the fine filter.
Close vent valve MKF60 AA512
as soon as the primary water emerges without bubbles.
Open shutoff valve
MKF60 AA513
High differential pressure across main filter
(after fine filter)
External part of primary water circuit is 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 circuit are possible due to resins in
the water treatment branch circuits 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,
place main filter 2 into operation and take main filter 1
out of service by filter changeover [1].
Place main filter 2 into operation by opening shutoff
valves:
MKF52 AA590 (before main filter 2)
MKF52 AA592 (vent at main filter)
MKF52 AA593 (after main filter 2).
Close shutoff valve
BHEL, Haridwar
2.3-9740-10550/1
0209E
Fault/Cause
MKF52 AA591 (drain at main filter 2)

immediately and shutoff valve
MKF52 AA592 (vent at main filter 2)
as soon as water emerges without bubbles.
Main filter 2 is now in service. Take main filter 1 out
of service by closing shutoff valves.
MKF52 AA580 (before main filter 1)
MKF52 AA583 (after main filter 1).
Open shutoff valves:
MKF52 AA581 (drain at main filter 1)
MKF52 AA582 (vent at main filter 1)
to drain the primary water from main filter 1. Discard
water.
system can be continued either with main filter 2 or with
cleaned main filter 1. When using main filter 1, operate
valves as specified above.

[1] 2.4-4740
2.3-9740-10550/2
0209E
Maintenance and Supervision of Primary

Water Filters
Turbogenerators
Operation
Fault/Cause
High water level in primary water tank
Q
Natural expansion of primary water due to
temperature rise.
Defective primary water cooler.
Fault Tracing
Water Level in Primary Water Tank
Remedy
A rise of the primary water level in the tank above the

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.
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 turbinegenerator. 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.
Water losses due to filling operation, evaporation and

water sampling.
Add water to restore required water level in primary

water tank.
BHEL, Haridwar
2.3-9760-10550/1
0209 E
Turbogenerators
Operation
Fault Tracing
Conductivity in Primary Water System
Fault/Cause
Remedy
High conductivity after ion exchanger

Q
Ion exchanger resins are exhausted and should be
replaced.
Deactivate the water treatment system by closing valves:

MKF60 AA502
MKF60 AA519
(control valve for water treatment

system)
(shutoff valve after water treatment
system).
Drain water from ion exchanger tank by opening

shutoff valves:
MKF60 AA503
MKF60 AA510
(vent before ion exchanger).

(drain after ion exchanger).
Terminate draining by closing shutoff valves:

MKF60 AA503
MKF60 AA510
(vent before ion exchanger).

(drain after ion exchanger).
After opening flanged connection and removing

connecting pipe, the cover of the ion exchanger tank
should be lifted off. Remove upper nozzle tray. Tilt tank
in its tilting device; remove exhausted resin mixture form
the tank and discard it, taking care that the nozzles in
the lower nozzle tray are not damaged.
Fill ion exchanger with new resins of quality KR and
place ion exchanger into service again [1].
Note: The use of reactivated resins is only
permissible in exceptional cases.
In such a case, the resins must be thoroughly
flushed to prevent the entrance of reactivating agent
into the primary water circuit.
It is recommended to procure new resins in due time
either directly from the competent representative of the
supplier,
Bayer Leverkusen AG
Sparte OC, Vertrieb 1-2
D 5090 Leverkusen,
or from
BHEL Haridwar
in order to maintain the recommended quality and a long,
reliable service period of the water treatment system.
The resins should be stored so that they are protected
form frost and prolonged exposure to temperatures in
excess of 30 0 C. According to the manufacturer's
instructions, storage of the resins at approximately 20 0
C should not exceed three months.
BHEL, Haridwar
2.3-9782-10550/1
0209 E
Fault/Cause
Q
Erratic behavior of conductivity meter system.
Remedy
Check the conductivity meter system [2].
Disturbances which seem to be caused by the transmitter
may possible be corrected by the following measures:
Remove transmitter form flow vessel and dip in
chromosulfuric acid. Clean electrodes and remove any
residual acid by rinsing in condensate or a similar medium
prior to reinstalling transmitter. Even minor traces of acid
at transmitter electrodes may result in a significant
temporary increase in the primary water conductivity. It is
recommended to measure the insulation resistance (500
V megger) between terminals 1/2 and 2/3 after transmitter
cleaning. With a dry transmitter, the insulation resistance
should not be less than 1 mega ohm.
High conductivity in main circuit

and/or
High conductivity after ion exchanger
Ion exchanger resinsd are exhausted and should be

replaced.
Defective primary water cooler.
Erratic behavior of conductivity meter system.
Take corrective actions as described above.

A defective primary water cooler will result in a rise of
primary water conductivity before the generator, with
minimum effect on the conductivity after the ion exchanger.
When it is obvious from these observations that a cooler is
defective, the defective cooler should be identified and
taken out of service by service by 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.
Take corrective actions are described above.

[1] 2.3-7120
[2] 2.3-7530
2.3-9782-10550/2
0209E
Filling the Water Treatment System

Activating the Primary Water Conductivity
Meter System
Turbogenerators
Operation
Fault/Cause
Low
Low
Low
Low
Q
flow
flow
flow
flow
rate
rate
rate
rate
Fault Tracing
Volume Flow Rates in Primary Water
System
Remedy
in
in
in
in
stator winding
phase A bushings
phase B bushings
phase C bushings
Insufficient discharge pressure, clogging or leakage.
BHEL, Haridwar
Insufficient cooling water flow results in insufficient

heat removal and mostly in serious damage to the
generator.
Since the effects of a cooler failure become
effective very quickly, a further drop in the flow rate
causes the signals to act on the generator mechanical
equipment protection, with the generator being
disconnected from the system and shut down.
Prior to reloading the generator, the fault must be
removed and/or identified.
2.3-9784-10550/1
0209 E
Turbogenerators
Operation
Fault/Cause
Fault Tracing
Alkalizer Unit for Primary Water System
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 in treatment circuit

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.

Faults which seem to be caused by the transmitter
may possibly be corrected by the following measures:
Remove transmitter from flow vessel and dip in RBS
solution (available from Messrs. Roth, Karlsruhe) or
chromosulfuric acid. Clean electrodes and remove any
residual acid by rinsing in condensate or a similar medium
prior to reinstalling transmitter. Even minor traces of acid
at transmitter electrodes may result in a significant
temporary increase in primary water conductivity. It is also
recommended to measure the insulation resistance (500
V megger) between terminals 1/2 and 2/3 after transmitter
cleaning. With a dry transmitter, the insulation resistance
should not be less than 1 mega ohm.
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.
Alkalizer unit has been deactivated because metering

pump was stopped
The following criteria result in stopping of the metering

pump and thus in deactivation of the alkalizer unit:
BHEL, Haridwar
Low volumetric flow rate in treatment circuit

High conductivity in treatment circuit
Cable breakage in measuring circuit
Defect of metering pump
2.3-9785-10550/1
0209 E
Fault/Cause
Remedy
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 advisable to change over the
controller to the manual mode and to lower the controller
output current to zero. Then start metering pump by pressing
the Metering Pump On key twice and reset controller for
automatic mode. The controller adjusts the conductivity to
the set point level within approximately 10 to 15 minutes.
Q
Controller is disturbed.
The fault display on the controller front lights up.

Press reset key and try to reactivate the controller. Check
and if necessary, correct controller setting.
NaOH injection can be continued until the fault is removed.
To do this, change over metering pump to the manual mode
and adjust stroking rate to get the required conductivity.
Automatic circuit breaker F1 has tripped.

Alarm provided Via CB Trip group alarm.
The alkalizer unit is de-energized.

Re-close automatic circuit breaker F1 in control
cabinet of alkalizer unit.
If circuit breaker is tripped again, identify and correct
tripping cause.

Alarm provided via CB Trip group alarm.
Signal transmitters and metering pump have been

deactivated due to loss of supply voltage. The controller
adjusts the output current to the safety set point level.
Prior to restarting the metering pump, change over
controller to manual mode and lower controller output
current to zero. Start metering pump and reset controller
for automatic mode.
Fine-wire fuse of metering pump is defective.
Check and, if necessary, replace fine-wire fuse at

right-hand top of metering pump (mode 1) front panel.
In an alkalizer unit equipped with a model 2 metering
pump, the fine-wire fuse is located behind the front panel.
After having shut off the voltage supply, e.g. activating
the automatic circuit breaker F1 and loosening of the
screws, carefully remove the front panel.

Alarm provided Via CB Trip group alarm.
Controller and A/D converter have been deactivated

due to loss of supply voltage (no flashing light signals).
Check and, if necessary, correct controller setting,
Reactivate control circuit.
Low conductivity in main circuit
Measuring circuit of conductivity transmitter is faulty.
2.3-9785-10550/2
0209E
Cancel alarm by pressing the acknowledge key as

soon as the conductivity has decreased below the limit
value after fault removal.
Fault/Cause
Q
Turbogenerators
Operation
Alkalizer unit has been deactivated for several hours.
Low NaOH level in tank

Q
Sodium hydroxide solution has been largely consumed.
Remaining quantity its only sufficient for about 40 hours.
Remedy
If possible, change over metering pump to the manual
mode at once [3] and adjust stroking rate to get the
required conductivity.
Fill NaOH tank with dilute sodium hydroxide solution [1].

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
in treatment circuit after a short time.
Q
A valve in treatment circuit was throttled or closed

due to incorrect operation.
High conductivity in treatment circuit

and/or
Note: The following status indications are signalled

by lamps on the alkalizer unit.
Loss of supply voltage
Check valve positions in treatment circuit and

readjust volumetric flow rate.
Note: If the conductivity continues to rise, the

metering pump is stopped, with in turn activates an
alarm for low conductivity in treatment circuit 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 [2].
If one of the lamps fails of light up during NaOH
injection, a lamp test should be performed first. To do
this, press lamp test key. All pilot and status indicating
lamps should light up.
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 twice.
Power supply of alkalizer unit has failed.
Controller deactivated
Metering pump stopped
BHEL, Haridwar
Correct fault and switch on supply voltage.

If circuit breaker is tripped again, identify and correct
tripping cause.
The lamp is extinguished when the controller is
deactivated.
The Metering Pump On lamp is extinguished when

the pump has been stopped by a planned shutdown or
due to a limit-value excursion.
2.3-9785-10550/3
0209E
Fault/Cause
Q
Remedy
If the circuit breaker is tripped again, identify and
correct tripping cause.

[1] 2.4-4785
[2] 2.3-9782
2.3-9785-10550/4
0209E
Maintenance and supervision - Alkalizer Unit

Fault Tracing - Conductivity in Primary
Water System.
Turbogenerators
Operation
Fault Tracing
Fuses on Rectifier Wheels
Fault/Cause
Remedy
Fuse indicator operated

Q
Failure of one or several diodes.
Note: After operation of one or several fuses, it

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 threephase 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
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
BHEL, Haridwar
2.3-9901-10550/1
0209 E
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.
Before installing new diodes and fuses, the
following checks must be made:
A ft e r c l e a n i n g t h e h e a t s i n k , t h e i n s u l a t i o n
resistance between isolated heat sink and wheel must
be measured using a 500 to 1000 volt megger.
Insulation resistance should be more than 10 M
.
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 .
After installation of
the enclosures and
reactivation of field ground fault detection system, the
generator may again be placed in service.

[1] 2.1-1810
2.3-9901-10550/2
0209E
Turbogenerators
Operation
Fault/Cause
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
conditions.
High cool air temperature

Q
The cause is an insufficient cooling water flow.
Trapped air has accumulated in cooler.
Cooler is fouled on water side.
BHEL, Haridwar
Fault Tracing
Exciter Temperatures
Remedy
With a rise in cold water temperature, higher

cooling water flow is required for removal of the loss
heat. Increase cooling water flow.
Increase cooling water volumetric flow rate up to

the maximum permissible limit.
Vent cooler by means of vent screws.
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.
2.3-9911-10550/1
0209 E
Turbogenerators
Operation
Fault/Cause
Liquid in exciter
Q
The cause is a leak or a tube rupture at the cooler
tube bundle.
Fault Tracing
Exciter Cooler
Remedy
Unload and shut down turbine-generator.

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
1
2
3
4
Compressed air hose

Hose
Hollow Plug
Cooler section
Fig. 1
5
6
7
Tube
Plug
Tube sheet
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
BHEL, Haridwar
2.3-9914-10550/1
0209 E
Fault/Cause
1
1
2
3
4
Plug
Tube sheet
Cooler tube
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
d e f e c t i v e t u b e s i s s u ff i c i e n t f o r e m e r g e n c y
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.
2.3-9914-10550/2
0209E
Fault Tracing
Stroboscope
Type LX5 (220 V)
Turbogenerators
Operation
Fault/Cause
Remedy
Stroboscope defective
Pins 2 and 9 on plug board 2 are interconnected for
a supply voltage of 220 V.
Printed circuit board 1 defective

Supply voltage of 220 V is available at pins 3 and 8.
Plug board 1, printed circuit board viewed from below
1
10
11
12
13
Check to ensure that supply voltage is available at

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 %.
Verify that following voltages are available:

Ground/pin
Ground/pin
Ground/pin
Ground/pin
12
6
7
11
abt.
abt.
abt.
abt.
310 V DC
23 V DC
5 V AC
24 V AC
Replace printed circuit board if, on pressing the On

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.
1
10
11
12
13
Relay d1 must pick up on depressing the On push

button. If the relay drops out again on releasing the push
button, the push button should be pressed again and held
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.

1
10
11
12
13
Ground/pin
Ground/pin
Ground/pin
Ground/pin
13
7
11
9
abt.
abt.
abt.
abt.
23 V DC
15 V DC
5 V AC
6-9 V AC
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.
BHEL, Haridwar
2.3-9941-10550/1
0209 E
Fault/Cause
Remedy
Defect on plug board 4

1
10
11
12
13
One flash tube failed
Verify that the following voltages are available:

Ground/pin 12
abt.
310 V DC
Ground/pin 11
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
are not obtained.
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.
2.3-9941-10550/2
0209E
Turbogenerators
Operation
Fault/Cause
Exciter dryer disturbed
Q
Limit switch failed to operate, i.e. motor-actuated
flap is hot in Open position.
Overheat protection has switched off the exciter

dryer. In most cause is no or an insufficient air
flow.
Fault Tracing
Remedy
Set lever for manual operation at flap shaft to

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.
Open door in exciter enclosure behind which the
dryer is located from the operating floor. Following a
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 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.

[1] 2.4-4925
BHEL, Haridwar
Maintenance and Supervision Exciter Dryer
2.3-9955-10550/1
0209E
Turbogenerators
Operation
Fault Tracing
in Exciter Field Circuit
Fault/Cause
Remedy
Ground fault detection system disturbed

Q
Carbon brushes have poor or no contact with
measuring sliprings.
Install carbon brushes and plug-in brush holders

strictly in accordance with maintenance instruction [1].
Exciter voltage response takes longer than 5 s.
Fault alarm is automatically extinguished after

removal of cause.
High-resistance ground fault in exciter circuit

(RE < 80 k )
Immediately investigate cause of ground fault alarm.

Measure insulation resistance in exciter circuit if the
generator can be disconnected from the system and deexcited [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

(RE < 5 k )
At RE < 5 k , a TUSA trip is activated by the electrical

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
[2] 2.5-3300
BHEL, Haridwar
Maintenance and Supervision or Ground

Fault Detection System
Insulation Resistance Measurements on
Rotor and Exciter Windings
2.3-9980-10550/1
0209E
Turbogenerators
Maintenance
Maintenance and Supervision

Introduction
The turbogenerator and its auxiliaries require

continuous maintenance and supervision to assure 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 operating 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.
BHEL, Haridwar
2.4-4200-10550/1
0209 E
Turbogenerators
Maintenance and Supervision of Stator
Maintenance
Check grounding brushes
Monitoring the Temperature of Components
It is important that all temperatures remain within

the specified upper and lower limits. If a temperature
deviation is observed the cause must be determined
immediately and the original temperature restored.
I f t h e r e e x i s ts t h e d a n g e r o f o v e r h e a t i n g , a
corresponding load reduction should be made.
The temperature between the top and bottom bars
of the stator winding are measured with resistance
temperature detectors (RTDs).
The RTDs are embedded in the winding and
distributed uniformly over the three phases. The
R T 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
approximately identical values for identical currents
in all three phases. If different temperatures are
indicated with identical currents in the three phases,
a check should be performed to determine if the slot
RTDs are correctly calibrated and/or compensated.
Differences in the temperature indication upto 5C
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 R T D s ,
compensating resistors and tolerances caused by
differences in the contact at the measuring point
selector switch. Other small temperature differences
may be due to different mounting conditions at the
RTDs.
2
Monitoring the Cooling Gas and Cooling Water

Temperatures
The temperature of the cooling gas in the

generator is measured with one RTD before and after
each cooler section. The RTDs installed after the
coolers indicate the temperature of the gas used for
generator cooling. The cooling water supply to the
individual cooler sections should be adjusted so that
the gas outlet temperatures at all cooler sections are
approximately identical. The setting of the cooling
water flow should be made by changing the
adjustment of the cooling water outlet valves. The
BHEL, Haridwar
Annualy
Every 6 Months
Every 3 Months
Check sight glasses after level detectors for liquid level

1
Weekly
Daily
Work required
Monthly
Maintenance Intervals
cooling water inlet valves at the individual cooler

sections should be fully opened.
To prevent undue stressing of the generator, it is
desirable to maintain a constant temperature in the
generator by control of the cooling water flow.
In addition to the gas temperatures, the cooling
water temperature is also measured. The cooling
water inlet temperature of all cooler sections should
be measured in the cooling water inlet pipes, while
the cooling water outlet temperature should be
measured separately for each cooler section in the
cooling water outlet pipe after each cooler section.
3
Hydrogen Pressure in Generator
On-load running should always be performed at

the specified hydrogen pressure, since it results in
minimum thermal stresses in the generator interior.
If the specified hydrogen pressure cannot be
maintained for unforeseeable reasons (e.g. lack of
gas, high gas losses), the generator should be
unloaded and de-excited when the pressure has
dropped by 0.4 bar (5.7 psig).
4
Primary Water Flow Rates
A n i n s u ff i c i e n t p r i m a r y w a t e r f l o w r e s u l t s i n
insufficient cooling of the water-cooled components.
Therefore, the flow rate must not fall below the lower
limit value.
5
Primary Water Temperature
Continuous recording of the primary water

temperature is essential to ensure safe on-load
running of the turbine-generator. Many faults can thus
be recognised and remedied at an early stage. This
i s pa r t i c u l a r l y i m p o r ta n t f o r a d i s t u r b e d c o o l e r
performance (fouling, venting etc.).
2.4-4210-10550/1
0209E
Note: The temperature of the cold primary

water should be higher than the H 2 cold gas
temperature by not less than 5K (9F) under
all conditions of operation in order to positively
avoid the formation of moisture condensate on
the
components carrying primary water. The
difference between the primary water inlet
temperature and the cold gas temperature is
measured directly and monitored continuously. An
alarm is activated when this differential
temperature drops below the predetermined value.
When no differential temperature exists any longer
or when the primary water inlet temperature is
even lower than cold gas temperature, the
generator must be unloaded and de-excited at
once.
6
Primary Water Pressure Before Stator Winding
The pressure of the primary water before entering

the stator winding can be taken as a reliable criteria
for a safe cooling water supply to the various branch
circuits.
A small change in pressure up to a maximum of
10% has no influence on cooling of the stator winding.
Major changes with rising tendency may be indicative
of a disturbance in uniform cooling in individual branch

circuits. To avoid any risk in cooling of the stator
winding, it is recommended to contact manufacturers
product service department and to ask for removal of
the cause.
7
Liquid Leakage Detection at Level Detectors
Liquid entering the generator housing is sensed

by level detectors. Sight glasses, located before and
after the level detectors, permit any leakage to be
readily detected before the liquid level will have risen
up to the level detectors.
8
Grounding Brushes
The carbon brushes should be checked at regular

intervals. During operation, the useful length of each
individual carbon brush can be determined by a visual
inspection. For limits of wear, see Description [1].
The carbon brushes should be replaced with new
ones having contact faces which match the rotor shaft
contour.
Note: Ensure to insert the grounding brushes so
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.
2.4-4210-10550/2
0209E
[1] 2.1-1820 Mechanical data
Turbogenerators
Maintenance

of Generator Coolers
Check cooler vents

1
General
Annualy
Every 6 Months
Every 3 Months
the measures outlined below should be taken.
Special measures should be taken to prevent corrosion damage to the cooler [1]. Cooler sections having
no cooling water flows for some time may be subject to
standstill corrosion. In addition to many other corrosive
influences, such as the different elements of the cooling
water, locally differing deposits, raw materials, etc., there
exists the danger that microorganisms on the tube walls
may die and decay due to a loss of fresh water supply
(lack of oxygen). Ammonia is formed from such decay
which may lead to stress corrosion cracking. Corrosion
damage can only be properly prevented if the cooler is
drained on the water side, cleaned, completely dried and
maintained in a dry condition. With the generator in commercial operation, such measures are often unfeasible,
particularly in cases of short outages. In such cases,
Fig. 1
Fig. 2
Cooler Section (disassembled)
Weekly
Daily
Work required
Monthly
Coolers
During normal operation, the cooling water flow

through all cooler sections. Since the coolers are designed for 100 % capacity at maximum cooling water
temperature, the condition may arise that the coolers
are supplied with smaller cooling water flows for long
periods. Depending on the purity of the cooling water,
this may result in deposits due to the lower water velocity in the cooler. To prevent cooler damage, it is therefore recommended to rinse the coolers with the full water flow during short outages. In addition, the coolers
should be frequently cleaned with brushes. For heavy
cooler contamination and if operational restrictions and
shutdowns are undesirable, it is recommended to install
a continuous cooler water purification system.
Purification Brush

[1] 2.3-5003
BHEL, Haridwar
Hints for cooler operation
2.4-4240-10550/1
0209E
Turbogenerators
Maintenance

of Bearings
Check EE ground bearing insulation
Fig. 1
Generator Bearing and Seal Insulation
BHEL, Haridwar
Annualy
Every 6 Months
Check exciter bearing insulation

General
During normal operation, no service or maintenance
work is required on the bearings of the generator, however, bearing vibrations, bearing temperatures, oil temperatures, and oil pressures should be continuously
monitored.
The generator bearings require particular attention
during each new startup, following brief shutdown. Careful monitoring will also be necessary within the first few
minutes after runup until the normal operating values
are restored. If the operating values prevailing after a
restart exceed the permissible limit values, the unit
should be shut down immediately.
The lift oil pressure for the shaft journals should be
adjusted so that the shaft is lifted by not more than 50 %
of the bearing top clearance (top clearance amounts to
0.12 % of the bearing diameter). To prevent any damage to the bearings the shaft lift oil system must be in
operation at speeds as specified in the turbine instruction manual.
At higher speeds, the lift oil pressure will settle at 40
to 80 bar. The oil pressure should be recorded in the
operating log. If a lower oil pressure is observed the re-
Every 3 Months
Check EE shaft seal insulation
Monthly
Daily
Work required
Weekly
Maintenance interval
X
spective bearings should be checked. Such pressure reduction may be indicative of damage in the area of contact surface, the bearing babbitt, leaking supply pipes,
or defective pressure limiting and check valves.
The temperature of the lubricating oil supplied to the
bearings is controlled by the cooling water flow to the
bearing oil cooler. The temperature of the generator
sleeve bearings are displayed in the control room.
2
Checking the Shaft Seal and Bearing Insulation

Checking the shaft seal and bearing insulation during operation [1] may be done by way of the shaft voltage prevailing with the generator running in an excited
condition. For the purpose, the potential of the insulated
shaft seals and bearings is accessible external to the
generator. With the generator running, the components
coming into contact with the shaft are separated from
the shaft by an oil film, which has insulating properties.
Consequently, a non-defined resistance value is set up
at the potential measuring points of the shaft seals and
bearing sleeves which is dictated by the magnitude of
the resistances of the oil film and insulating parts.

[1] 2.5-0300 Checking the Bearing and Seal Insulation
2.4-4250-10550/1
0209 E
Turbogenerators
Maintenance

of Rotor
Measure insulation resistance

1
Monitoring Rotor Vibrations
The vibrations of the generator rotor should be monitored and any change should be carefully observed.
Should a change in vibration characteristics be noted, it
is recommended to have the manufacturers product
Annualy
Every 6 Months
Every 3 Months
Weekly
Daily
Work required
Monthly
service personnel determine the cause and assist in

correcting any problems.
2
Measuring Insulation Resistance
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
BHEL, Haridwar
2.4-4310-10550/1
0209E
Turbogenerators
Maintenance

Seal Oil Pumps and
Bearing Vapor Exhausters
Change over seal oil pumps 1 and 2
Perform functional check of standby seal oil pump
Change over bearing vapor exhausters
Repack regreasing devices of bearing vapor exhauster shaft seals with grease
1
Seal Oil Pumps

To prevent dry running of the pump and to ensure
proper lubrication of the shaft seal, each new or
overhauled seal oil pump should be filled with turbine oil
via the oil filling plug, unless this has already been
accomplished through the oil supplied to the oil inlet of
the pump. In addition, the oil ensures proper sealing of
the shafts for pump priming.
Change over seal oil pumps 1 and 2 at monthly
intervals. To do this, start standby pump by manual
control. Then stop pump so far in service by manual
control.
Perform functional check of standby seal oil pump 3
once per month. To do this, start standby pump by
1
2
3
4
Annualy
Every 6 Months
Every 3 Months
Weekly
Daily
Work required
Monthly
manual control. After a short running period, this pump

will then be automatically stopped again after elapse of
a present time delay. Check to ensure that the indications
showing that the standby seal oil pump is in operation
are displayed during the short running period.
Perform changeover to standby pump once per
month. Check pump delivery pressure and then change
over to normal-service pump.
2

The bearing vapor exhausters are provided with a
regreasing device for the axial shaft seal. Repack
regreasing devices with grease every six months.
The exhausters should be changed over once per
month. To do this, follow the same procedure as for the
seal oil pumps.
Venting Screw/oil filling plug

Discharge flange
Pressure relief valve
Drive shaft
Fig. 1
Seal Oil Pump
1
2
Regreasing device
Drive motor
Fig. 2 Bearing Vapour Exhauster
BHEL, Haridwar
2.4-4520-10550/1
0209E
Turbogenerators
Maintenance

Seal Oil Coolers
Check service cooler for proper venting
Check seal oil supply lines and shutoff valves for leakages
General
One of the two seal oil coolers in the air side and
hydrogen side seal oil circuits will be in service.
Serving as standby unit, the second cooler is filled
on its oil side, while it should be empty, clean and dry
on its cooling water side in order to preclude standstill
corrosion on the cooling water side. The cooling water
vent and the drain valve should be kept open to
maintain the cooler in a dry condition.
2. Cooler Changeover
When changing over the coolers, the standby
cooler must first be filled on its water side, with care
being taken to ensure that the cooler is properly
vented on both the water and oil sides.
The three-way valves should be changed over by
turning the common handwheel, which actuates both
valves simultaneously. The right-hand seal oil cooler
is placed into service on its oil side by turning the
handwheel counter-clockwise upto the stop. If the
handwheel is turned clockwise, the left-hand cooler
is taken into operation. The changeover procedure
does not result in an interruption of the oil flow.
When making a changeover on the oil side, take
BHEL, Haridwar
Annualy
Every 6 Months
Every 3 Months
Weekly
Daily
Work required
Monthly
care that the three-way valve for cooling water inlet

is actuated simultaneously. The cooling water volume
flow for the cooler taken into service should be
adjusted at the outlet valve so that the specified oil
outlet temperatures obtained.
3. Cooler Cleaning
In-service cleaning of the standby seal oil cooler
on its cooling water side is possible after disassembly
of the upper return water channel. During cleaning,
the cooler can be kept filled on its oil side. The seal
oil cooler removed from service should be cleaned
with tube brushes. The use of Perlon brushes ensures
both a careful treatment of the tube wall and good
cleaning results. To ensure thorough tube cleaning,
the tube interior should be wet, since dry dirt deposits
are more difficult to remove. After completion of
cleaning and refitting of the upper water channel, the
cooler should briefly be flushed with the full water
flow for the complete removal of any residual dirt
deposits. Deposits which cannot be removed by
mechanical means may require chemical cleaning. If
t h e r e i s i n s u ff i c i e n t e x p e r i e n c e a n d e q u i p m e n t
available, it is recommended to have this cleaning
work performed by a suitably qualified contractor.
2.4-4540-10550/1
0209E
Turbogenerators
Maintenance

Seal Oil Filters
Check degree of contamination of seal oil filters
The degree of contamination of the seal oil filter

can be directly seen at the differential pressure indicator. As the contamination of the filter increases, corresponding to an increase in the pressure drop across
the seal oil filter, a higher differential pressure is indicated. At a preset value, an alarm signal is activated.
When the alarm signal has been activated, the
standby filter should be placed in service and the contaminated filter removed from service by means of the
Annualy
Every 6 Months
Every 3 Months
Weekly
Daily
Work required
Monthly
change-over valve assembly. Check filter valve for

closed position.
Drain the seal oil from the filter housing via the
drain plug and remove the filter cover. The screen filter should be removed and cleaned thoroughly. Prior
to reassembly, the filter should be flushed with turbine oil to remove any solvent residue. The filter housing should be filled with turbine oil and the filter reassembled. Open filler valve and vent the filter.
Clean the filters during each inspection.
BHEL, Haridwar
2.4-4550-10550/1
0209 E
Turbogenerators
Maintenance

Gas Consumption
Check gas consumption
Annualy
Every 6 Months
Every 3 Months
Check shutoff valves for free movement
Check gas supply lines and shutoff valves for leaks
General
Caution: The CO2 bottle rack should be equipped with

full bottles so that a sufficient quantity of carbon dioxide
will be available for any required displacement of the
hydrogen.
A sufficient number of full hydrogen bottles should
be kept in stock at all times taking into consideration the
gas consumption rate of the unit and the availability of
new hydrogen.
According to section 4.6e in VDE 0530, Part 3, not
more than two H2 bottles should be connected and open
during normal operation.
On occurrence of a leak and the resulting higher gas
consumption, only the open H2 bottles would be emptied
at a faster rate. In addition an alarm is activate to alert
the operator in due time.
It is recommended that, to improve the operating
reliability, only the hydrogen bottles in service should be
connected to the hydrogen bottle rack, while the other
connections should be isolated by means of the shutoff
valves at the H2 bottle rack manifold.
The connection of new gas bottles should be entered
in the operating logs.
2
Weekly
Daily
Work required
Monthly
Gas quantities escaping uncontrolled are those lost

through leaks in the generator and gas system.
If an undue loss of gas occurs on the unit, the location
of the leak must be determined [1].
Since this leakage gas may present a danger to the
environment, it should not amount to more than 12m 3
(s.t.p.) during 24 hours. In the event of the gas leakage
losses exceeding 12m3 (s.t.p.) during 24 hours, leak tests
should be performed and the gas losses reduced below
this limit. In case such measures are not successful, even
on reduction of the gas pressure in connection with a
corresponding load reduction, the unit should be shut
down and the hydrogen removed from the generator (see
section 4.6d in VDE 0530, Part 3).
2.1 Handling the Handy-Tector
The sniffer probe of the Handy-Tector should be led
over the surface of the test object as slowly as possible.
Note that with a leakage gas lighter than air the leak
detection should be carried out above the object and
with gases heavier than air underneath of the test object.
Gas Consumption
During operation, the loss of H 2 gas must be

monitored continuously on the basis of H 2 consumption.
The total gas consumption consists of the hydrogen
quantities escaping both controlled and uncontrolled.
The gas quantity escaping under control is composed
of the hydrogen flowing out continuously via the purity
meter system for measuring the gas purity in the
generator, and the gas removed from the generator
through the seal oil and discharged into the vent gas
line.
Fig. 1 Handy-Tector

[1] 2.5-0310
Leakage Tests
BHEL, Haridwar
2.4-4610-10550/1
0209E
Turbogenerators
Maintenance

Primary Water Pumps
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

The shafts of the primary water pumps are supported
in oil-lubricated bearings. Check oil levels in bearings at
regular intervals.
The exact oil level in the pump in service cannot be
determined at the oil sight glass due to oil foaming. The
oil level in the pump in service should be visible in the
middle of the oil sight glass. The oil should be changed
after about 3000 operating hours (at least once a year).
BHEL, Haridwar
Annualy
Every 6 Months
Every 3 Months
Weekly
Daily
Work required
Monthly
Checking Readiness for Starting

To ensure that the standby pump is ready for
operation on a continuous basis, start and immediately
stop this pump once a week.
3
Changing Over Pumps

The primary water pumps should be changed over
at regular intervals (at least once a month) so that
they will be alternately in service.
2.4-4720-10550/1
0209 E
Turbogenerators
Maintenance

Check service cooler for proper venting
Check seal oil supply lines and shutoff valves for leakages
General
The degree of contamination of the primary water
filters can be seen at the differential pressure indicator.
At predetermined differential pressures, alarms are
activated in addition to signal filter contamination.
During each inspection of the unit, the main filters
should be cleaned and the filter element of the fine filter
replaced.
Warning : Primary water contains dissolved hydrogen.
When draining he filter, care should be exercised
because of resulting degassing of water.
2
Main Filter
The main filter is only insignificantly contaminated
even after a service period of several years due to the
purity of the primary water and the cleanliness of the
entire primary water system. Cleaning during operation
will therefore normally be not required. Should it
nevertheless become necessary to clean the main filter
during service, place main filter 2 in operation and take
main filter out of service.
To do this, close shutoff valve
MKF52AA591
(drain, main filter 2)
Open shutoff valves :

MKF52AA590
MKF52AA593
(before main filter 2)

(after main filter 2).
Close shutoff valve :

MKF52AA592
(vent, main filter 2)
as soon as water emerges without bubbles. Main filter 2

is now in service.
Close shutoff valves :
MKF52AA580
MKF52AA583
(before main filter 1)

(after main filter 1).
Open shutoff valves :
Annualy
Every 6 Months
Every 3 Months
Weekly
Daily
Work required
Monthly
MKF52AA581
(drain, main filter 1)
MKF52AA582
(vent, main filter 1).
Discard primary water drained from main filter 1. Main
filter 1 can now be cleaned [1].
system can be continued either with main filter 2 or with
cleaned main filter 1.
3
Fine Filter
The fine filter can also be taken out of service during
normal operation for replacement of the contaminated
one-way filter element.
The procedure for any required filter element replacement of the fine filter is as follows :
Take fine filter out of service [2].
Remove contaminated filter element.
Remove vent pipe and hex nuts from filter cover and
lift off cover.
Hold filter insert at handle and turn counterclockwise.
After removal of filter insert from filter housing, loosen
hex nuts and remove bottom seating ring. Withdraw contaminated filter element.
Insert new filter element and close filter.
Prior to installing a new filter element, clean filter
sealing faces and seating rings and check O-rings for
damage. Install filter element and replace bottom seating ring. Fit and tighten one hex nut until the support
plate rests on the upper seating ring. Fit and firmly tighten
(lock) second hex nut.
Hold filter insert at handle and turn clockwise until
filter insert is firmly locked in filter housing.
Reposition and bolt down filter cover. Uniform contact pressure must be obtained by tightening nuts alternately at opposite points.
Refit vent pipe to filter cover so that a tight connection is obtained.
Fine filter can be taken into service [2].
[1] 2.5-7300
[2] 2.3-9740
BHEL, Haridwar

2.4-4740-10550/1
0209 E
Turbogenerators
Maintenance

of Primary Water Coolers
Check primary water cooler vents

1
Maintenance of Coolers on Primary Water Side

With normal cooling water conditions and the
generator carrying rated load, two of the three primary
water coolers will be in operation. The standby third
cooler should be filled on its primary water side.
A small amount of primary water continues to flow
through the standby cooler via the parallel-connected
drain and vent valves. In this way, deterioration of the
conductivity of the primary water volume in the cooler
can be avoided.
When making a cooler changeover take care that
the primary water flow through the coolers is not
interrupted.
2
Maintenance of coolers on Cooling Water Side

The standby cooler, filled on its primary water side,
should be empty, clean and dry on its cooling water side
in order to preclude standstill corrosion. The vent and
drain valves on the secondary side should be kept open
to maintain the cooler in satisfactorily dry condition.
Note: If the second primary water cooler is not required
for a longer period of time, due to the cooling water
conditions and the heat loss to be dissipated, it can be
taken out of service on its cooling water side, i.e.,
drained, cleaned and dried.
Sp e c i a l m e a s u r e s s h o u l d b e ta k e n t o p r e v e n t
corrosion damage to the coolers. Cooler sections having
no cooling water flows for some time may be subject to
BHEL, Haridwar
Annualy
Every 6 Months
Every 3 Months
Weekly
Daily
Work required
Monthly
x
standstill corrosion. In addition to many other
corrosive influences, such as the different elements
of the cooling water, locally differing deposits, raw
materials, etc., there exists the danger that micro
organisms on the tube walls may die and decay due
to a loss of fresh water supply (lack of oxygen).
Ammonia is formed from such decay which may lead
to stress corrosion cracking. Corrosion damage can
only be properly prevented if the cooler is drained
on the water side, cleaned, completely dried and
maintained in a dry condition. With the generator in
commercial operation, such measures are often
unfeasible, particularly in cases of short outages.
In such cases, the measures outlined below should
be taken:
During normal operation, the cooling water flows
through two cooler sections. Since the coolers are
designed for 100 % capacity at maximum cooling
water temperature, the condition may arise that the
coolers are frequently supplied with small cooling
water volume flows for long periods. Depending on
the purity of the cooling water, this may result in
deposits due to the lower water velocity in the cooler.
To p r e v e n t c o o l e r d a m a g e , i t i s t h e r e f o r e
recommended to rinse the coolers alternately with
the full cooling water volume flow during short
outages. In addition, the coolers should be
frequently cleaned with brushes. For heavy cooler
contamination and if operational restrictions and
shutdowns are undesirable, it is recommended to
install a continuous cooler water purification system.
All continuous vents should be checked for proper
functioning.
2.4-4750-10550/1
0209E
Turbogenerators
Maintenance
The Primary water tank is mounted on the stator frame
and serves as an expansion tank during operation. A
sufficient water level in the primary water tank is the
prerequisite for reliable primary water circulation.
The water level in the primary water tank is
displayed on a local water level gauge. One capacitive
level monitoring system is provided to activate a low
water level alarm.
Any loss of primary water in the total circuit can
be compensated for by introducing make-up water
upstream of the ion exchanger. The quantity of makeup water is totally at a water meter and is indicative
of the leak tightness of the primary water system.
If it is necessary to add make-up water to the
primary water system during operation, close control
valve.
MKF60 AA502
(before ion exchanger)
and then open shutoff valve

MKF60 AA504
(in make-up line)
to admit water into the primary water system via the

ion exchanger.

of Water Level in Primary Water Tank
Note: During make-up operation, the flow velocity

should not be higher than during normal operation
of the water treatment system. Check volume flow
at volume meter MKF60 CF502.
During make-up operation, a maximum of 100
dm (26 US gallons) of water may be added to the
primary water circuit. Added water volume is
totally on volume flow meter MKF60 CF501.
However, if this amount of make-up water is
insufficient, purge the primary water tank with
nitrogen [1].
Nitrogen purging must also be performed if the
cumulative amount of added water exceeds
100dm 3 within the past month.
During this procedure, the water level in the
primary water tank should be observed carefully,
making sure that no primary water enters the vent
gas system.
3
Addition of water is stopped by closing shutoff valve

MKF60 AA504
(in make-up line)
as soon as the water level in the primary water tank has

reached its nominal value.
Reopen shutoff valve
MKF60 AA502
(before ion exchanger).

[1] 2.3-6810 N2 Purging After Filling of Primary Water
system
BHEL, Haridwar
2.4-4760-10550/1
0209E
Turbogenerators
Maintenance

Record conductivity after ion exchanger and in main circuit
Maintenance work to the conductivity meter system

is restricted to monthly checking of the transducer by
means of the test selector switch.
The check can be performed while the units is in
operation.
Turn associated test selector switch to zero position
Xk =0 mho/cm. With switch in this position, a zero
indication is given at conductivity indicator.
Turn associated test selector switch to test value 1.5
mho/cm . With switch in this position, instrument
should indicate a value of 1.5mmho/cm.
Turn test selector switch to operation position X k =
mho/cm. With switch in this position, conductivity
indicator indicates current conductivity of primary
Annualy
Every 6 Months
Every 3 Months
Check conductivity meter system by means of test selector switch

1
Weekly
Daily
Work required
Monthly
water.
2. Ion Exchanger
2.1 Replacing Ion Exchanger Resins
A replacement of the ion exchanger resins is required
when the conductivity downstream of the ion exchanger
is higher than in main circuit or rises to a value 0.5mho/
cm.
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
BHEL, Haridwar
2.4-4780-10550/1
0209E
Turbogenerators
Maintenance

Alkalizer Unit
Check level in NaOH tank
Analyze water sample taken from treatment circuit
Level in NaOH Tank
Check and record level in NaOH tank during daily

inspection of turbogenerator.
About 2dm3 of dilute sodium hydroxide is injected
into the primary water circuit each day.
With the given capacity of the NaOH tank, refilling
the tank with sodium hydroxide will be required at
intervals of about two months.
Fill NaOH tank with dilute sodium hydroxide solution
after a low level alarm has been given at the latest.
1.1 Adding Sodium Hydroxide Solution
When preparing the sodium hydroxide solution and
filling the NaOH tank of the alkaline unit, make sure to
avoid the formation of carbonates as far as practicable
by reducing the time of free exposure to the atmosphere
to the absolute minimum.
To prepare the sodium hydroxide solution and to fill
the NaOH tank, observe the following procedure:
Prepare concentrated sodium hydroxide solution in
laboratory (observing the specification [1]). To do
this, dissolve the necessary quantity of sodium
hydroxide (caustic soda) in approximately 8-10dm 3
of water [2] to obtain the specified concentration of
10 to 20g of NaOH per dm3.
Caution: When handling sodium hydroxide (caustic
soda), make sure to observe the applicable safety
regulations.
Set controller in control cabinet of alkaline unit for
BHEL, Haridwar
Annualy
Every 6 Months
Every 3 Months
Analyze water sample taken from primary water circuit
The controller in the alkalizer unit maintains the

conductivity of the treated primary water at a constant
value.
Alkalizer unit monitoring requires regular checking
of the volumetric flow rate and level in the NaOH tank
and water sampling.
1
Weekly
Daily
Work required
Monthly
manual control and then lower manipulated

variable (controller output current) to zero.
Open NaOH tank and add concentrated sodium
hydroxide solution.
Fill NaOH tank with water [2] to the required level,
Stir solution for proper mixing.
Reclose NaOH tank so that it is tightly sealed and
secure against opening.
Reset controller for automatic control.
Note: Due to temporary deactivation of the alkalizer unit,
the conductivity of the treated water will drop to < 0.1
mmho/cm, and a corresponding alarm will be activated
in the control cabinet of the alkalizer unit. Cancel the
alarm by depressing the Acknowledge button as soon
as conductivity of the treated water has been restored
to its nominal value.
Replace the lime filter in the NaOH tank vent each
time the NaOH tank is refilled. To do this, observe this
procedure:
Hold glass vessel and loosen wing bolt until

clamping fixture can be moved.
Position clamping fixture with wing bolt beneath
2.4-4785-10550/1
0209 E
the glass vessel and carefully tighten wing bolt.

Slowly lower glass vessel to a point below the
immersion tube.
Fill glass vessel to about 80-90% with soda lime
complying with the applicable specification [1].
Clean sealing faces and slowly press glass vessel
against gasket from below by moving it to and fro.
2
Water Analysis
We recommended chemical analysis of the primary
water in the main circuit and treatment circuit (sampling
downstream of fine filter) at monthly intervals. Keeping
the sample excluded from the atmosphere at a constant
temperature of 25oC, the following parameters should
be determined:
Conductivity
pH
Na+ ion concentration
Cu concentration (total)
Fe concentration (total)
Table 1 shows the normal and limit values to be
expected.
Parameters
Normal
Conductivity
pH
Na+ ion
concentration
Cu concentration
Fe concentration
1.8-2.0 mho/cm 2.0 mho/cm

8.5-9
Table1
25 to 250 ppb
<5 ppb
<5 ppb
Limit
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
conductivity of the water should be measured
downstream of a highly acidic cation exchanger (H +
form). The conductivity provides information on the
presence of other unwanted anions in addition to the
OH ions that determine the alkalinity. The measurement
should be performed with the sample excluded from the
atmosphere to prevent a falsification of the reading by
the carbon dioxide contained in the ambient air. When
correct water treatment, the conductivity at 25oC should
be 0.1 mho/cm.
Unwanted anions, such as HCO3-, CO 3- -, SO4- - and
Cl- can be admitted with
the makeup water
air or H2 leakage
filter elements or ion exchanger resins not
complying with the specifications [3].
The anions are normally absorbed by the anion
exchanger resins in the mixed-bed filters and can have
a permanently detrimental effect on the alkalization
process only when the ion exchanger is exhausted.
300 ppb
10 ppb
10 ppb
Normal and Limit Values of Primary Water
Chemistry
Also refer to the

[1] 2.1-1888
[2] 2.1-1885
[3] 2.1-1887
2.4-4785-10550/2
0209E
following information
Additive Specification for Alkalizer Unit
Primary Water Specification
Specification for Ion Exchange Resins
Turbogenerators
Maintenance

Fuses on Rectifier Wheels
Check Fuses
Measure insulation resistance

1
Annualy
Every 6 Months
Every 3 Months
Weekly
Daily
Work required
Monthly
Fuse Monitoring
With the aid of the stroboscope whose light frequency is automatically controlled, it is possible to
observe each separate fuse on both wheels. To activate the stroboscope, press the On push-button. It is
then possible to select either flash tube 1 or flash tube
2 by pressing the corresponding push-button Lamp1
or Lamp2 to observe each successive fuse on the
rectifier wheel. By pressing the feed or return pushbutton, the flashes can be timed so that a continuous
slow-motion observation of each fuse is possible.
The position of the fuse indicator shows whether
a fuse is intact or blown due to diode failure. If the
color-coded fuse indicator has taken a radial position,
the fuse has blown. To determine the condition of the
entire rectifier wheel, it is necessary to know in which
arm of the bridge each blown fuse belongs. The bridge
arm can be determined from the color marking above

the fuse on the edge of the rectifier wheel.
The operating limitations [1] must be observed if
several fuses have blown.
In normal operation, the fuses should be monitored
at least once each day. A check is required at once
following abnormal operating conditions, e.g. shortcircuit on the system close to the power plant, asynchronous running, etc. If the exciter is operated with
defective fuses, monitoring should be done on an
hourly basis. If no additional fuses have blown after
two further shifts, normal running routine may be continued.
2
Measuring the Insulation Resistances
Check the insulation resistances of the windings

to ground and the insulation resistances between the
diode heat sinks and the rectifier wheel [2].

[1] 2.5-1810
[2] 2.5-9000
BHEL, Haridwar

Excitation System
2.4-4910-10550/1
0209E
Turbogenerators
Maintenance

Exciter Dryer
Inspect and, if necessary, replace prefilter
2.1 Replacing the Dust Filters
1.1 Replacing the Prefilter

To inspect or replace the prefilter, open the door
accommodating the prefilter.
Loosen wing nuts and then remove filter frame and
the two filter pads.
A slightly contaminated coarse filter can be cleaned
by beating or blown out with compressed air from
the air-leaving side. The fine filter can be reused if
in proper condition.
In case of more severe contamination, both filter
pads should be replaced.
For reassembly of the filter, follow the same
procedure in reverse order.
BHEL, Haridwar
Annualy
Every 6 Months
Note : The life of the prefilter depends on the dust concentration in the power house and on the service hours
of the exciter dryer. It is recommended to inspect the
prefilter at shorter intervals during the commissioning
phase because of the high dust content of the air and
the relatively long period of exciter dryer operation.
The prefilter is installed in the door behind which the

exciter dryer is located. This door is an integral part of
the exciter enclosure.
The prefilter consists of a coarse (Acelan) filter and
a fine (Microsorlit-F) filter. The coarse filter is located
upstream of the fine filter.
Every 3 Months
Inspect and, if necessary, replace dust filter in Exciter dryer
Prefilter
Monthly
Daily
Work required
Weekly
Dust Filters
One dust filter each is provided behind the intake
branches on both sides of the exciter dryer. With
proper and regular maintenance of the prefilter, dust
filters will be required only once per year.
De-energize the exciter dryer.

Open the door containing the prefilter.
Disconnect electrical and mechanical connections,
if necessary, and remove dryer.
Loosen screws at connection branch by about
three turns
Turn connection branch counterclockwise for
removal.
Remove filter frame with dust filter.
Blow out dust filter with compressed air from the
air-leaving side or wash dust filter. If necessary,
replace dust filter.
Reinsert filter frame with clean dust filter into the
dryer, making sure that the filter frame joint is in
the bottom center position.
Refit connection branch and turn it clockwise
before tightening the screws.
After replacement of both dust filters, properly
restore all connections.
Close door and energize exciter dryer.
The exciter dryer is ready for further operation.
2.4-4925-10550/1
0209 E
Turbogenerators
Maintenance

Ventillation and
Make-Up Air Filter of Exciter
Check make-up air filters in exciter enclosure
Perform functional check of exciter drying system and clean filters, if necessary.
Make-up Air Filters in Exciter Enclosure

The make-up air filters in the exciter enclosure are
contaminated by the continuous addition of the air in
the exciter cooling circuit. They should be checked at
regular intervals and replaced, if required.
BHEL, Haridwar
Annualy
Every 6 Months
Every 3 Months
Monthly
Daily
Work required
Weekly

Slightly contaminated filter pads should be blown out
with clean compressed air from the clean air side or
washed in a water bath at a water temperature of approximately 30o C, adding a neutral detergent.
Depending on the operating conditions, the ball bearing of the ventilator and the generator should be filled
with new grease every two to three years.
2 .4-4930-10550/1
0209 E
Turbogenerators
Maintenance

of Exciter Coolers
Check exciter cooler vents

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

[1] 2.3-5003
BHEL, Haridwar
2 .4-4940-10550/1
0209 E
Turbogenerators
Maintenance

of Ground Fault Detection System
Check carbon brushes of ground fault detection system
Annualy
Every 6 Months
Every 3 Months
Weekly
Daily
Work required
Monthly

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
brush holder by inserting a gauge stick of insulating
material into the bore of the brush holder.
If a carbon brush must be replaced, the brush holder
should be released from its lock and a new carbon brush
fitted, making sure that the carbon layer comes before
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
or by grinding to size at the slipring when the unit is at
rest. Carbon brush wear depends on several factors. The
normal service life of a set of carbon brushes may be
determined by keeping a record of brush replacements
over a period of several years.
BHEL, Haridwar
1
1.
2.
3.
4.
5.
Terminal board
Bore for gage stick
Plug-in brush holder
Brush carrier segment
Slipring
Fig.1
Brush Holder for Ground Fault Detection
Note: Remove only one brush holder at a time in order

not to disturb proper operation of the ground fault
detection system. When inserting a new double-layer
carbon brush, make sure that silver layer comes after
carbon layer in direction of rotation
2 .4-4990-10550/1
0209 E
Turbogenerators
Inspection
Reliable operation of the turbogenerator will be ensured
only if inspections and overhauls are carried out at regular
intervals so that any faults can be detected and corrected
before they result in costly failures. Following each
inspection or overhaul, the next inspection should be
scheduled.
Provided that commercial tools can be used and that no
special skills are required for the dismantling and erection
work, the inspections can be performed by skilled power
station staff. In all other cases, however, such as for the
inspection of the shaft seals and their auxiliaries, the
services of the manufacturers product service personnel
will be required.
During an inspection, special attention should be given
to avoiding the effects of moisture on austenitic retaining
ring materials as a preventive measure against stress
corrosion.
According to the conventional interpretation, the
conditions for stress corrosion to occur are given by the
combination of sufficiently high tensile stresses and a
sensitive material/corrosion medium system. In hightensile steel, this sensitive system already develops when
the material is exposed to the moisture in the air. Extended
storage until startup and extended shutdown or stand-by
Introduction
periods of turbogenerators may thus result in a latent hazard

to components which are made of a material sensitive to
stress corrosion. Endangered parts of the turbogenerator
are, for instance, the rotor retaining rings which consist of
high-tensile austenitic steel. This latent hazard can only be
positively avoided by taking all preventive measures
required to fully protect those components of the
turbogenerator which may be affected by stress corrosion
against the effects of moisture [1].
The shutdown of a turbogenerator for inspection should
be made in exactly the reverse order as during
commissioning. It should be noted in particular that the
hydrogen must be removed from the generator housing
with carbon dioxide only. Should opening of the gas system
or of the generator proper be required during an inspection,
it is required to replace the carbon dioxide with air.
In the event the manufacturers personnel are required
for a scheduled inspection or overhaul, it is recommended
to notify the manufacturer well in advance. The estimated
duration of the inspection or overhaul should also be stated.
The spare parts stored for repairs and overhauls
should be checked at regular intervals. Components packed
in plastic sheeting mostly contain a desiccant which must
be replaced or reactivated from time to time.

[1] 2.5-1003
BHEL, Haridwar
Measures to Prevent Corrosion During

Inspections
2.5-0010-10550/1
0209E
Turbogenerators
Inspection
Determination of
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
BHEL, Haridwar
2.5-0019-10550/1
0209 E
Turbogenerators
Inspection
Note
Generator rotors are high-grade components which
are sensitive to moisture. For this reason, they must be
protected against corrosion and mechanical damage during
transport and storage.
The packing precautions and the organizational
measures for protection during transport and storage are
described below and summarized in [1]. This description
contains all details required for restoring the standard
packing provided by BHEL for delivery of the rotor. If a
rotor is to be returned to the manufacturers works for
overhaul or in the case of a prolonged outage of the
generator involving a separate storage of the rotor, the
requirements specified in the following must be met for
protection of the rotor.
Any deviations from the standard packing due to special
circumstances shall be subject to the approval of BHEL.
Contents
1. Basic Makeup of Packing
2. Definitions
3. Summary of Rotor Packing Requirements
4. Sealed Packing
4.1 Production Appliances and Packing Materials
4.2 Protection of Metallically Bright Shaft Ends
4.3 Providing the Plastic Sheeting Covers
4.4 Desiccant
5. Skid and Outer Protection
5.1 Land Transport
(Less Than One Month)
5.2 Land Transport or Sea Transport
or Longer Duration
6. Protection of Packing During Transit
6.1 Organizational Measures
6.2 Loading
6.3 Receiving Inspection
7. Storage
7.1 Storage Area
7.2 Checks During Storage Period
7.3 Removal From Storage
1. Basic Makeup of Packing
The packing precautions and organizational measures
during transport and storage are intended for reliably
preventing the effects of moisture on the rotor and
especially on the rotor retaining rings which may be
BHEL, Haridwar
Packing, Transport and Storage

of Generator Rotors
endangered by stress corrosion and for protection against

mechanical damage during transport and transshipment
procedures.
For protection against the effects of moisture, the rotor
retaining rings and the rotor body are packed in sealed
plastic sheeting covers, adding materials for moisture
absorption. This sealed packing is protected with a second
plastic sheeting cover. In the case of sea transport, a third
plastic sheeting cover is provided for the rotor retaining
rings and the rotor body. This cover forms a second
additional barrier against the diffusion of moisture into the
innermost plastic sheeting cover.
The metallically bright shaft ends (shaft journals and
couplings) are protected with a hard wax coating.
The rotor is then placed on a skid with closed bottom
and secured in position for protection against mechanical
damage. For land transport not exceeding one month, this
unit is protected against external influences by a wooden
enclosure resting on the bottom frame of the skid. This
enclosure must be removed prior to each transshipment to
hitch the rotor with a lath grid in place at the middle of the
rotor body.
In the case of land transport exceeding one month and
with sea transport, the enclosure forms an integral part of
the skid. The hitch should then be taken directly at the skid.
The complete cargo is covered with tarpaulins for
protection from the elements.
Rotors with water-cooled windings are protected
against corrosion by filling the water passages with pure
nitrogen after drying to a gauge pressure of 0.5 to 1 bar
via a cover at the exciter end. The pressure can be read
on a permanently installed pressure gauge.
2
Definitions
2.1 Land Transport

The packing provided for this mode of shipment affords
sufficient protection for land transport under moderate
climatic conditions and for a scheduled transit period of
not more than one month. This provides a reliable protection
for short-distance transport (from BHEL, Haridwar to
destinations in India ).
This type of packing also ensures sufficient protection
during subsequent storage in a covered hall, e.g.
powerhouse. Following the receiving inspection, the
insulation resistance of the rotor winding and the condition
of the desiccant should be checked at intervals of one
month and the desiccant reactivated, if necessary.
2.2 Sea Transport
The packing provided for this mode of shipment
2.5-0030-10550/1
0209 E
affords protection during shipment by sea, during

unavoidable outdoor storage and for transport periods and
under conditions exceeding those under item 2.1. The
additional packing, as compared to land transport, consists
of a third plastic sheeting cover and a closed, seaworthy
outer packing. The desiccant included in the plastic sheeting
covers is sufficient for the scheduled transport period,
but for not more than six months.
The inspections required during storage are the same
as specified for land transport under item 2.1.
4.1 Production Appliances and Packing Material

In addition to the standard tools, such as scissors,
knife, etc., special appliances are required for obtaining a
packing affording corrosion protection.
Q
Summary of Rotor Packing Requirements
This summary [1] contains information on the makeup

of the packing and on the procedures required to maintain
the packing in sealed condition. A detailed description is
given in the following section.
4
Sealed Packing
The obtain a reliable and long-lasting corrosion

protection, both suitable production appliances and
materials and appropriate methods of packing are required.
The basic prerequisites are:
Q
Dry Condition of Rotor Prior to Packing

The rotor must be dried if it is expected to be in a wet
condition due to operational faults. To do this, the rotor
and especially the rotor retaining rings and end winding
portions should be dried with dry air by means of an air
dryer (e.g.. Munters dryer).
The following packing materials are used, which are

available from BHEL, HARIDWAR on request:
Q
Q
Q
Q
Q
Q
Water-Cooled Rotor Winding

Drying the cooling water circuit of the rotor winding
should be performed with a vacuum pump, heating the
winding with direct current to approximately 60 to 70C.
Drying can be terminated when a pressure of less than
5 torr has been maintained on the hot rotor for a period
of five hours. Following this, the rotor winding should
be filled with pure nitrogen to a gauge pressure of 0.5
bar via the end cover at the exciter end.
The equipment and power sources required for vacuum
drying should be obtained by the user in due time. The
mechanical data required for the procurement of the
equipment are available from the manufacturer on
request.
Weather-Protected Packing Area
Packing and unpacking is only permissible in a weatherprotected area, preferably in a hall.
No Delays in Packing Procedure
Care must be taken to ensure that after its removal the
rotor will not suffer any moisture condensation or
accidental wetting. Packing the rotor should therefore
be performed immediately after withdrawal of the rotor
and any required drying in order to minimise any
uncontrolled phases.
2.5-0030-10550/2
0209E
Heat-impulse fixture for heat sealing of polyethylene

plastic sheeting, consisting of:
heat impulse generator and
heat sealing tongs for a minimum seam length of 200
mm,
Heated plate to melt wax-coated sheeting for bonding
(e.g. electric iron).
Blower with small delivery rating for checking the plastic
sheeting cover for tightness and for extracting the test
air (e.g. vacuum cleaner).
Air dryer for any required drying of rotor end windings
prior to packing.
Q
Q
Q
Q
Q
Polyethylene sheeting, 0.2 mm thick, endless, preferred

width 6000 mm
Rubber board with canvas reinforcement, 3 mm thick,
minimum width 1000 mm
Wax-coated linen binding with 1 mm wax coating, 100
mm wide (e.g. Denso binding)
Hard wax for application by brush (e.g. Tectyl 506)
Cold degreasing agent
Wax-coated aluminum foil
Adhesive for plastic sheeting
Adhesive tape for plastic sheeting
Foam material, which does not absorb water, 5 to 10
mm thick (e.g. polyurethane)
Silica gel in linen pouches as desiccant
Moisture indicators for functional checking of desiccant
(color indicators for 30%, 40% and 50% relative
humidity)
Hemp rope, 2 mm thick, for attaching desiccant pouches
Fabric tape, 20 mm, endless
Steel band, 1 mm thick, 30 mm wide, with turnbuckle
and tensioning device
Lath grid for taking a hitch at the rotor body consisting
of hardwood laths 50x80x3000mm, nailed to 5mm thick
fabric mat.
4.2
Protection of Metallically Bright Shaft Ends

The metallically bright shaft ends should be cleaned
and degreased and protected with a hard wax coating
(e.g. Tectyl 506) of sufficient thickness (dark-brown). In
addition, the areas of support in the skid should be wrapped
with two layers of wax-coated bindings (e.g. Denso
binding) and a 3 mm thick canvas-reinforced rubber mat.
All other areas contacting the skid should also be covered
with 3 mm thick rubber board.
4.3
Providing the Plastic Sheeting Covers

The polyethylene sheeting covers are made directly
on the components to be protected. To protect the plastic

Turbogenerators
sheeting cover from damage, any contact with sharp edges
must be avoided.
Edges should be padded with layers of
Inspection
rubber board or foam rubber. The use of excelsior,
corrugated cardboard, felt or other hygroscopic materials
is not permissible. Care should be taken to ensure that the
plastic sheeting cover remains intact during the subsequent
packing procedures. Even pinpricks and minute tears in
the plastic sheeting will render tight sealing ineffective.
Within the range of rotor support in the skid and of other
contact points (upper shipping saddles), the polyethylene
sheeting should be inserted between two rubber boards
of sufficient size for protection against damage. At the
end winding, each plastic sheeting cover is provided with
a 500 mm dia. opening for connection of a plastic sheeting
hose having the same diameter and a length of
approximately 1m. After checking the cover for tight sealing,
the desiccant is added via this hose, which is then closed
by heat-sealing.
To maintain the sealed range in a dry condition
desiccant (see Item 4.4) is added to each plastic sheeting
cover.
After heat-sealing and tight wrapping with waxcoated bindings, each plastic sheeting cover should be
checked for tight sealing. To do this, one corner of the
plastic sheeting hose should be cut for insertion of a
vacuum cleaner hose (discharge end) and tightly sealed
with a binding. If the cover remains inflated during the
following two hours, the cover is properly sealed. Following
this check, the air should be drawn off.
4.3.1 First Plastic Sheeting Cover
As a first step, the entire rotor body should be
wrapped with wax-coated aluminum foil with 50 to 70 mm
overlap, with the wax coating facing the rotor body. Seams
and overlapping portions should be sealed airtight by melting
the wax coating with an electric iron.
To protect the aluminum foil from being damaged by
the handling ropes, a canvas-reinforced rubber mat, 3 mm
thick and approximately 2500 to 3000 mm wide (dependent
on overall length of rotor) should be placed around the
center of gravity of the rotor. This rubber mat consists of
individual sections, each having a length corresponding to
the rotor body diameter + 100 mm and arranged with an
overlap of not less than 100 mm. All overlap seams are
sealed with wax-coated canvas bindings. Axial overlap
seams are additionally secured with steel bands. The
overlap seam at the top on the circumference is secured in
axial direction by wooden lath, 80x40 mm, which is also
held in place with steel bands.
Finally, a lath grid (hardwood laths attached to fabric
mat or fabric tape) should be placed in position for hitching.
The grid should cover not less than the lower half twothirds of the rotor body circumference and be adequately
secured with steel bands. The wooden laths must be on
the outside and arranged so that the rubber mat is
BHEL, Haridwar
approximately 150 mm wider at each end of the rotor. The

range between the free shaft portion protected with hard
wax and the end of the rotor body should then be wrapped
with polyethylene sheeting which is to be sealed tightly
with wax-coated canvas bindings at the rotor body and
free shaft portion.
Experience has shown that in the case of larger
rotor body diameters (>1300 mm), the aluminum foil cannot
be wrapped around the rotor with sufficient tightness and
may thus be omitted. In such cases, the above mentioned
polyethylene sheeting should extend beyond the rubber
mat at the middle of the rotor body and should be sealed
tightly with wax-coated canvas bindings at these points.
The precautionary measures specified under Items
4.2 to 4.3.1 provide for the minimum packing requirements
and are sufficient for land transport not exceeding 20
hours. In the case of rotors provided with aluminum foil
within the range of the rotor body, sealing of the rubber
mat at the middle of the rotor body will not be required for
short-distance transport.
4.3.2 Second Plastic Sheeting Cover
In addition to the first plastic sheeting cover described
under Item 4.3.1, a second polyethylene sheeting cover of
the same type should be provided between the shaft ends
and the rubber mat at the middle of the rotor body. To
separate the two plastic sheeting covers, a 5 to 10 mm
thick layer of foam material should be placed over the top
half circumference of the rotor retaining rings and rotor
body.
Two plastic sheeting covers are required for land
transport and storage as defined under Item 2.1.
4.3.3 Third Plastic Sheeting Cover
For sea transport and outdoor storage as defined
under Item 2.2, an additional diffusion barrier is provided.
This third polyethylene sheeting cover protects the entire
range of the rotor between the shaft journals at either
end. It is placed over the plastic sheeting covers according
to Items 4.3.1 and 4.3.2 and is to be made in the same
manner.
The plastic sheeting is placed over the rotor before the
rotor is supported on the skid. Within the range of rotor
support the plastic sheeting is inserted between two rubber
mats of 3 mm thickness each. After the rotor has been
supported on the skid, its upper half portion (rotor body
and retaining rings) should be covered with a 5 to 10 mm
thick layer of foam material outside the lath grid area, and
then the plastic sheeting cover should be heat-sealed.
4.4 Desiccant
4.4.1 Type and Application
The desiccant consists of silica gel in dust-free and
air-permeable pouches. It should be inserted into each
plastic sheeting cover via the plastic sheeting hoses at the
end windings. The desiccant must be placed so that it can
2.5-0030-10550/3
0209E
2.5-0030-10550/4
0209E
be easily replaced when this becomes necessary and that

Turbogenerators
it does not come into contact with steel or winding
components (danger
of corrosion). If necessary, cover
Inspection
contact area with polyethylene or rubber sheeting.
All pouches must be tied together with a hemp rope,
and, when used, they must be in an active, i.e. absolutely
dry condition
are to be closed and reinserted into the plastic sheeting

covers as quickly as possible. Care should be taken to
ensure that the pouches do not come into contact with
metal parts. The opening in the plastic sheeting cover should
then be resealed with a heat-sealing unit.
4.4.2 Desiccant Quantities

The desiccant quantities [1] are proportioned to
accommodate highly adverse climatic conditions. The
maximum quantity is sufficient for a shipping time not
exceeding six-month.
BHEL, HARIDWAR generator rotors are delivered in

box type shipping containers, consisting of a skid and an
enclosure. Figs. 4 and 5 depict typical examples. It is
recommended to keep this shipping container for future
needs, unless an adjustable universal skid is used for land
transport which is available from BHEL, HARIDWAR, if
requested in due time. The information given in the following
relates to the remounting of the rotor in sealed packing on
the skid and to the provision of the outer protection.
4.4.3 Checking and Reactivation

The moisture absorption capacity of the desiccant
must be checked after completion of shipment, after
interruptions in transit involving a storage period of more
than one month and during normal storage at the site (see
Item 7.2). To do this, use the moisture indicators (Fig. 3)
inserted in the plastic sheeting covers at a distance of not
less than 5 cm from the sheeting. The moisture indicators
are marked with their respective location identifications as
illustrated in Fig. 2 and show the relative humidity inside
the cover in three ranges (>30%, >40% and >50%). With
the packing in dry condition, all circles are blue. A change
in color to pink in the respective circle indicates the relative
humidity in percent. As soon as the 40% indicator changes
to the pink color, the desiccant must be removed and
replaced or reactivated by drying.
All circles pink:
danger of corrosion
Two circles pink: replace desiccant
One circle pink:
Fig. 3
warning
50
40
30
Moisture Indicator
Make sure that sufficient replacement desiccant or

the necessary drying facility for reactivation is available.
After opening, the plastic sheeting cover should be
provisionally resealed, but must not be left in this condition
for more than 20 hours.
For reactivation, the pouches should be dried in a
drying oven at a temperature of 110C for 12 hours. If a
drying oven is not available, the desiccant should be
removed from the pouch, spread out in a thin layer on a
metal plate and dried at 110 to 130C for several hours until
the weight of the desiccant remains constant. The
desiccant should then be filled back into the pouches which
BHEL, Haridwar
Skid and Outer Protection
5.1 Land Transport (Less Than One Month)

For land Transport, the rotor should be supported on a
skid similar to Fig. 4. The points of support should be padded
with rubber mats for protection of the plastic sheeting
covers. At the shaft ends, the rotor should be attached to
the skid by means of upper saddles and secured in axial
direction.
For loading operations, the hitch should be taken either at
the middle of the rotor body (lath grid) or at the rotor ends.
During transit, the rotor should be protected against external
influences by a wooden enclosure resting on the bottom
frame of the skid. Both long sides of this protective
enclosure should be clearly stencil-marked with the
following note.
Caution: Remove protective enclosure for rotor
transshipment.
The complete cargo should be covered with a lashed
tarpaulin.
5.2 Land Transport or Sea Transport of Longer
Duration
For land transport exceeding one month and for sea
transport, the rotor should be packed in a closed, selfsupporting container. The setup for two-pole rotors
corresponds to Fig. 2. The container bottom should have
openings with perforatedplate covers for ventilation and
to prevent the accumulation of water. In addition, inspection
openings with covers should be provided on the long sides
for access to the desiccant pouches via the plastic sheeting
hoses. An inspection opening at the exciter end should
provide access to the contact pins on the exciter-end end
cover of the rotor for measurement of the insulation
resistance of the rotor winding.
Prior to closing the container, the rotor should be
covered with 3 mm thick pressboard panels and
polyethylene sheeting, taking care to avoid the formation
of troughs in which water might accumulate. The container
lid should be covered with tar board sanded on one side
2.5-0030-10550/5
0209E
and folding down over the edges not less than 200 mm.
The total weight and the dimensions of the cargo should
be marked on the container. In addition the hitching range
should be color-marked. The complete cargo should be
covered with a tarpaulin for protection against the elements.
6 Protection of Packing During Transit :
6.1 Organizational Measures :
Proper packing of the rotor will prevent both the ingress
and the condensation of moisture during transit, unless
the sealed packing is damaged by improper loading
procedures or customs inspections. This should be avoided
by suitable precautions, enabling a quick restoration of the
dry condition of any damaged sealed packing. These
measures include :
On the Cargo:
Q
Q
Q
Instructions for correct handling.

Reference to Sealed Packing on shipping container.
Indication of desiccant quantity inserted into each
individual plastic sheeting cover behind inspection hole
cover.
Attaching this instruction 2.5 0030.
In the Accompanying Documents:

Q
Reference to Sealed Packing.
Q
Reference to arrangements for customs clearance at
place of installation.
Q
Request for immediate drying in case of transport
damage with moisture penetration.
Q
Check list relating to condition of desiccant [2].
Q
Checklist relating to insulation resistance of rotor
winding [3].
6.2 Loading
If a flatcar is used for transport, the cargo should be
loaded so that it can slide on the car, i.e., the skid must not
be secured in position and must be free to move in both
directions of running. Provision should be made for a sliding
distance of approximately 1.5m at either end.
Planks , approximately 50 mm thick, should be nailed to
the long sides adjacent to the battens.
If a deep well wagon is used for transport, the skidmounted rotor should be secured in position at both ends
of the loading bridge. The bridge through should be sealed
with boards for protection against stones.
During shunting operations, the car must never be
allowed to pass over a hump. A corresponding note should
be included in the waybill and affixed to the car in a well
visible location.
6.3 Receiving Inspection
After arrival of the rotor, the consignee should examine
the packing for external damage. The condition of the
desiccant can be ascertained at the moisture indicators. In
addition, the insulation resistance of the rotor winding
2.5-0030-10550/6
0209E
should be checked. In the case of a water-cooled rotor

winding the pressure of the nitrogen blanket should also
be checked. The date of the receiving inspection should
be entered in the respective section on the inspection hole
covers. The results of the receiving inspection should be
recorded in the check lists [2], [3], copies of which should
be forwarded to the consignor.
If the packing is found in damaged condition, it should
be resealed as soon as possible. The same requirement
applies if the seals were opened by the customs authorities.
If the moisture absorption capacity of the desiccant is
no longer sufficient (40 % indicator is pink), the desiccant
should be removed from the plastic sheeting cover, with
the shipping container protected from the environment, and
reactivated (see Item 4.4.3). If the rotor is unpacked
immediately after delivery, it may become necessary to
bring it to ambient temperature level for protection against
moisture condensation. If the rotor temperature is equal to
or higher than the room temperature, there will be no need
for raising the temperature of the rotor to the level of the
ambient temperature. The rotor temperature can be
measured at the accessible rotor ends using a temperature
measuring instrument. If the rotor temperature is lower
than the ambient temperature, steps must be taken to
ensure that the rotor temperature will be 5 degC (safety
margin) higher than the dew point temperature of the
ambient air [4].
In the case of outdoor units, the rotor installation phase
should be timed so that the unpacked rotor will not be
exposed to extreme changes in temperature as this will
involve the risk of moisture condensation.
7
Storage
The preventive measures during storage provide for

maintaining the dry condition of the rotor in the sealed
packing without any interruptions until commencement of
the installation.
To this end, certain minimum requirements must be
observed, which are dependent on the condition of the
storage area. In addition, the condition of the packing and
of the desiccant contained in the packing must be checked
at regular intervals. To obtain additional verification, the
insulation resistance of the rotor winding should be
measured.
As long as the nitrogen pressure is still slightly above
atmosphere, it will normally not be necessary to recharge
a water-cooled rotor winding with nitrogen. If the nitrogen
pressure has dropped to zero, the winding should be filled
with pure nitrogen to a gauge pressure of 0.5 bar from the
nitrogen bottle permanently installed in the shipping
container.
7.1 Storage Area
Sufficiently ventilated and dry storage rooms for stable
support of the parts in a fully accessible location are
favorable preconditions for storage. If outdoor storage
cannot be avoided, a heavy-duty outer packing of the

Turbogenerators
seaworthy type must be provided. The outdoor storage
facility must beInspection
set up in such a way that the stored item is
protected against rainfall and moisture from the ground.
This would include placing a waterproof shelter over the
shipping container which affords sufficient ventilation. In
addition, the stored item should be blocked up on the solid
ground for protection against moisture. Enough space must
be left between the boxes to permit inspections and checks.
7.2 Checks During Storage Period
Following the receiving inspection, surveillance of the
equipment should be conducted by repeat checks at
intervals of four weeks. The checks required are the same
as specified for the receiving inspection under Item 6.3.
The dates of the repeat checks should be recorded on the

outer packing below the date of the receiving inspection
and in the check lists [2],[3].
7.3 Removal from Storage
If the storage area and the place of installation are not
located in the same room (power house or workshop), the
rotor temperature may be below the dew point level on
transfer of the rotor from a cold storage area to a warm
power house. To protect the rotor from moisture
condensation, it should be left in its sealed packing for
several days and allowed to assume the ambient
temperature prior to removing the packing for immediate
installation.

[1] 2.5-0031 Preventive Measures for Transport and
Storage of Generator Rotors (Summary)
[2] 2.5-0032 Checking Desiccant in Generator Rotor
Packing
BHEL, Haridwar
[3] 2.5-0033 Insulation Resistance Measurements on

Rotor and Exciter Windings During Storage
(Test Report)
[4] 2.5-0019 Determination of Dewpoint Temperature
2.5-0030-10550/7
0209E
Preventive Measures for Transport and

Storage of Generator Rotors
Summary
Turbogenerators
Purpose/
Phase
A
Corrosion
Protection
of shaft
ends
B
Corrosion
Protection
of rotor
winding
C
First packing
of rotor
retaining
rings and
rotor body
in plastic
sheeting
cover
(sufficient
for shortdistance
transport up
to 20 hours
and immediate installation)
D
Protection
of first
packing
C by
second
plastic sheeting cover
E
Protection
of packings
C and D by
third plastic
sheeting
cover
Component
Prev. Measure
Inspection
Protective Materials and Setup

Land Transport
Short-Distance
Transport Period Less
Than One Month
Sea Transport
Shipment by Sea or
Transport Period More
Than One Month
Shaft journals 1
Couplings
Hard wax coating (e.g. Tectyl 506) of sufficient thickness (dark-brown color).
Additionally protect areas of support in skid with two layers of wax-coated
bindings and one layer of 3 mm canvas-reinforced rubber mat.
Watercooled
rotor
winding
Fill dried rotor winding with pure nitrogen to a gauge pressure of 0.3 to 0.5 bar
through cover at exciter end.
Rotor
Body
Place wax-coated aluminum foil over entire range of rotor body (only for rotor body
diameters < 1300 mm, due to difficult handling)
5
Retaining
6
rings
Fans
(water boxes)
7
Rotor body
and
retaining
rings
Rotor body
and
retaining
rings
BHEL, Haridwar
Place 3 mm canvas-reinforced rubber mat, 2500 to 3600 mm wide (dependent on

length of rotor) around center of gravity; seal overlap seams with wax-coated bindings
and steel bands; secure axial overlap seam with wooden lath.
Place lath grid on fabric mat, about 300 mm narrower than 4 , around two-thirds of
rotor circumference and secure at top.
Place 0.2 mm polythene sheeting between shaft ends 1 and body ends 3 and
rubber mat 4 , respectively, seal joints with wax-coated bindings at both ends,
heat-seal seams
Check plastic sheeting cover for tight sealing by inflation with air and recheck after
two hours.
Add desiccant per m2 of sheeting surface shipping time up to 1 month: 500 g; up to

3 months : 1000 g; up to 6 months: 1500 g. Plus 280 g for each Kg of wood and 35 g
for each Kg of foam material within plastic cover. Moisture indicators for relative
humidity > 30%, > 40%, > 50%.
Place 0.2 mm polythene sheeting between shaft ends 1 and rubber mat 4 over a
5 to 10 mm foam mat around top half circumference of rotor retaining rings and rotor
body.
10
Check heat-sealed and tightly wrapped plastic cover 9 for tight sealing as
under 7
11
Add desiccant and moisture indicators as under 8 .
12
Not required for land transport.
foam mat and cover entire rotor between shaft ends

as under 9 . With four-pole rotors, foam mat is split
within range of lath grid; insert plastic sheeting
between 3mm rubber boards. Check for tight sealing as under 7 . Add desiccant as under 8 .
2.5-0031-10550/1
0209 E
F
Transit
protection
G
Loading
H
Receiving
of cargo
J
Storage
K
Removal
from storage
Component
One Month
Prev. Measure
Purpose/
Phase
Protective Materials and Setup

Land Transport
Short-Distance
Transport Period Less Than One Month
Sea Transport
Shipment by Sea or
Transport Period More Than One Month
Tightly
sealed rotor
13
Tightly sealed rotor 1 to 11 on skid

with closed bottom under enclosure and
tarpaulin
Tightly sealed rotor 1 to 11 in closed

self-supporting shipping container Under
tarpaulin.
Complete
cargo
14
Hitch point on rotor at lath grid in center

of gravity after removal of enclosure.
Hitch point on shipping container; in the

case of four-pole rotors on Steel sleeve
at mid-length of skid.
Complete
packing
and rotor
winding
15
Check outer packing and relative humidity inside plastic sheeting at moisture indicators.
Replace desiccant when relative humidity is higher than 40 %. Return check list with
details on condition of packing and insulation resistances of rotor 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.
Storage area
17
With packing for land transport, only in a hall kept at a moderate temperature. For
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
packing
and rotor
winding
18
During storage (including interruptions in transit), check outer packing for damage and
tight sealing, insulation resistance of rotor winding and, if applicable, nitrogen blanket at
intervals of four weeks.
Rotor
19
Maintain tight sealing of packing as long as possible until rotor is installed. Protection
against condensation hazard by preventive measure 16
2.5-0031-10550/2
0209E
Checking Desiccant in
Packing of Components
Turbogenerators
Inspection
Desiccant Checking Requirements
The absorbent capacity of the desiccant must be
checked after shipment has been completed and at intervals of one month during any subsequent storage period.
Prior to
shipment
Condition of
outer
packing
Storage area
of compotent
Location
identification
of moisture
indicator
Company
Shipping
or
storage
phase
Name
Sl. No.:
Date
Job name:
The results should be recorded in the table below. The

desiccant must be removed and replaced or reactivated
by drying when a change in the color of the 40% moisture
indicator is observed.
Type:
Moisture indicator
blue or pink?
Bottom
Center
Top
circle
circle
circle
(30%)
(40%)
(50%)
Weight of
desiccant
in packing
in Kg
Replacement or
reactivation
of desiccant
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
TE 1
TE 2
TE 3
EE 1
EE 2
EE 3
BHEL, Haridwar
2.5-0032-10550/1
0209 E
Insulation Resistance Measurements

Test Report
Turbogenerators
Inspection
Checking the Insulation Resistances
of Rotor Windings in Sealed Packing
The insulation resistance of the rotor winding should
Job name :
be checked after shipment has been completed and at

intervals of one month during any subsequent storage
period. The results should be recorded in the table below.
Sl No.:
Shipping or
storage phase
Type :
Component :
Prior to
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
Indicator
in packing
blue or
pink?
TE1
TE1
50
40
30
50
40
30
Pressure of Nitrogen
blanket in bar
Inaulation Resistance in M ohm
Applied voltage in V
15 s
30 s
45 s
1 min
2 min
3 min
4 min
5 min
6 min
7 min
8 min
9 min
10 min
Notes:
1 The insulation resistance should be measured with an
insulation measuring device, applying a voltage of 100
V, but not more than 250 V.
2 Prior to each measurement, any static charges should
be removed by grounding the windings as a precautionary measure (10 minutes).
BHEL, Haridwar
3
4
5
The connection to the rotor winding should be made at

a specially identified bolt on the exciter-end end cover.
The connection to the rotor body should be made at a
specially identified bolt on the exciter-end end cover.
After each measurement, any static charges should
be removed by short-circuiting the winding through
the rotor body (not less than 20 minutes).
2.5-0033-10550/1
0209 E
Turbogenerators
Preparation of Machinery Parts
Inspection
1
General
The machinery parts to be assembled are delivered

ready for mounting, unless certain portions must be
protected during transport against corrosion or damage.
In case of orders for delivery to other countries, all
sensitive portions of the machinery parts, e.g., journals,
are provided with a protective coating and protected against
damage.
In case of orders for delivery to overseas countries,
all machined surfaces are provided with a protective
coating. In addition, complete assemblies are sealed in
plastic sheeting.
2
Removal of Protective Coating
The protective coating applied at the manufacturers

works should be carefully removed prior to assembly. The
surfaces to be cleaned should be washed with petroleum
or a similar agent. When using trichlorethylene, the cleaned
surfaces should be carefully dried and afterwards a thin
oil film should be applied. Non-observance of this
requirement implies the danger of corrosion.
Particularly thick layers of protective coating should be
softened by applying one of the above-mentioned cleaning
agents and then be removed by means of a hardwood
board (approximately 10 cm x 10 cm x 1 cm).
Caution: Never use scrapers, finishing trowels or
sheet metal strips for removing the protective
coating from highly sensitive machinery parts
(journals, etc.)
The covers protecting the components of the DC plugin contact assembly should be removed shortly before
coupling the rotors.
Make sure that the sleeves and bolts of the DC.
BHEL, Haridwar
plug-in contact assembly of the exciter rotor will

not come into contact with any solvent.
Cleaning of internal and external threads should be
done by chasing, using suitable taps or cutting dies. The
dimensions of the external and internal threads may be
taken from the respective drawings. Use dry compressed
air to blow out the re-tapped holes.
Where no taps are available cleaning of the tapped
holes may also be carried out with the aid of the original
screws. At first, the screws should be cleaned by means
of solvent and a brush. The cleaned screws should then
be dipped into a solvent and immediately afterwards be
screwed into the holes for thread cleaning.
If required, this procedure should be repeated several
times until the threads are free from protective coating.
3
Remedying Minor Damage
Damaged machinery parts should be reconditioned as

dictated by the extent of the damage and the operational
requirements unless the nature of the damage does not
warrant such remedying.
Seriously damaged parts should be returned to the
manufacturers works together with a damage or failure
report.
The machinery parts and the fixing and locating
elements should be checked for burrs and compression
marks, and such imperfections should be removed by
means of a smooth-cut file. Fine finished surfaces should
only be polished by means of an oilstone.
Caution: Burrs and compression marks on bearing
metal surfaces should only be removed by means of
a spoon scraper or flat scraper.
2.5-0200-10550/1
0209 E
Turbogenerators
Checking the Bearing and Seal Insulation
Inspection
1
General
During operation of a generator, voltages are set up along
the rotor due to magnetic unbalances and ring excitation.
This shaft voltage would cause a destructive current to flow
through the bearing, shaft seal and other components if the
rotor were not insulated from ground at least at the exciter
end. For reasons of interchangeability, all stator components
coming into contact with the generator rotor are insulated. At
the exciter, all bearings or the complete exciter are insulated.
2
Checking the Shaft Seal and Bearing Insulation

During Installation
2.1 Bearing Saddle

Prior to inserting the rotor and supporting it on the
bearings, the insulation resistance of the built-in bearing saddle
should be measured separately by means of a 100 V megger
applied between the bearing saddle and the lower part of the
stator frame. The values measured should be recorded.
With satisfactory insulation, a value in excess of 10
megohms is to be expected. If an insulation resistance value
below three megohms is measured, the insulating parts should
be checked for moisture, contamination or metallic contacts.
If required, the insulation should be dried at 80C maximum.
The measurement should be repeated immediately after
the rotor has been supported on the bearings.
Caution: With this measurement and the following
checks both rotor bearings must be insulated, and the
generator rotor must not come into contact with the
turbine shaft through measuring devices or similar
parts, to prevent the generator rotor from being
grounded.
Since, with the rotor inserted, all individual
resistances measured previously are now in parallel
in the measuring circuit, the total resistance will be
slightly lower than the lowest individual resistance
value measured before.
2.2 Inner and Outer Labyrinth Rings
Inner and outer labyrinth rings are insulated from other
components. The insulation resistance of each individual
labyrinth ring should be measured after installation in order to
preclude any lengthy search for faulty mounting on
measurement of a poor insulation resistance. Proceed with
mounting of the next component only after having identified
and removed the cause of a poor insulation resistance. After
installation of all insulated components the total resistance
will be slightly lower than the lowest individual resistance
value measured before.
2.3 Shaft Seals
Both shaft seals are mounted such they are insulated.
To check the insulation resistance, follow the same procedure
as outlined for the labyrinth rings. It is also be expected that
BHEL, Haridwar
the total resistance will likewise be lower than the lowest

individual resistance measured before.
2.4 Pedestal Bearing of Exciter
The insulation resistance between the bearing pedestal
and base frame should be measured immediately after
mounting of the pedestal.
With satisfactory insulation, a value in excess of 10
megohms is to be expected. Following this, bolt the associated
oil pipe to the bearing pedestal being careful to insulate it. It is
also recommended to repeat the insulation resistance
measurement after fitting of each individual pipe. If a sufficiently
high resistance value is measured (five megohms) proceed
with fitting of the next pipe. Finally, measure the insulation
resistance to the base frame of the bearing pedestal with the
connected pipe work. If this value is higher than three
megohms , proceed with mounting of the exciter rotor.
2.5 Final Checking
After the exciter rotor has been coupled to the generator
rotor and insulated from the bearing pedestal, a final insulation
check should be performed. The total insulation resistance
must not be less than one megohm. Due to contact with the
shaft, the measuring circuit covers in parallel.
TE/EE bearings
TE/EE shaft seals
Exciter bearing pedestal with pipe work
3
Checking the Shaft Seal and Bearing Insulation of

the Assembled Unit
Checking the shaft seal and bearing insulation during
operation may be done by way of the shaft voltage prevailing
with the generator running in an excited condition. For this
purpose, the potential of the insulated shaft seals and bearings
is accessible external to the generator. With the generator
running, the components coming into contact with the shaft
are separated from the shaft by an oil film, which has insulating
properties. Consequently, a non-defined resistance value is
set up at the potential measuring points of the shaft seals
and bearing sleeves which is dictated by the magnitude of
the resistances of the oil film and insulating parts. The
following method permits the insulation to be checked without
disassembly of components being required.
Useful results are, however, to be expected only if the
turbine end of generator rotor and the turbine shaft are
grounded properly as defined during the measurements.
Grounding must be maintained to discharge to ground any
static charges occurring continuously during operation due
to steam and oil film friction.
3.1 Checking the Insulation with the Generator in an
Excited Condition
2.5-0300-10550/1
0209 E
Due to the rotor grounding arrangement at the turbine

end, the shaft voltage should be measured at the exciter end.
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.
reduction of the original shaft voltage or in its complete

collapse.
1 Voltmeter (AC range)
Fig. 3 Measurement of Shaft Current With the

Generator in Excited Condition

Fig.1 Measurement of Shaft Voltage
Generator in Excited Condition
With
the
Measurement should be performed by means of an AVOmeter in the AC range. The voltage should be picked off the
shaft through a sliding contact with an insulated handle, which
is connected to the meter by a circle.
The shaft voltage measured in this way should then be
compared with the voltage according to Fig. 2. If the two

Fig. 2 Measurement of Shaft Voltage at Exciter End
With the Generator in Exciter Condition
readings are not identical, the rotor grounding system should

be rectified first before taking any further readings to check
the insulation for shaft currents.
If the shaft voltage can be exactly measured according
to Fig.2, the measuring brush on the shaft should first be
connected to the potential measuring terminal of the insulated
component (bearing sleeve or shaft seal) at the exciter end
by means of a cable. The oil film of the component is thus
bridged, with the component assuming the shaft potential.
With satisfactory insulation, the instrument will continue to
indicate a shaft voltage of the original magnitude. In the event
of insufficient insulation resistance, a current will flow
through the insulation, which may be read at the ammeter
connected into the circuit. Bridging of the oil film results in a
2.5-0300-10550/2
0209E
2 Ammeter
The resulting current can be measured for a brief moment

by means of an ammeter connected into the circuit between
the measuring brush and the potential measuring terminal.
3.2 Checking the Insulation With the Generator in NonExcited Condition
If the previous tests are inconclusive, additional tests
may be performed in consultation with the manufacturer
1 Measuring Bridge
Fig. 4 Measurement of Insulation Resistance With the Unit in
Non-Excited Condition
to locate insulation defects with the generator running and in

non-excited condition. A bridge instrument must be used. To
measure the resistance of the insulated component with
respect to the shaft and ground, the bridge instrument should
be connected between this component and ground.
The resistance (Roil and Rins in series) of the parts in contact
with the shaft are then connected in parallel with the
measuring voltage. This measurement is not practicable with
the generator at standstill, since a stable oil film providing for
full insulation can be formed above a speed of approximately
3.33 to 6.66 s-1.
In case of a low insulation resistance, it must be assumed
that the insulation is defective, requiring detailed checking of
the insulating parts. (Contact the manufacturer).
Turbogenerators
Test Norms During Overhaul
Inspection
Hydraulic pressure test of hydrogen gas coolers.

(No leakage is allowed)
8 bar for 30 mts
Hydraulic pressure test for brushless exciter coolers

8 bar for 30 mts
Gas tightness test of TG Rotor. (No visual leakage

is allowed. The test is to be conducted either with
nitrogen or helium).
6 bar for 6 hrs.

Press. drop not
more than 0.5 bar
Gas tightness test of exciter rotor. (Condition of

testing same as a Sl. 3 above)
do-
Hydraulic test for stator winding and primary water system.

(No visual leakage is allowed)
6 bar for 48 hours

by N2 cushion
Hydraulic test pressure for seal oil and ring relief oil
inlet pipeline in the end shield
(No leakage and pressure drop is allowed)
10 bar for 15 mts
Pneumatic test for seal oil and ring relief oil inlet
pipeline. (No leakage & pressure drop is allowed).
6 bar for 30 mts
Hydraulic test of seal oil cooler

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

i)
Shell side
ii)
Tube side
10 Kg for 30 mts
10 Kg for 30 mts
10
Test on diodes for reverse blocking capability

(by 1KV megger with two diodes in parallel circuit)
IR > 5 Mega ohms
11
Measurement of fuse resistance on the diode wheel

by passing 10 Amps regulated D.C. current
(Fuse Type 800V/800Amp)
155+6% Micro ohm

at 20 deg. C
12
IR measurement of heat sinks.

(By 500V megger)
Min. 10 Mega ohms.
BHEL, Haridwar
2.5-0305-10550/1
0209 E
Turbogenerators
Inspection
To ensure trouble free operation, all systems should be
checked and operated strictly in accordance with sound,
safe and accepted practice.
1
Leakage Test of Primary Water Circuit
Leakage Tests of Generator and

Gas System
z
VG
p1
= duration of leakage test, hrs

= generator volume, m3 (see Mechanical
Data)
= gauge pressure within the system at
beginning of leakage test, mbar
= gauge pressure within the system at end
of leakage test, mbar
= barometer reading at beginning of leakage
test, mbar
= barometer reading at end of leakage test,
mbar
= temperature of the gaseous atmosphere at
beginning of leakage test, C
= temperature of the gaseous atmosphere at
end of leakage test, C
The primary water circuit must be filled with water for

leakage testing. The pressure gauge in the waste gas pipe
should be replaced for the duration of the test with a pressure gauge having a range of not less than 6 bar. A nitrogen cushion at a gauge pressure of 6 bar is to be provided
on the water level in the primary water tank and maintained for a test period of not less than 48 hours. During
the test, the entire circuit should be carefully checked for
leakage. Any leaks detected should be repaired, and the
leakage test repeated.
p2
If an air loss higher than 2.4 m3 (s.t.p.)*/24 hrs results,

a search for the leak must be made. The likely location of
leaks, such as
Leakage Test of H2 Gas System Using Air
After assembling the generator and placing the seal oil

system into operation, the generator, including the connected gas system, must be leak tested using compressed
air. A special connection is provided for this purpose.
The test pressure should be equal to the generator
operating pressure. A class 0.6 precision pressure gauge
should be used for pressure measurement.
The duration of the leakage test should be at least 48
hours.
During this test the stator winding should be filled with
water. The primary water tank should be at atmosphere
pressure and the waste gas pipes closed. Though the
primary water circuit has already been leak tested, the
internal primary water circuit should be included in the
leakage test of H2 gas system. For this purpose, the pressure gauge in the waste gas pipe of the primary water
tank should be replaced by a U-tube gauge, permitting even
small pressure increases to be measured. Should a pressure increase be observed in the primary water tank, a
leak of the primary water system within the generator
would be expected and must be located and repaired.
The H2 gas system may be considered sufficiently tight
if the loss of air is below 1.5 m3/24 hrs = 100 dm3/hr
(s.t.p.)* at this test.
The loss of air is determined as follows :
0.2694 x 24
p1 + p B1
p 2 + pB2
V = . V G (
-
)
273 + t2
Z
273 + t 1
Where
V
= loss of air in m3 (s.t.p.)* per 24 hour periods
0.2694
273K
1013.25 mbar
BHEL, Haridwar
p B1
p B2
t1
t2
Q
Q
Q
Q
Q
flange connections,
joints,
screw couplings,
welds,
bushings, etc.,
should be examined thoroughly. Suspected areas should

be brushed with Diprol or other foaming solution. The
formation of bubbles (foam) indicates a leak.
If a satisfactory tightness is established the generator
may be filled with CO2, and subsequently with H2.
If, as an exception, a leakage test using hydrogen is
performed, the leakage rate may be four times as high as
during a leakage using air. Leak detection during this test
should be performed by means of a gas leak detection.
3
Leakage Control of H 2 System During Actual

Operation
During operation, the loss of H2 gas must be monitored

continuously on the basis of H2 consumption. The quantity
of hydrogen leaking uncontrolled may amount to 12 m 3
(s.t.p.)*/24 hrs. Note that only the quantity of gas leaving
uncontrolled should be used for evaluating the tightness.
Losses such as the steady controlled gas loss occurring
at the electrical purity meter system and the gas removed
from the generator through the seal oil should not be
counted.
2.5-0310-10550/1
0209 E
Leak Detection by Means of a Gas Leak Detector
If an undue loss of gas occurs on the unit, the

location of the leak must be determined. To do this, we
recommend a leak detector of the Handy-Tector type
with battery charger (product of Edwards Hochvacuum
GmbH, Frankfurt/Main, West Germany).
4.1 Description of the Handy-Tector
The equipment consists of a battery driven manually
operated leak detector with two sniffler probes (made
of stainless steel and plastic) and a battery charger.
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
practical manner. The pistol form allows one-hand

operation. The overall dimensions of the equipment are
150 x 160 x 65 mm. The Handy-Tector is supplied in a
portable leather case.
4.2 Handling the Handy-Tector
The sniffer probe of the Handy-Tector should be
led over the surface of the test object as slowly as
possible. Note that with a leakage gas lighter than air
the leak detection should be carried out above the object,
and with gases heavier than air underneath of the test
object.
Fig.1
Handy-Tector
* s.t.p. = Standard temperature and pressure, 0oC and

1.013 bar
2.5-0310-10550/2
0209E
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.
If the oil piping must be flushed the following procedure
should be used.
2
Preparation of Bearing Compartments
1
1
2
3
4
Flushing Oil
The oil used for flushing must be provided by the user
BHEL, Haridwar
Oil Drain at Generator Bearing
and oil supplier as laid down in the generator manufacturers

oil specification. In this connection, it may become necessary
to consult the turbine manufacturer too.
The following methods are possible :
Preparing the Lube Oil System for Flushing
During flushing, the highest possible oil velocity is to

be maintained in the pipes.
When the bearings are installed, make sure that no
contaminated oil is introduced between shaft and babbit.
To do this, remove the upper half bearing sleeves and fit
temporary oil drain pipes to the inlet openings of the lower
half sleeves. Remove the valve cones from the permanently
adjustable throttle valves before the bearings and insert
the flushing screens supplied with the throttle valves. Make
sure that the hoses of the shaft lift oil system are not
connected to the bearings, as otherwise contaminated oil
will be admitted to the bearing journal.
Oil drain
Bearing saddle
Seal
Bearing sleeve
Fig. 1
Prior to commencement of the flushing procedure, the

bearing compartments should be cleaned carefully. If any
reworking has been done in the bearing compartments
(e.g. drilling), the chips should be removed by means of a
magnet. In addition, the bearing compartments should be
cleaned with lint-free rags (never use cotton waste). The
cleaning agents used should leave no residue. After
cleaning, the bearing compartments should be subjected
to a thorough visual inspection.
Use of the same oil grade for both flushing and

operation. On completion of the flushing procedure, oil
samples should be taken and analyzed to decide
whether the flushing oil charge can be used as service
oil change after treatment by the oil supplier.
Use of an oil grade intended for use as flushing oil
only. Its properties, particularly its viscosity, are
matched to the special application. The oil charge is
completely drained on completion of the flushing
procedure and replaced by a new service oil charge.
The properties of the service oil and flushing oil must
be suitably matched.
Flushing Procedure
Flushing all bearing oil lines and all shaft lift oil pipes
of the generator should be performed in conjunction
with the turbine according to the instructions issued for
the turbine.
During flushing, the oil lines should be hammered
regularly to remove dirt particles from the walls. During
the last third of the entire flushing period, the screens
2.5-0320-10550/1
0209 E
should be temporarily installed in the throttle valves

upstream of the bearings for checking the dirt
accumulation.
After draining of the flushing oil, remove any left dirt
deposits from the bearing compartments. Remove all
bypasses, orifice plates or blank flanges as well as the
additionally installed filters. Refit the valve cones in the
throttle valves before the bearings. Assemble the
bearings ready for operation. The hoses of the shaft lift
oil system should be connected to the bearings and
2.5-0320-10550/2
0209E
checked for tightness.

6
Supervision of Oil Circuits
After recommissioning, all screens and filters should

be replaced and/or cleaned as frequently as possible.
During commissioning, the oil should be checked for
contamination, e.g. via vent ports. In case of an extremely
high dirt content due to carbon dust, construction work,
etc., special precautionary measures should be taken.
Turbogenerators
Inspection
The high strength austenitic material used for the rotor
retaining rings, etc. is susceptible to stress corrosion if it
is simultaneously subjected to high tensile stresses and
moisture (e.g. moisture condensing from the ambient air).
If persisting for a sufficiently long period, stress corrosion
will lead to crack initiation and crack growth. Since tensile
stresses are due to the shrink fit of these components and
thus unavoidable, any prolonged exposure to moisture must
be positively prevented.
During an inspection, the individual components of the
generator are exposed to the ambient conditions which
may result in hazards to these components. It is therefore
strongly recommended to take suitable measures for
preventing any exposure to moisture, especially rain, snow,
liquids of any kind and condensation., Covering the
components will not afford sufficient protection.
To avoid the above-mentioned hazards, the assembly
work during an inspection should be accomplished under
protection from weather conditions. The generator should
only be opened if an uninterrupted execution of the work
will be ensured and provided that the necessary protective
measures can be taken. After opening of the unit and
withdrawal of the rotor, the stator openings should be
promptly reclosed. The stator should be dried by means of
a portable air dryer or fan-forced heater and kept above
ambient temperature level. The air dryer or fan-forced
heater should be arranged so that the air will circulate
through the stator interior in a closed circuit for ventilation
BHEL, Haridwar
Measures to Prevent Corrosion

During Inspections
of the entire internal space .

The rotor should be protected in such a manner that
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 practicable. The heat
loss of the pump is sufficient to keep the temperature of
the primary water and thus of the stator winding above
ambient temperature level.
The cooling water should be drained from the coolers.
The coolers should be cleaned, dried and maintained in dry
condition by suitable measures.
During inspection work on the exciter unit , it should be
observed that the devices installed as a precautionary
measure, such as anticondensation heating system and
air dryer will no longer be effective after removal of the
exciter enclosure. The required protection should be
restored by suitable measures (covers, etc.) and portable
dryers or hot-air blowers.
Normally, a condensation hazard can be recognized
with the help of dewpoint measuring device. In case of
doubt, however, it is recommended to dry the components
on a continuous basis in order to achieve a markedly low
dewpoint temperature on these components, i.e. to maintain
their temperature above ambient temperature level.
2.5-1003-10550/1
0209E
Turbogenerators
Inspection
Preventive Measures to Avoid Stress

Corrosion
Survey
Phase
Keyword
Transport
Packing:
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
documents:
Reference to special packing and request for restoration after opening due to
customs or in-transit damage.
Damage to
Packing:
Restore proper condition of dry packing immediately. For details, see description
accompanying the cargo.
Receiving:
Check effectiveness of dry packing and desiccant. Record condition in checklist.

Request for repeat checks according to checklist during subsequent storage.
Condition:
Maintain dry packing until immediately before assembly.
Check:
Monthly functional check of dry packing and desiccant according to checklist.
Storage area:
Indoor storage in dry building; outdoor storage in seaworthy packing, under shelter
protected against precipitation/ground moisture.
Outdoor
installation:
Transport to job site in dry packing. Acclimatization in dry packing to avoid condensation after unpacking.
Installation under shelter. Removal of dry packing from retaining rings (1 st layer) as
late as possible.
Storage
Installation
Open generator
rotor installed:
Ready for
Operation
(standstill
or turning
gear
operation)
Sched.
mainten.
Without
removal
Sched.
mainten.
with
rotor
removal
Precautionary Measure and Checks
10 With danger of condensation (outdoor installations and open power house), blow
dry air from portable air dryers into rotor end windings and RR * wheels
Generator closed, 11
filled with
H2 gas:
Exciter unit
in enclosure
Outdoor
installation:
H 2 cooled generators:
Pass small cooling water flow through H2 cooler to ensure that cooler is coldest
component in the generator (condensation hazard!).
12 RR* exciter units:

Drying process with stationary or mobile air dryer.
13 Generator closed: Measures as under Ready for operation
14 Generator open: Shelters must prevent precipitation from entering the generator;
the retaining ring areas must be covered and kept dry by supplying dry air.rotor
Indoor
installation:
15 If rotor is set down in dry power house with even temperature, it is sufficient if the
entire rotor is covered against dirt and wetness. If danger of condensation, the rotor
areas between the bearing journals must be provided with dry packing.
Outdoor
installation:
16 Set down rotor under shelter and provide rotor areas between bearing journals with
dry packing
* RR = Rotating rectifier
BHEL, Haridwar
2.5-1005-10550/1
0209 E
Turbogenerators
Inspection Schedule
Foreword
Inspection
Preventive maintenance of generators serves to
avoid major problems or damage while the unit is in
service.
Apart from its scope, the timing of an inspection is
important. To account for the deterioration and stresses
due to different modes of operation, both the number of
operating hours and the number of starts are used as
criteria determining the intervals between the
inspections.
The intervals recommended in the following are the
same as those indicated in the VDEW Recommendations
for intervals between Generator Inspections (published
by Vereinigung Deutscher Elektrizitatswerke VDEW
e.V. in 1980). This Foreword contains a large number
of extracts from the VDE Recommendations.
The guiding values given in the VDEW
Recommendations are to assist the power plant owners/
operators in scheduling inspections, taking into account
also own experience on the performance of their
generators and that of sister machines.
1
Types of Inspections
Depending on the scope of work, a differentiation is

made between initial inspection, minor inspection and
major inspection.
Type
Feature
Duration
where
Tequiv
Tact
ns
Ts
=
=
=
=
equivalent operating hours

actual operating hours
number of starts
additional number of operating hours to be
considered for one start. According to the
present state of knowledge 20 hours
account for one start of a turbogenerator.
The recommendations given in the following apply to

normal operation without major disturbances. Abnormal
disturbances, such as close-in system faults, faulty
synchronizing, asynchronous running and inadmissibly high
unbalanced load, may necessitate shortening of the
respective inspection interval or an immediate check.
When scheduling inspections, also consider the
following factors :
Wear and deterioration of components.
Deterioration of running behaviour.
Q Frequency of load rejections associated with overspeed.
Q Earth faults or interturn faults in generator field circuit.
Q Hydrogen, water or cooler leaks.
Q Change in coolant flow rates.
Q Fouling of air-cooled generators.
Q Deterioration of shaft insulation.
Q Inherent fault (recognized deficiency in comparable
machines or components).
Q
Q
Initial
Inspection
Extensive checks, incl.

removal of rotor
Approx.
6 to 9 weeks
Minor
Inspection
Specific checks and

maintenance without
removal of rotor
Approx.
1 to 3 weeks
With proper performance of the generator and provided

that the inspection findings obtained by the preceeding
inspection(s) have been favourable, the intervals between
inspections may be lengthened within reasonable limits.
Major
Inspection
Removal of rotor
Approx.
6 to 9 weeks
Table 1
Recommendations for Scheduling Inspections

It is recommended to perform the initial inspection after
Types of Inspection
The initial inspection is the first major inspection of the

generator involving the removal of the rotor and is an
essential prerequisite for assuring high reliability on a longterm basis. The scope of work and checks to be performed
should be agreed upon with the manufacturer in good time.
The date of the initial inspection should be determined under
due consideration of changes that are likely to occur after
a relatively short service period.
The time periods given are guiding values. Depending
on the scope of the planned work of inspection findings,
the inspection period is either shortened or lengthened.
2
Influences
Scheduling of the initial inspection and of the
subsequent inspections mainly depends on the number of
operating hours and on the number of starts. Both
influences are considered in the parameter equivalent
operating hours.
T equiv = Tact + n s . T s
BHEL, Haridwar
10,000 h < Tequiv < 20,000 h

equivalent operating hours and to observe an interval of
40,000 h < Tequiv < 60,000 h
equivalent operating hours between two major inspections.
It is recommended to perform minor inspections, i.e.
specific brief checks and maintenance work, during the
service period between major inspections. When
scheduling minor inspections consideration has to be given
not only to the technical requirements of the generator but
also to those outage periods of the unit that are not
attributable to the generator.
Scheduling of the initial inspection is primarily dictated
by the state of the art embodied in the end winding and
stator slot support systems. The synthetic and insulating
materials used in generator manufacturing tend to develop
plastic flow (creep) under the influence of pressure and
temperature, especially during the initial period after
2.5-1010-10550/1
0209E
Tact
ns
ns. Ts
Tequiv
hours
Starts/year
hours
hours
A Continuous/base load
7000
10
200
7200
B Continuous/occasional peak load
4000
100
2000
6000
C Peak load (abt. 1 start/day)
2000
300
6000
8000
D Peak load (abt. 2 starts/day)
1000
500
10000
11000
Operating duty
Table 2 Equivalent Operating Hours T equiv for One-Year Operation With Different Operating Duties
commissioning. The resulting setting and looseness can

be corrected during the initial inspection. Any deficiencies
due to manufacture, assembly or new design can thus be
identified and eliminated at an early date.
The specified interval between major inspections is in
accordance with the present state of the art in generator
engineering.
The special stresses attributable to each start or
shutdown of the unit are considered in the equivalent
operating hours Tequiv of the generator which account for
the number of starts (ns). These stresses include :
effects of expansion and friction on winding and
insulation due to thermal and centrifugal force cycles.
special vibratory forces arising when passing through
natural frequencies of various generator components.
material fatigue, especially of rotating parts, resulting
from the centrifugal force cycle.

The additional number of 20 operating hours to be
considered for one start (T s) has been determined by an
agreement reflecting the present state of knowledge.
4
Inspection Schedule
All important maintenance activities required for
maintaining the generator and its auxiliaries in proper
condition are listed on the following Inspection Schedule
pages.
If the work required in each case is performed at the
specified intervals, major financial losses and prolonged
outages can be minimized, the result being a high availability
of the generator.
Actual operating hours Tact (103 Hr)

Fig.1 Typical equivalent operating hours of Turbogenerators
2.5-1010-10550/2
0209E
Turbogenerators
Inspection
2000
4000
6000
8000 Hrs
Fig.2 Graph for Determining the Equivalent Operating Hours of Turbogenerators
BHEL, Haridwar
2.5-1010-10550/3
0209E
Turbogenerators
Initial inspection
Minor Inspection
Major inspection
Inspection
Inspection Schedule
Stator
Measure insulation resistance of stator winding
Stator winding insulation
Dismantle stator end shield and replace gaskets
work required
Dismantle bushing compartment and replace all gaskets
x*
Dismantle bushings and replace gaskets
x*
Check condition of stator core
Check slot wedging system and end winding support structure
Check coil connections (preloading, voltage drop)
x*
Replace all generator flange gaskets
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
Clean filters in primary water circuit
x
x
Check balancing orifices in phase connector
x*
Check strainers at phase connector flanges
x*
Leakage test of primary water system
Leakage test of H2 system
* Normally required only at every second major overhaul

1) Dissipation factor measurement, charging and leakage current measurement, and, in particular cases, high potential test.
BHEL, Haridwar
2.5-1020-10550/1
0209E
Major inspection
Work required
Minor Inspection
Inspection
Inspection Schedule
Rotor
First Inspection
Turbogenerators
Perform runout check
Withdraw and check rotor
Perform ultrasonic testing of rotor retaining rings
Check rotor wedges and retaining rings
Check end windings and gas outlet ducts
Measure insulation resistance of rotor winding
Check bearing surfaces
Check shaft seal contact faces
Check rotor fan
Check coupling flanges
Check rotor alignment
BHEL, Haridwar
2.5-1030-10550/1
0209E
Turbogenerators
Initial inspection
Minor Inspection
Major inspection
Inspection
Inspection Schedule
Coolers
Check cooling water inlet and outlet pipes, vent pipes, drain pipes and mounting of all coolers
Check condition and performance of temperature and pressure measuring devices at all coolers
Clean H2 on water side
Check condition and, if required, recondition H2 cooler water channels
Work required
General
Hydrogen Cooler
Dismantle H2 cooler; check water and oil sides; clean, if required; replace gaskets
and perform pressure tests
Seal oil Cooler

Clean seal oil coolers on water side
Check condition and, if required, recondition seal oil cooler water channels
Dismantle seal oil coolers; check water and oil sides; clean, if required; replace gaskets

Clean primary water coolers on secondary water side
Check condition and, if required, recondition water channels of primary water coolers
Dismantle primary water coolers; check and clean primary and secondary water sides; replace
gaskets and perform pressure tests
Exciter Cooler
Clean exciter water coolers on water side
Check condition and, if required, recondition exciter cooler water channels
Dismantle exciter coolers; check and clean water and air sides; replace gaskets
Note: No cleaning on water side is required on coolers supplied with condensate.
BHEL, Haridwar
2.5-1040-10550/1
0209E
Major inspection
Work required
Minor Inspection
Inspection
Inspection Schedule
Bearings
First Inspection
Turbogenerators
Check and , if required, replace bearing insulation
Check bearing surfaces and babbitt bonding
Check bearing clearances
Check seating of bearing sleeves on bearing saddles
Check labyrinth rings and, if required, replace seal strips
Check condition and performance of bearing temperature monitoring system
Check condition and performance of shaft lift oil system
BHEL, Haridwar
2.5-1050-10550/1
0209E
Major inspection
Work required
Minor Inspection
Inspection
Inspection Schedule
Shaft Seals
First Inspection
Turbogenerators
Check shaft seal insulation
Replace shaft seal insulation and gaskets
Check sliding contact faces of seal rings and seal ring carriers
Check contact faces of seal rings
Check seal rings clearances
Check inner labyrinth rings and, if required, replace seal strips
BHEL, Haridwar
2.5-1060-10550/1
0209E
Turbogenerators
Inspection Schedule
Seal Oil System
Initial inspection
Minor Inspection
Major inspection
Inspection
Perform functional check
Check coupling
Work required
Seal oil pumps

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

Regrease bearings after 8000 operating hours at the least
BHEL, Haridwar
2.5-1071-10550/1
0209E
Turbogenerators
First Inspection
Minor Inspection
Major inspection
Inspection
Inspection Schedule
Gas System
Check condition and performance of all pressure reducers
Check performance of all valves (leakage, operation)
Work required
Replace valve gaskets and inserts
Replace flange gaskets
x*
Perform functional check of gas dryer (leakages, heater and fan)
Replace gas dryer desiccant (replace cover gaskets)
Replace PTFE sleeves in multi-way valves
x*
Replace flange gaskets of gas dryer
Replace gaskets and coating of CO2 flash evaporator
Check condition and performance of CO2 flash evaporator
Replace dust filter in gas purity meter system

Check complete gas system for leakages
x
x
BHEL, Haridwar
2.5-1072-10550/1
0209E
Turbogenerators
Initial inspection
Minor Inspection
Major inspection
Inspection
Inspection Schedule
Functional check
Check coupling
Change bearing oil in pump casings 1)
Regrease bearing of drive motor 2)
Check and, if required, replace bearing of drive motors and pumps
Work required
Primary water pumps
Replace bearings and oil seal rings of drive motors and pumps
Replace sliding-ring glands of pumps
Check and clean main filter
Perform functional check of ion exchangers (replace resins, if required)
Perform functional check of fine filter
Replace Micro-Clean cartridges in fine filter
Check shutoff valves and non-return flaps for leakage
Perform functional test of valves and, if required, replace wearing parts
Replace valve stuffing boxes
x*
Check condition and performance of all measuring and supervisory devices
Replace all flange gaskets
x
x*
Check complete primary water system for leakage
Inspect and, if required, clean NaOH tank in alkalizer unit
Check feed valve in alkalizer unit for tight shutoff
Check cable and pipe conduits in NaOH tank for firm attachment
Replace diaphragm pump
1)
2)

Change Bearing oil in pump casing at intervals of 3000 operating hours
Regrease antifriction bearings of drive motors at intervals of 8000 operating hours
BHEL, Haridwar
2.5-1073-10550/1
0209E
Check condition and performance of temperature gauges and alarms
Replace gaskets at temperature measuring points
Major inspection
Work required
Minor Inspection
Inspection
Inspection Schedule
Generator Suppervisory Equipment
First Inspection
Turbogenerators
x
x*
Check condition and performance of level meter system (liquid level alarm switches)
Check condition and performance of grounding brush
BHEL, Haridwar
2.5-108010550/1
0209E
Turbogenerators
Initial inspection
Minor Inspection
Major inspection
Inspection
Inspection Schedule
Excitation System
Check radial bolts for H2 leakage 1)
Dismantle exciter
Check insulation resistances of windings
Work required
x
x
Replace fuses
x
x
Check condition and performance of rectifier wheels; check stator and rotor windings
Check coupling flange
Check contact pin and Multicontact-strip and, if required, replace
Replace Multicontact-strip
x*
Check alignment
Check bearing and pipe insulation
Replace bearing and pipe insulation
x*
Check bearing surface and babbitt bonding
Check bearing clearances
Clean seating of spherical portions of bearings
Check labyrinth rings and, if required, replace seal strips
Check air filter
Check condition and performance of ground fault detection system
Clean prefilter for exciter dryer and replace if required
Perform functional test of emergency cooling flaps
Check emergency cooling flaps for tight closing by in-service pressure measurement
*
1)
Normally required only at every second major inspection.

To be performed before H2 removal; using liquid leak indicators (e.g. DIPROL) is not permitted.
BHEL, Haridwar
2.5-1090-10550/1
0209E
Turbogenerators
Inspection
Preservation measures will have to be taken when a
water-cooled generator is to be shut down.
The scope of the preservation work required depends
on the duration of the shutdown, on the overall conditions
in the vicinity of the unit and on the extent to which checks
and inspections are possible during such period. The
preservation measures recommended in the following are
sufficient under normal conditions. High relative humidity
in combination with severe temperature changes involves
the risk that the temperature of certain surfaces in the
generator may drop below the dew point, resulting in the
possible formation of a moisture film due to condensation
on these generator components. In such a case, special
measures may be required for preservation of the rotor
retaining rings and rectifier wheels [1].
1
Generator Interior
The hydrogen gas should be removed from the
generator. The stator and rotor windings should then be
protected against moisture by maintaining the generator
interior at a moderate temperature or in dry condition by
suitable means. This may, for instance, be achieved by the
provision of a hot air blower or dryer. The generator interior
can also be maintained in a sufficiently dry condition by
keeping the primary water system in operation as mentioned
under Item 7 with activated primary water heating system,
if provided. No additional blowers are then required.
If additional blowers are used for drying, the air should
be admitted and discharged via branches at the exciter
and turbine end manhole covers
Prior to recommissioning the generator, the insulation
resistances of the stator and rotor windings should be
measured and the windings dried, if required.
2
Bearing and Shaft Seals

No preservation measures are required on the bearings
of the turbogenerator and exciter and on the H2 shaft seals.
However, the bearing and seal oil systems should be
placed into operation once a week and the entire system
adequately flushed with water free oil. After activation of
the oil systems, the shaft should be operated on the turning
gear for approximately three to four hours.
The supply of water to the bearing oil and seal oil
coolers is not required during this period.
Measures for Preservation of Generator

During Standstill
Coolers
All coolers should be drained on their water sides
and dried by suitable measures. During the outage, the
drains and vents should be kept open.
Caution : Never leave water-filled coolers standing
idle for several weeks.
For cooler drying, hot air or dry ambient air may be
used which should be admitted by means of blowers
via the cooling water inlet/outlet flanges. A fan-forced
heater with a rating of 1-2 kW has proved satisfactory
for this purpose.
4
Exciter
The exciter should be protected against the
formation of a moisture film due to condensation To do
this, the cooler should be drained, dried and maintained
in a dry condition, and the exciter drying system should
be kept in operation continuously.
The carbon brushes should be lifted off and the
sliprings covered with oiled paper.
5
Bright Components
All accessible bright components, e.g. exposed shaft
portions, should be protected with a suitable corrosion
inhibiting oil or grease, e.g. Tectyl.
6
Seal Oil and Gas Systems

Except for the work already mentioned, no
preservation measures are required on the coolers of
the seal oil system.
During the weekly activation of the seal oil system
for turning the shaft, the system should be inspected
for proper functioning by checking all operating values.
All valves in the gas system should be closed. No
additional measures are required.
7

After completion of the assembly or following a
prolonged shutdown of the unit, the primary water
system should be placed into operation or kept in
service, with monitoring and maintenance to be
performed in accordance with the information given in
the turbogenerator manual.

[1] 2.5 0030
BHEL, Haridwar
Packing Transport and Storage of Generator Rotors
2.5-1100-10550/1
0209 E
Turbogenerators
Stator
Inspection
After each shutdown, the insulation resistances should

be measured prior to carrying out the inspection [1], [2],
[3]. Depending on the scope of the inspection, the slot
wedges should be checked for proper seating. The seating
of the end windings should also be checked.
After opening the generator, the interior should always
be inspected for contamination of any kind. If contamination
is detected, its cause should be determined and corrected
in order to preclude any new contamination. The generator
interior should be cleaned thoroughly.
The bushings and expansion joints should be inspected
to ensure a proper connection between the bushings and
the phase connectors. The bushings should also be
checked for proper connection to the bus bars arranged
external to the generator.
All primary water hoses and pipes should be checked,

leaving the generator filled with primary water, if possible.
When dismantling of the hydrogen cooler is required
for inspection, the cooler wells in the stator frame should
be checked for cleanliness.
All stator flanges should be checked for proper
alignment and seating. The stator should be checked for
tight anchoring to the foundation.
All metering connections should be checked for proper
mounting and condition as far as practicable. This should
include both the electrical metering connections and the
pipe connections to the measuring instruments.
Prior to recommissioning, the insulation resistance of
the stator winding should be measured and, if necessary,
improved.

[1] 2.5 2300
[2] 2.5 3300
[3] 2.5 2310
BHEL, Haridwar
Insulation Resistance Measurement on Stator

Winding
Insulation Resistance Measurement on Rotor and
Exciter Windings
Drying the windings
2.5-2000-10550/1
0209E
Turbogenerators
Cementing the Joints of

Profiled Gaskets
Inspection
1
Survey of Adhesives
1.1 Sicomet 50
Profiled gaskets should preferably be cemented
together by means of Sicomet one-component adhesive.
This adhesive meets all requirements, its only disadvantage
being the difficulties encountered in storage.
Sicomet should be protected from moisture, heat and
sunlight and should therefore be stored in a dry, cool and
dark place. To prevent an increase in viscosity and
discoloring of the adhesive Sicomet is best stored at a
temperature of 10C. If stored under these conditions,
Sicomet has an unlimited working life. Defrost Sicomet
prior to use and bring to room temperature.
Repeated freezing and defrosting does not affect the
bonding properties. The maximum storage time at room
temperature is six months. The adhesive not used up must
be stored at a temperature of 10C immediately.
1.2 Pattex
Pattex cannot be used for cementing together gaskets
because of its low temperature stability (50C max.) and
insufficient oil resistance.
The use of other adhesives, as, for instance, rubber
cement, is likewise not permissible.
2
Preparatory Work and Application of Adhesive
2.1 Preparatory Work

The exact length of profiled gasket is determined by
inserting it in the center of the sealing groove, allowing 30
to 40 mm in length for overlapping at the joint. The joint

faces could be cut so that the overlapping portion to be
cemented is approximately 30 to 40 mm long. When cutting
take care that the profiles does not suffer any visible
distortion and that the pressure applied after pulling
together the part to be mounted is exerted on the area of
cut (see arrow in Fig. 1). The faces to be cemented together
should be well roughened.
2.2 Cementing the Joint
The adhesive should be applied in drops on the joint
areas to be cemented together, using a plastic or metal
spreader for obtaining a thin film Immediately afterwards
the joint faces should be assembled and located in position.
Because of the short curing time of 10 to 30 sec. any
readjustment will be almost impossible. After curing, any
cement residue should be removed from the outer surface
of the bonded joint by means of emery paper.
Warning : Sicomet should only be used in well
ventilated work areas. Care must be taken to avoid
body contact. In the event of contact with the eye,
rinse immediately with ample amounts of distilled
or potable water to dilute the adhesive. The eye
should then be treated to sooth any inflammation
and a physician immediately consulted.
2.3 Breaking the Cemented Joints
Cemented joints which are to be broken should be
placed in a bath of either dimethyl-formamide for a brief
period or ethylacetate for a longer time, resulting in swelling.
30 to 40 mm
Fig. 1 Cementing of a Profiled Gasket
BHEL, Haridwar
2.5-2120-10550/1
0209E
Turbogenerators
Inspection
1
General
The joints of the end shields and their flange
surfaces toward the generator frame are sealed
gastight with profiled gaskets. Experience has shown
that an additional sealing compound must be applied in
order to obtain a gastight seal at the Tee-joints of these
packings and at the flange surface of the seal ring
carrier.
2
Sealing Compound
The recommended sealing compound is silicone
compound S with hardener TL.
These should be mixed in a ratio of 100 g silicone
compound S to 3g hardener TL.
2.1 Preparing the Sealing Compound
Mixing of silicone compound S and hardener TL
in the above-mentioned ratio should be done in a clean
and completely dry container. At a temperature of +20C,
the prepared mixture is usable for about 1 to 1 hours.
Following this period, the sealing compound starts to
thicken and will have completely solidified after 3 to 4
hours.
Fig. 1
Sealing Generator End Shield Joints
Bonding Agent
Prior to applying the sealing compound, the surfaces to
be sealed should be wiped with a bonding agent using a
clean, lint free cloth.
4
Mounting the Lower Half End Shield

Prior to attaching the lower half end shield to the
generator frame, wipe the flange surface with bounding
agent over a width of 100 mm at the location of the agent.
Wipe the mating flange surface of the generator frame
with bonding agent too. Immediately before mounting the
respective lower half end shield, silicone compound S
and hardener TL should be thoroughly mixed using the
ratio mentioned earlier. A thick coating of the compound
should be brushed on the surfaces previously treated with
bonding agent. The lower half end shield should then be
carefully mounted, paying particular attention to the gasket.
After curing, any surplus seating compound should be
removed with of a knife, scraper or similar device.
5
Mounting the Upper Half End Shield

Suspend the upper half end shield from the crane and
wipe its flange surface with bonding agent within the range
Mounting the Upper Half End shield
BHEL, Haridwar
2.5-2160-10550/1
0209E
of the joint over a width of 100mm at the location of the

gasket. Wipe the mating flange surface of the generator
frame with bonding agent too. Following this, the joint
1
2
4
5
1
2
3
4
5
surfaces of the lower and upper half end shields should

be wiped with bonding agent within the range of the Tee
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
mounted, paying particular attention to the flange and joint
gaskets.
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.
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
as a result of the contact pressure established by bolting
the end shield halves together as well as any surplus
sealing compound should be cut flush with the flange
surface with a sharp knife.
Upper half end shield

Retaining device for gasket
Joint bolt
Lower half bearing
Rotor shaft
Fig. 2 Upper Half End Shield Lowered in Position
1 2
1
2
3
4
5
6
2 3
4 5
Inner labyrinth ring

Gasket
Shim, 3 mm
Flat iron bar for gasket
Mounting screw for retaining device
Lower half end shield
Fig. 3 Gasket in Lower Half Stator End Shield With

Retaining Device
2.5-2160-10550/2
0209E
1
2
3
4
5
6
Lower half end shield

Gasket
Mounting screw for retaining device
Flat iron bar for gasket
Lower half bearing
Rotor shaft
Fig. 4 Retaining Device for Gasket
Note : Detaching the flat iron bar and cutting flush the
gasket should be done immediately prior to mounting the
respective seal ring carrier. Experience has shown that
the gasket will be forced out if seal ring carrier is not
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
extreme care after the sealing compound has cured.
Turbogenerators

on Stator Winding
Inspection
During manufacture and transport, the insulation of the
stator winding may have been exposed to moisture which
would reduce the insulation resistance of the windings.
The insulation resistance should therefore be measured
prior to initial startup, after prolonged shutdowns and after
work on the windings. If required, the generator should be
dried until a sufficient insulation resistance is obtained.
1
Required Insulation Resistance of Stator Winding

The insulation resistance measured is dependent on
the temperature. To permit a proper assessment, a
correction to an agreed reference temperature (formerly
75oC) must be made.
An insulation resistance of 1 megohm per each kilovolt
of rated voltage at 75oC is normally attainable without any
difficulties.
New international standards specify an insulation
resistance of not less than 1 megohm per each kilovolt of
rated generator voltage at 40oC.
A correction of the insulation resistance measured at
10000
5000
3000
2000
Insulation Resistance R in megohm
1000
500
300
200
100
50
30
20
10
5
3
2
the winding temperature prevailing during the measurement

to the above reference temperature can be made using
the diagram in Fig.1.
If the insulation resistance measured is lower than the
specified minimum value, the neutral connections must be
separated and the insulation resistances of the individual
winding phases measured. During the test, the other two
phases which are not involved should be grounded. If the
insulation resistances of the individual phases are likewise
lower than the required limit value, drying of the windings
will be indispensable. Great differences in the insulation
resistance values are indicative of local contaminations,
e.g. insulators at bus duct or terminal bushings. If
practicable, additional connections should be separated.
If this measure does not result in an improvement, it is
recommended to obtain the services of a specialist from
the manufacturers work.
2
Measurement of Insulation Resistance

Prior to each measurement, the generator must be deexcited and any static charges removed by grounding the
windings. The windings should also be grounded after
each measurement for the duration of the recharging
period.
The insulation resistance of the stator is measured
between the winding copper and the stator core.
Prior to primary water filling, the insulation resistances
of the individual stator winding phases with respect to the
steel part should be measured by means of a 2.5 to 5 kV
megger.
During normal operation, the winding bars are
electrically connected to the grounded cooling water
manifolds through the water in the water inlet and outlet
hoses.
Because of the considerably lower resistance in the
hoses, a determination of the insulation resistance
according to the known methods is no longer practicable.
To enable, nevertheless, a measurement of the
insulation resistance, this turbogenerator with water| design
cooled stator winding incorporates the following
features:
Q
1
0
20
40
60
80
100
120
140
160
Temperature in oC
Q
Fig. 1 Diagram for Correction of insulation Resistance

Measured to a Temperature of 40 o C
BHEL, Haridwar
The water manifolds for the cooling water are insulated

for 5 kV against the frame and connected outside the
generator via cables to the insulated contacts. During
normal operation, these contacts are connected to the
frame, and thus grounded.
The bushing hoses are provided with contact sleeves.
During measurements, the primary cooling water must

be flowing, the required conductivity being < 1 mho/cm.
2.5-2300-10550/1
0209 E
To measure the leakage current according to Fig.2, the

water manifolds should be disconnected from ground,
joined to the contact sleeves and connected to the same
power source as the windings. A micro ammeter should be
inserted in the connection to the windings. Since, in addition
to the very low leakage current, the power source is now
required to supply the possibly very high partial currents
via the cooling water connections, batteries are not suitable
for this purpose. The dc voltage should therefore be
obtained from a stabilized power supply.
The measuring circuit is shown in Fig.2.
To determine the insulation resistance of water-cooled
windings, the currents due to any cells resulting from the
cooling water in the hoses between the winding copper
and the water manifolds of steel must be taken into
consideration. For this reason, the insulation resistance of
the complete winding should first be measured by applying
a positive voltage. After discharging, the measurement
should be repeated with a negative voltage.
Note : Current may pass through zero. In such a case, the
ammeter should be changed over and the current read
and recorded, observing the negative sign. The recharging

current is the mean value of the tests performed with
positive and negative voltage.
Individual phases can be tested by a similar procedure.
The insulation resistance (R10) is calculated from the applied
voltage and the 10 minute recharging current,
U (kV)
R10 = = 103 M
I (mA)
Note : When the generator is filled with hydrogen, make
sure that the rotor shaft ends are properly grounded during
measurement and discharging.
During measurement, the movement of ammeter A N is
connected to the positive pole of the stabilized power
supply (approximately 1000V to ground).
Temperature detectors may be installed in the ringshaped water manifold. To protect the connected metering
leads and measuring instruments, the metering leads
should be disconnected at the generator terminal strip (at
stator frame) during the above test.
After completion of the measurements the measuring
circuit should be removed.
Stator winding connection and terminal arrangement as

shown in the diagram are schematic only and may not match
exactly with the machine.
Fig. 2 Circuit Arrangement for Measuring the insulation Resistance R 10
1 =
2 =
3 =
4 =
5 =
6 =
7 =
G1 =
G2 =
G3 =
B =
UB =
AN =
IUVW=
S =
Stator
Rotor
Terminal Bushing
Water manifold ground contact
Generator ground connection
Hose with contact sleeve
Ground connection for manifolds
Grounding of generator frame
Grounding of TE shaft end
Grounding of EE shaft end
Stabilized power supply
Voltmeter
Ammeter
Current to winding
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.
2.5-2300-10550/2
0209E
Turbogenerators
Inspection
The epoxy resin insulation used for the stator windings
absorbs practically no moisture. Any reduction of the
insulation resistance during transport, erection or a
prolonged shutdown is mostly caused by the formation of
a moisture film on the surface of the insulation. Such a
moisture film can be prevented or removed by inserting
one forced air heater (approximately 2 kW) into each of
the two end shield compartments of the open machine via
the respective manhole covers.
The generator interior can thus be heated to a
temperature slightly above the ambient temperature. This
will provide for adequate drying of the stator and rotor
windings. The primary water pump should also be kept in
operation when the generator is at rest in order to maintain
low conductivity of the primary water. The circulation of
the water with closed primary water coolers will result in
a slight temperature rise of the primary water and also of
BHEL, Haridwar
Drying the Windings
the stator winding. The resultant temperature prevents

condensation of new moisture of the windings. When the
generator is again sealed, the windings will normally remain
dry.
In the event of a prolonged shutdown of the generator
it is preferred that the hydrogen be retained in the generator,
thereby eliminating surface moisture on the windings. If
the hydrogen has to be removed from the generator for
any reason, the primary water pump should be kept in
service and the winding temperature maintained at a value
above ambient temperature. This should eliminate moisture
problems.
Should it become necessary to check the insulation
resistance of the stator windings, e.g. after operation of
the differential or ground fault detection system the
insulation resistance should be checked for a lowresistance ground fault with a megger.
2.5-2310-10550/1
0209E
Turbogenerators
Inspection
1
Function of Slot Support System

The slot wedging system serves to ensure that the
bars are, and remain, tight in the slots and that they are
permanently protected from possible vibrations in order to
avoid damage to the insulation and the bars. Such forced
vibration of loose bars can be caused by the pulsating
electromagnetic forces. A slot wedging system using a
preloaded corrugated spring of epoxy-glass-laminate, the
so-called top ripple spring (TRS), inserted between the
slot material and the slot wedge-
results in preloading forces far in excess of the

pulsating electromagnetic forces,
Test Instruction for

Stator Slot Support System
With Top Ripple Springs
-
compensates for shrinkage (setting) of the slot material

by providing for resilience.
Bar vibrations are thus permanently suppressed.

The required preloading force is obtained during
wedging by compressing the springs, except for a small
residual amount of the normal spring deflection of
approximately 2 mm. To achieve this, filler strips of the
required thickness are used. The force which the preloaded
spring exerts on the slot material can be determined by
depressing the slot wedge from outside [1]. The test
pressure to be applied for checking must be higher than
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.
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,
however, the check should cover not less than 20 % of
the total number of slot wedges. This means that at least
every fifth slot wedge must be checked, excluding the
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
configuration is obtained on the stator bore circumference,
with the measuring points not being located side by side
but staggered from slot to slot.
2
3
4-5
6
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
Number x Thickness
4
1
2
3
4
5
6
7
Stator core
Slot wedge
Driving strip
Filler strip
Compression strip
Top ripple spring (TRS)
Stator bar
Fig. 1
7
F = Test pressure
a = Spring deflection
N B = Slot width
(equated with TRS width)
KL = Length of slot wedge
(equated with TRS length)
Stator Slot Support System Using Top Ripple

Spring
BHEL, Haridwar
Test Pressure F
Per Wedge
1 x 0.8 mm
10 bar x NB in cm x KL in cm
1 x 0.9 mm
2 x 0.9 mm
2.3 Permissible Slot Wedge Movements

To account for the very high electromagnetic forces on
generators, the permissible slot wedge movements
specified below are very small. They include adequate
safety margins for preloading and resilience to ensure
2.5-2340-10550/1
0209 E
reliable bar support during the subsequent service period.

Q
Slot wedge movement shall not exceed 0.55 mm for not

less than 60 % of all measuring points.
Slot wedge movement at remaining 40 % of measuring
points shall not exceed 0.75 mm.
If one slot wedge movement of more than 0.75 mm is
measured in any slot, the number of measuring points
for this particular slot should be doubled. If two
wedges in any slot exhibit movements of more than
0.75 mm, all wedges of this particular slot shall be
checked (except for end wedges) to ensure that
not more than two excursions per slot exist.
For slot widths of more than 60 mm, an additional
slot wedge movement of 0.1 mm is permissible to
account for the elastic spring action of the slot
wedges.
If the actual slot wedge movements measured during

the next major overhaul are larger than the above
guiding values, the condition of the slot support system
will be separately investigated by BHEL, Haridwar who
will then issue recommendations regarding the need for
rewedging under due consideration of :
Q
Q
Q
Q
the specific electromagnetic forces and preloading

forces
the specific relaxation due to setting
the statistical experience with comparable units
customers specific requirements in respect of future
inspection intervals.
The individual assessment of the preloading

conditions relies on a comparison of the actual spring
2.5-2340-10550/2
0209E
loading with the electromagnetic force arising in the

particular generator. The remaining deflection determined
by depressing the slot wedges permits the actual
condition of the spring to be readily derived from the
known stress-strain characteristic of the top ripple
spring.
The test record with the results of the depression
check should be forwarded to BHEL for evaluation in
each case.
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
Rewedging
During a rewedging operation [2], the preloading of
the spring is restored by inserting filler strips of the
required thickness. To enable an easier and more reliable
determination of the thickness of the filler strips, it is
recommended to measure the movements of all wedges
prior to rewedging. A residual spring deflection is
required for elastic compensation of the thermal
expansion of the bars in the slots. After rewedging of
the complete winding, the following slot wedge
movements are permissible :
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
all measuring points.
Slot wedge movement at remaining 25 % of measuring
points shall not exceed 0.45 mm.
For test pressure to be applied, see table under item 2.2.
Note : New top ripples springs must only be fitted

if the existing springs are found damaged.
Also refer to following information

[1] 2.5 2342
Test equipment for Stator Slot Support System
[2] 2.5 2345
Rewedging of Stator Winding

Radial Wedge Movements
Test Record
Turbogenerators
Inspection
Project name:
Sl No:
Generator type
No of slots
*
*
Date of test
Checked by:
Deptt:
Signature
Radial movement of slot wedges at major overhaul

Radial movement of slot wedges after rewedging
mm, Length of slot wedge KL mm
Slot width
NB
TRS thickness . . . . . mm, No of springs fitted . . . . .
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
Slot Support System)
Slot no 1 = end of phase A top bar at EE, counting to be
continued in counterclockwise direction)
Pump pressure p =
p=
test pressure F
Piston area AK
. . . . (bar) . . . . (cm) . . . . . (cm)
. . . . .(cm2)
p = . . . . . . . . . bar
Mean value of radial wedge movement in 1/100 mm derived from readings of two dial indicators ar thrust piece
Slot
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
39
40
TE
1 2
Slot wedge No.

3
BHEL, Haridwar
EE
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
2.5-2341-10550/1
0209E
Slot
No.
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
TE
1
Slot wedge No.

3
2.5-2341-10550/2
0209E
EE
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
Test Equipment for

Turbogenerators
Inspection
The test equipment consists of two principal
assemblies:
Q
Q
Hydraulic system
Mechanical system
The test equipment was designed for use on generators

of any size without any significant modifications being
required and can normally be assembled from locally
available standard components.
1
Hydraulic System
The hydraulic system consists of an oil-hydraulic jack

with hand-operated pump. The equipment should be of
moderate size and weight for convenient use in the stator
bore.
1
2
3
4
5
6
Mating thrust shim (fabric base laminate)

Tube Aluminium
Hydraulic jack
Thrust piece
Hydraulic pump
Hydraulic hose
7
8
9
10
11
For exact setting of the jack pressure, a precision

pressure gauge must be provided between the jack and
the pump.
The connections between the pump and jack should
consist of hydraulic hoses. Rigid pipe connections are not
advisable, since the equipment must be suitable for use in
the stator bore.
2
Mechanical System
The mechanical system consists of a light metal tube of

approximately 50 mm dia. x 5 mm (part 2).
To prevent compression marks on the stator core, a
mating thrust shim of fabric base laminate measuring
approximately 100 x 100 mm should be provided, taking
care that this size matches the radius of the stator core
(part 1).
Precision pressure gauge

Dial indicator
Magnetic stand
Stator core
Slot wedge
BA
AK
NB
KL
=
=
=
=
Stator bore
Effective piston area
Effective slot width
Length of slot wedge
Fig. 1 Test equipment
* Select range depending of pressure

** Attach magnetic stand to stator core in bore. Place dial indicator stud to thrust piece.
BHEL, Haridwar
2.5-2342-10550/1
0209E
The thrust piece and jack should be connected to the

tube with intermediate fittings to obtain a single unit for
case of handling.
The hydraulic pressure is transmitted to the slot wedge
through a thrust piece. The thrust piece should match the
slot width (NB) and the length of the slot wedge (KL) and
must be approximately 70 mm high to ensure a sufficient
resistance to bending (part 4).
Tube, thrust pieces and jack (part 3) should be
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
2.5-2342-10550/2
0209E

[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
Instructions for Checking the

Turbogenerators
Inspection
1
Stator Slot Support System Configuration

Number x thickness of top ripple springs :
Slot width
Slot wedge thickness
(NB):
(KD)
.1..x.0.9 mm*
..48..mm
..14..mm*
Check thickness on site.

Inform BHEL, Haridwar in case of deviations.
Magnetically Induced Slot Forces

PB = ..0.143N/mm2
Specific Test Pressure

PF = .18..bar
Permissible Radial Wedge Movement
.0.90. mm
.1.10. mm
for not less than 60 % of measuring points

for remaining measuring points (40 % max.)
If a wedge movement of more than 1.10.. 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,
Note: If the above guiding values are exceeded,

consult BHEL, Haridwar for advice, who will then
issue recommendations regarding the need for
rewedging under due consideration of :
Q
Q
the specific relaxation due to setting

the statistical experience with comparable units
BHEL, Haridwar
all wedges in this slot (except for end wedges) should be

checked to ensure that not more than two excursions per
slot exist.
customers specific requirements in respect of the

future inspection intervals.
The test record with the results of the spring

deflection check should be forwarded to BHEL,
Haridwar for evaluation in any case.
2.5-2343-10550/1
0209E
Turbogenerators
Inspection
1
Rewedging of Stator Winding
Note
The need for rewedging may arise from the results of

a check[1]. The results of this check are contained in the
test record [2]. The permissible values specified in the test
instruction [1] include considerable safety margins to
ensure reliable operation during the service period until
the next scheduled major overhaul. For this reason, the
decision on any major rewedging should only be taken
after consultation with the BHEL specialists.
Rewedging is done by inserting filler strips between
the top ripple spring (TRS) and the compression strip to
restore the preloading of the top ripple spring. It is
recommended to have this work performed by BHEL
specialists or under their supervision.
Prior to rewedging, the radial movement of all slot
wedges should be measured as recommended in [1]. This
will enable an economical and fast implementation of the
rewedging work.
1
All parts of the slot support system, including the top

ripple springs, can normally be reused.
Be careful to avoid damage when driving out the slot
closing elements. Slot wedges found with a permanent
deformation of 0.6 mm and more across their broad side
should be replaced. The cemented end wedges require
particular attention. Any end wedges found damaged
should be replaced by new wedges made with the same
dimensions and geometry as the original end wedges. The
holes for the ventilating slots in the flanks of the end wedge
should preferably be provided during the actual rewedging
procedure.
Wear of the top ripple spring is revealed by light
discolorations at the peaks and valleys of the corrugations,
these being indicative of separations between the individual
glass cloth laminations. This effect has, however, hardly
any influence on the stress-strain characteristics of the
TRS. Replacing such a TRS will normally not be required.
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
1 Stator core
2 Slot wedge
3 Driving strip
4 Filler strip
Fig. 1
7
5 Compression strip
6 Top ripple spring (TRS)
7 Stator bar
Removal of Slot Closing Elements
It is advisable to adopt a slot-wise approach for

rewedging. As a first step, each slot wedge should be
marked with the slot No. and wedge No. on its top, using a
felt pen. Marking should be done in accordance with the
scheme specified in the test record [2].
In order to remove the slot wedges, start at one end of
the stator core and remove wedges up to mid-length of
core. Before proceeding with the removal of the remaining
wedges, lock slot material in first half by inserting auxiliary
wedges with a spacing of 500 mm. Set down each slot
wedge removed together with the associated top ripple
spring and the filler, compression and driving strips (tied
together with adhesive tape).
BHEL, Haridwar
Checking the Slot Closing Elements Removed
Rewedging Procedure
Provided that the slot closing elements removed can be

reused, rewedging is done by inserting additional filler
strips. The thickness of the filter strips depends on the
difference between the radial movement of the slot wedge
measured prior to its removal as recorded in the test record
[2] and the radial movement required after rewedging as
specified in [1]. In the case of units where all slot wedges
were checked, the thickness of the filler strip can be
separately determined for each slot wedges :
Actual Value
Radial movement of slot

wedges measured
- Nominal Value = Nominal radial movement of
slot wedge
= Thickness of filler strip
Example :
0.85
- 0.20
= 0.65 mm
(radial movement of slot wedge

measured)
(mean of upper and lower limit of
nominal value)
(approximate thickness of filler strip
= 0.7 mm)
2.5-2345-10550/1
0209E
If only a restricted number of slot wedges is checked

(not less than 20 %), adherence to the specified radial
movement may not be ensured. The thickness of the filler
strip should preferably be determined on the basis of the
mean value of the radial wedge movement in the respective
slot.
The filler strips corresponding to BHEL specifications.
Rewedging should be started at mid-length of the core
in direction towards the core ends. To do this, remove the
auxiliary wedges from one half slot section between midlength of core end and then refit original slot wedges in the
correct locations as marked. Proceed with the second half
section by following the same procedure. After rewedging
of both halves of one slot has been completed, it is
recommended to check the radial movement of the slot
wedges according to [1]. The results will be helpful in
optimizing the rewedging procedure. It is known from
experience that a comparison between the force required

for driving in the slot wedge and the radial movement of
the slot wedge after rewedging provides information
enabling the fitter to make a correct assessment of the
necessary thickness of the filler strips. Such information
will be particularly useful on units where not all slot wedges
were checked.
Then proceed with rewedging of the remaining slots.
Provided that sufficient experience is available checking
the radial movement of the slot wedges will not be required
after rewedging of each slot. A final check [1] should be
performed after rewedging of all slots has been completed.
This check should include not less than 20 % of the total
number of slot wedges.
Proceed with cementing of end wedges [3] after
completion of this check.
Also refer to the following Information
2.5-2345-10550/2
0209E
[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
[3] 2.5 2346 Cementing Stator Slot End Wedges
Turbogenerators
Cementing Stator Slot End Wedges

at Trubine and Exciter Ends
Inspection
1
General
The procedure described in the following presupposes
that the end wedges removed can be reused or that new
end wedges have been made after the pattern of any
damaged wedges.
end wedge must be 60 mm shorter than the end wedge. The

resulting space should be packed with filter strips which
must be cemented together and to the end wedge and
compression strip for protection against displacement.
Cementing the top ripple spring is not permissible.
Cementing the End Wedges

Prior to driving in the end wedge (part 2) roughen
surfaces of compression strip (part 7) with abrasive cloth
over a length of not less than 50 mm from core end, except
for surface in contact with the stator bar, and apply a thin
coat of adhesive. Roughen filler strips (parts 5 and 6) with
abrasive cloth over a length of 50 mm on both surfaces,
brush both surfaces with a thin coat of adhesive and then
insert filler strips. Roughen driving strip (part 3) with abrasive
cloth over a length of 50 mm and brush driving strip surfaces
with adhesive. Insert driving strip and top ripple spring.
Roughen recessed portion of end wedge with abrasive cloth
and apply a thin coat of adhesive prior to driving in the end
wedge with a mallet and hammer. Drive in end wedge, leaving
a clearance of approximately 3m between the end wedge
and the adjacent slot wedge.
Place a suitably shaped piece of Metallon on the
compression strip ahead of the filler strips and the end wedge
and smoothen Metallon surface.
Adhesive
Metallon E 2082, or equivalent available from BHEL
Haridwar.
3
Preparing the Adhesive

Press equal lengths of adhesive and hardener on to a
suitable base and mix to a uniform grey color. The prepared
mixture is usable for approximately one hour at room
temperature.
At room temperature, the adhesive has a cure time of
one to two days. After curing, the material is not brittle but
similar to rubber.
4
Preparatory Work
The end wedges should be cemented to the core on
both flanks over a length of not less than 50 mm as referred
to the core end. These portions of the end wedge flanks are
recessed by 0.5 mm to provide reservoirs for the adhesive.
When checking the installation of the end wedges, make
sure that the end of the end wedge is positioned on the
supporting keyway of the core. If the wedge end coincides
with a ventilating slot in the core, the end wedge should be
shortened by 5 mm. The top ripple spring pertaining to the
End of core
Caution: If bond extends over a length of two or three core

packets, make sure that no Metallon is left in ventilating
slots. Remove surplus Metallon prior to curing.
50 mm
3 mm
A
10 mm
1
2
3
4
Stator core
End wedge
Driving strip
Top ripple spring
BHEL, Haridwar
5
6
7
8
Filler
Filler strip
Compression strip
Top bar
Notes
A End wedges are positioned on supporting keyway of core
B Metallon bon; compression springmust be 10 mm longer than wedge
C Cementing lower surface of compression stripto bar is not permissible
D Thickness of filler (part 5)
when using one top ripple spring : 1mm;
when using two top ripple springs: 2 mm
2.5-2346-10550/1
0209E
Turbogenerators
Inspection
1
General
The silver plated contact surfaces and the bright copper

surfaces of the contact faces should be treated with
contact grease primarily to fill up the gaps remaining after
bolting.
In addition, the contact grease improves the electrical
conductivity of the contact surfaces, it is chemically inert
and water-repellent, it does not dry up, it cleans oxidized
contact surfaces and protects them against corrosion.
Contact grease has a grease-like, pasty consistency.
2
Treatment of Bolted Contact Surfaces
Application
Degrease silver-plated contact surfaces by means of
BHEL, Haridwar
a cloth wetted with solvent. In the case of the terminal

bushing make sure that the insulators never come into
contact with the solvent.
Copper surfaces without silver coating should be
cleaned and degreased by means of solvent after emerypolishing.
After this preparatory treatment, apply the contact
grease to the contact surfaces with clean fingers in such
a quantity that a little excess grease is pressed out all
around on bolting of the contact faces.
If greased surfaces are soiled prior to making the bolted
connection, these should be cleaned and greased anew.
Excess contact grease should be wiped off with a
clean rag.
2.5-2350-10550/1
0209E
Turbogenerators
Inspection
1
Leakage Test of Field Current Lead
Before starting overhaul work and H2 purging, check

H2 seals at the field current lead for leakage. To do this,
use a leak detector and check coupling flange between
generator and exciter rotors and field studs at rectifier
wheels for gas leakage.
If no H2 gas leak is detected, the exciter should be
dismantled. The exciter rotor should be uncoupled from
the generator and a new leakage test of the central field
connection performed.
If a leak is detected during this leakage test, the
manufacturer must be notified. The hydrogen should be
purged from the generator only after completion of the
leakage test.
2
Rotor Wedges and Retaining Rings
If the rotor is removed, examine it carefully. The wedges

and retaining rings should be inspected for proper
condition.
3
Shaft Journals and Shaft Seal Contact Faces
The shaft journals and shaft seal contact faces should

be checked for grooves. If any irregularities are detected,
reconditioning should be carried out according to
instructions from our service personnel.
4
Cleaning the Rotor

After each withdrawal, the rotor should be cleaned
Rotor
thoroughly, even if the visual inspection did not reveal

any contamination. Careful cleaning is important so as
not to damage any of the numerous insulated parts. It
is, therefore, recommended to make use of the services
of our experienced product service personnel who will
carefully remove any dirt accumulations below the
retaining rings and within the range of the end windings
by means of a special vacuum cleaner. Any inexpert
use of compressed air involves the risk of cooling duct
clogging and of damage to insulated parts.
5
Contact Pins and Plug-in Socket Strips
The contact pins and plug-in socket strips should be

checked for arc erosion and proper contact resistances.
Proper seating of the contact pins on the plug-in socket
strips can be verified by visual examination.
6
Coupling
The coupling flange at the rotor should be checked

both at the guide flanges and at the fitting bolt holes.
The coupling bolts should be inspected for proper
condition.
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
[2] 2.5 2310 Drying the Windings
BHEL, Haridwar
2.5-3000-10550/1
0209E
Turbogenerators

Inspection
During manufacture and transport, the insulation of the

rotor winding may have been exposed to moisture which
would reduce the insulation resistance of the winding.
The insulation resistance should therefore be measured
prior to initial startup, after prolonged shutdowns and after
work on the winding. If required, the generator should be
dried until a sufficient insulation resistance is obtained.
1
100
K
Required Insulation Resistance of Rotor Winding
The insulation resistance should amount to 1 megohm

at 40oC.
At winding temperatures other than 40oC, a correction
can be made using the curve shown in Fig.1
2
Note: When the generator is filled with hydrogen, make

sure that the rotor shaft ends are properly grounded during
measurement and discharging
10
R 40oC = R m eas x K
Measurement of Insulation Resistance
Prior to each measurement, the generator must be deexcited and any static charges removed by grounding the
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
approximately two minutes.
After each measurement, the winding capacitance
should be discharged for not less than two minutes.
The measurement should be performed with the
measuring brushes for the ground fault detection system
lifted off the sliprings.
BHEL, Haridwar
0.1
0
10
20
30
40
50
60
70
80
90
Slot Temperature in C
Fig. 1 Correction curve for Insulation resistance
Measured (Rmeas) to a temperature of 40oC
2.5-3300-10550/1
0209E
Turbogenerators
Inspection
Austenitic retaining rings manufactured from
X55MnCr(N)18k steel are sensitive to stress corrosion,
if persisting sufficiently long in an unfavourable
environment during storage, operation or outages,
stress corrosion may lead to crack initiation and crack
growth. In addition to preventive measures to avoid
stress corrosion, it is advisable to arrange for
examination of the retaining rings at the power plant.
Such an examination is urgently required after
disturbance during which the retaining rings are exposed
to moisture. In the following the use of the ultrasonic
inspection method for non-destructive examination is
outlined and recommendation are given on the test
procedure.
1
Purpose and Scope of Ultrasonic Examination
Ultrasonic examination of the shrink-fitted retaining

rings serves to detect incipient cracks and particularly
those which have already grown to a dangerous size.
The examination can only be performed with the rotor
withdrawn. It is therefore recommended to subject the
retaining rings to such an examination during a major
overhaul involving the withdrawal of the rotor.
In addition, it is recommended to repeat this
examination at regular intervals. Any changes detected
when comparing the test results with the previous
results provide useful information for assessing the
integrity of the retaining rings. The intervals at which
the examination should be repeated can be the same as
the scheduled inspection intervals but should be
determined on the basis of the inspection facts.
2
Flaw Detection
Ultrasonic examination of the shrink fitted retaining

rings inevitably also involves the generation of spurious
BHEL, Haridwar
Ultrasonic Examination of
Rotor Retaining Rings at Power Plant
echoes, resulting in the difficulties in the interpretation
of the ultrasonic indications, particularly within the range
of the shrink fits and on shapes deviating from the
smooth cylindrical outline. Based on previous
experience and using special probe heads and reference
blocks, the BHEL specialists are in a position to
determine with a high degree of probability the flaw
size from the indications obtained. According to
experience so far available, the detectable flaw size is
far below the critical flaw size that may result in a
sudden forced rupture. If the echoes reflected by a
flaw are markedly above the spurious echo level of the
inner periphery and can be interrupted as incipient
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
further examination.
3
Execution of Ultrasonic Examination
To perform the examination, the rotor must be

removed and supported so that an inspection is
practicable on the entire circumference of the retaining
ring. The coating of the retaining ring should be stripped
with a paint remover. Care should be taken to ensure
that the winding and insulating parts do not come into
contact with the paint remover. Openings in the pole
areas and the gaps between the retaining ring and rotor
body should be sealed.
After completion of the examination, the oil-wetted
portions of the retaining ring should be degreased with
a solvent. When performing cleaning work care should
be taken to ensure that the winding and insulating parts
do not come into contact with the solvent. The retaining
ring should then be repainted and the rotor reinserted.
Approximately three days are required for
preparations and execution of the examination, including
repainting of the retaining rings.
2.5-3357-10550/1
0209E
Turbogenerators
Inspection
Depending on the extent of the inspection, the
hydrogen coolers should be cleaned thoroughly both
on the gas and water sides. During a less extensive
inspection, when the hydrogen is left in the generator,
the tubes should be cleaned on the water side only. For
this purpose, no withdrawal of the coolers will be
necessary. The return water channel can be removed
after the inlet and outlet valves at the coolers are closed.
It is advisable for wet cleaning to slightly lower than the
cooler water level by opening the outlet valve for a
short time.
The tubes are cleaned by special brushes, which
are moved up and down in the individual tubes of the
tube bundle. After all tubes are well brushed, any dirt
should be drawn off through the drain connection in the
inlet/outlet water channel. The vent pipe connection in
the inlet/outlet water channel should be detached for
brushing of the cooler vent pipe. After all tubes are
brushed, a new flat gasket should be fitted and the
return water channel tightly bolted to the upper
tubesheet of the cooler section. This should be followed
by reopening the inlet and outlet valves. Whereby the
tube bundle is flushed with cooling water. The cooler
cleaning interval depends on the cooling water condition
and is indicated when a substantial reduction of the
cooling capacity is observed at the coolers. A repetition
of the tube cleaning every two months may be necessary
when the cooling water is heavily contaminated. It may
be possible, however, that the interval between one
cleaning and the next amount to several years. It is
recommended to perform the first cleaning operation
two months after initial commissioning. The date at which
Hydrogen Cooler
the next cleaning will be required can be determined at

that time. The intervals for cleaning can, however, be
definitely fixed only after several years of operation.
Brushing of the tubes normally suffices for cleaning.
Any scale deposits which cannot be removed by
brushing should be dissolved with a hydrochloric acid
solution. For this purpose, a 10% solution with the usual
picking additives left in the tubes for several hours will
be sufficient. It is advisable, in the event of sufficient
experience not being available, to have such chemical
cleaning work be performed by specialist firms.
The coolers should be withdrawn from their wells
when more extensive inspection work is required. After
withdrawal, the coolers should be thoroughly inspected
on the gas side. On detection of any contaminations,
the gas side should be cleaned by means of dry and
clean compressed air. The coolers should then be
installed in the generator housing, using new gaskets
for reassembly.
At every generators inspection, the return water
channel and inlet/outlet water channel of the hydrogen
cooler sections should be removed. Care should be
taken in this work so that the water channels and
gaskets are not damaged and that their location is
sufficiently marked for easy reassembly. The water
channels should then be cleaned thoroughly. The
smallest trace of contaminations should be removed.
Any damage detected on the protective coast must be
properly remedied prior to reassembly of the cooler.
After cleaning, the water channels and gaskets can be
installed observing of the aligning marks. For additional
details, see separate instruction [1].

[1] TWA 57 905 Measures to prevent Corrosion damage
BHEL, Haridwar
2.5-4000-10550/1
0209E
Turbogenerators
Inspection
1
General
Each cooler section consists of a tube bundle, the

upper and lower tubesheets and the inlet/outlet and
return water channels. The upper tubesheet is larger
than the cooler well opening and used to fix the cooler.
Gastight sealing of this tubesheet is done by a round
cord packing. The lower tubesheet is sealed but is freely
movable and capable of following the differential
movement of the cooler due to the different thermal
expansions. Gastight sealing of the lower tubesheet is
done by a packingtype seal.
2
Checking the Generator
Prior to inserting a cooler section, the cooler well

should be thoroughly checked for dirt or other foreign
matter. All compartments and surfaces in the well should
be subjected to a vacuum cleaner treatment. Never use
compressed air for this purpose, since the compressed
air will only raise the dirt and carry it to inaccessible
locations. The flange and sealing faces and the groove
for insertion of the round-cord packing should be
cleaned. Any burrs or compression marks should be
removed with a smooth-cut file.
3
Sealing the Cooler Section at the Upper Half

Stator End Shield
The round-cord packing should be cemented

together in accordance with the instructions given
elsewhere in this Manual [1], and then inserted into the
groove.
4
Inserting the Coolers
The cooler section to be inserted should be cleaned

and suspended from the crane hook using the
suspension device of the return water channel. A second
wire rope should be attached to the nozzles of the inlet/
outlet water channel and suspended from a second
crane hook The cooler section should be brought in an
upright position. With the cooler section in vertical
BHEL, Haridwar
Insertion and Removal of

Hydrogen Coolers
position, the lower wire rope should be removed and
the section positioned over the respective cooler well
opening.
If no second crane is available for bringing the cooler
section in vertical position, the sections should be raised
by means of one crane hoist only, exercising utmost
care. To do this, suitable wooden supports should be
placed on the operating floor in order to protect the
cooler sections against damage at the tilting edge and
to ensure a firm footing of the section on the floor during
tilting.
The cooler section should be slowly inserted into
the cooler well, taking care that the resilient seal strips
bed against the gas baffle and that the round-cord
packing is correctly positioned in the groove.
The seal strips, which are resiliently mounted to the
side walls of the cooler section, serve to seal the gap
between the cooler section and the cooler well. In case
these seal strips fail to perform their function, hydrogen
can flow past the cooler section without being cooled.
For this section, the seal strips should be thoroughly
checked for proper functioning.
After the cooler section has been lowered into
position, the wire ropes should be removed and an
alignment check performed at the lower tubesheet.
There must be a uniform spacing between the tubesheet
and the cooler well opening on all sides. The upper
tubesheet should then be firmly bolted.
5
Sealing the Cooler Section at the Lower

Tubesheet
After alignment of the cooler section in the cooler

well and tightening of the flange bolts at the upper
tubesheet, the hydrogen gasket should be inserted.
Note: During operation, the cooler section against
expands in downward direction, requiring a gastight
sliding contact between the tubesheet and the Vee
gasket over the distance due to thermal expansion.
For this reason, the compression ring should not be
tightened excessively, as otherwise the sliding motion
will be impaired and/or excessive contact.
2.5-4100-10550/1
0209E
Turbogenerators
Inspection
The insulation resistance of insulated bearings
should be measured prior to each inspection. The
bearings should then be dismantled and cleaned
thoroughly. Bearing sleeves and shaft journals should
be checked for proper condition. If grooves are detected
the manufacture should be asked for advice whether
BHEL, Haridwar
Bearings
the bearing may be used further. If a low insulation

resistance has been previously measured, the
respective bearing should be inspected thoroughly for
any damage by cathodic action. The inspection
procedure described above should be performed at all
sleeve bearings of the turbine generator.
2.5-5000-10550/1
0209E
Turbogenerators
Inspection
A differentiation is made between a minor, a medium
and a full-scale inspection. A minor inspection includes
measurement of clearances and a visual examination. A
medium or full-scale inspection is automatically assumed
if withdrawal of the rotor is required for which purpose
the entire shaft seals will have to be dismantled and
should be subjected to a close inspection.
After dismantling, all shaft seal components should
BHEL, Haridwar
Shaft Seal
be carefully and thoroughly cleaned. All points subjects

to natural wear should be inspected closely.
Reassembly of the shaft seals should be performed
with utmost care.
During each inspection, a check should be made to
ensure that the seal rings are still sufficiently insulated
from the stator frame.
2.5-6000-10550/1
0209E
Turbogenerators
Inspection
The work to be performed at an inspection is very
difficult to determine in advance. The scope of this work
depends on what defects were detected from the date
of the last inspection. The operating log should be
checked to determine which deficiencies should be
corrected at the inspection.
The following inspection work should normally be
performed :
1
Seal Oil System
for damage or wear. Replace the seals if they are worm

or damaged.
4
The safety valves should be removed and cleaned

with turbine oil. Check safety valves for proper
performance on pressure gauge panel prior to
installation.
Seal Oil Filters

5
The filter to be cleaned should be taken out of service

by changeover to the standby filter.
Remove cover of seal oil filter and complete screen
inserts. Clean screen inserts with a solvent. To do this,
drive out cotter pin and unscrew knurled unit. Base,
fabric-lined supporting cylinder and screen ring can
now be pulled off the magnetic strainer unit. Rinse the
screen inserts with clean turbine oil to thoroughly
remove any solvent residue. Reassemble using new
gaskets.
2
Differential Pressure Regulating Valves
Disconnect the signal pipes from the pressure

regulating valves. Drain the seal oil from the signal pipes.
Disassemble the valve head and valve yoke.
This work should be performed with utmost care so
as to avoid damage to the sliding surfaces. Before
removing the valve yoke, unload the compression spring.
Remove the main bellows and the upper and lower
sealing bellows. Check all sliding surfaces and valve
cones for damage or wear. If damage or wear is
detected on the sliding surfaces, the bushings should
be replaced. Replace the main bellows and the upper
and lower sealing bellows.
3
Safety Valves
Pressure Equalizing Valves
Prior to disassembly of the pressure equalizing

valves, unload the compression springs, disconnect the
signal pipes and drain the oil. Check the sliding surfaces
BHEL, Haridwar
Shutoff Valves and Check Valves
Inspect shutoff valves and check valves for proper

operation. If necessary, replace the valve inserts.
6
Pressure Measuring Points
The signal pipes to the pressure gauges should be

drained and flushed with clean turbine oil.
7
Seal Oil Tank and Float Valves
Remove the seal oil tank cover and check the float
valve for free movement. If the performance of a float
valve is unsatisfactory, the valve should be removed
and replaced.
If sludge has accumulated, the seal oil tank should
be cleaned.
8
Thermostats and Contacts
Check thermostats, contacts of pressure gauges and

pressure switches for proper operation.
All checking, cleaning and reconditioning work
should be performed with utmost care to ensure reliable
operation of the entire seal oil equipment for a prolonged
period of time. When recommissioning the seal oil
system, be sure that all status indications and alarms
function properly. All control gear, safety equipment,
filters, coolers, signal and pressure sensing pipes should
be carefully vented at operating pressure.
2.5-7100-10550/1
0209E
Turbogenerators
Inspection
1
Electrical Motors of Seal Oil Pumps
At the manufacturers works, the antifriction

bearings of the seal oil pump motors are packed with
grease sufficient to give troublefree service for a period
of two to three years. For this purpose, a grease on
lithium-soap base with a drop point above 160C is used.
The period will be shorter under onerous service
conditions or at high ambient temperatures. On expiry
of this period, a thorough cleaning of the bearing interior
and an inspection for wear will be required. This work
necessitates a withdrawal of the armature, followed
by washing the 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 bearings should then be packed with
grease of the same grade, taking care that both sides
of the cages are covered with grease so that an
effective seal is obtained against the ingress of foreign
matter. The unit can then be reassembled. After
reassembly, a check should be made whether the shaft
turns properly in the bearings.
Measure the carbon brush wear on dc motors. If the
brushes are heavily worn, new carbon brushes should
be installed.
Measure the insulation resistances between the
windings and ground with a 500 V megger. If the
insulation resistances does not comply with the related
equipment manuals, the motors should be dried in an
oven at approximately 70C for several hours.
BHEL, Haridwar
Seal Oil Pumps and

Seal Oil Pumps
Disassemble the seal oil pumps. Check whether the

dummy pistons, the screws or the deep-groove ball
bearing are worm. The passages in the casing insert
and the sliding rings should also be checked. The seal
rings and gaskets should be examined for tight sealing
and replaced, if required.
Prior to recommissioning the seal oil system, add a
small quantity of turbine oil via the oil filling plugs on the
seal oil pumps to ensure proper lubrication of the shaft
seal and the necessary sealing of the screws for suction.
3
Bearing Vapor Exhausters
The antifriction bearings of the exhauster motors

normally require no maintenance.
After approximately 8000 operating hours, the
bearing vapor exhausters should be thoroughly
examined. The motor should be disassembled and the
bearings cleaned and packed with new high melting
point grease or replaced by new bearings. Remove the
old grease from the regreasing device and check the
packing washer and seals for wear. If necessary,
replace the packing washer and seals. Be sure to
observe the specified order of the spring washers and
spacers when reassembling the unit. On
recommissioning of the unit, measure the vacuum in the
bearing compartments.
2.5-7120-10550/1
0209E
Turbogenerators
Seal Oil Coolers
Inspection
After isolation of the cooling water inlet and outlet,
the upper water channels should be removed and their
position marked. Use tube cleaning brushes to clean
the tube interior.
Make sure that all deposits in the tubes and water
channels are fully removed. Take care that the protective
coating on the tube surfaces is not damaged during
cleaning, as this would promote corrosion. The drain
and vent holes in the water channels should be checked
for freedom from deposits and dirt. The vent and drain
cocks should be thoroughly cleaned and checked for
proper operation.
If cleaning of the tube exterior should be required,
the tube bundle should be placed into a bath with a
suitable cleaning fluid Cleaning by means of steam using
solvents is also possible. After each cleaning procedure,
the tube bundle should be well rinsed with turbine oil
inside and around the tubes to remove the last traces
of the solvent. Use only new gaskets when
reassembling the seal oil coolers.
For additional details, see separate instruction [1].
Also refre to the following sections

[1] TWA 57 905
Measures to Prevent Corrosion Damage
BHEL, Haridwar
2.5-7130-10550/1
0209E
Turbogenerators
Gas System
Inspection
difficult to determine in advance. The scope of this work
depends on what defects were detected from the date
of the last inspection. The operating log should be
checked to determine which deficiencies should be
corrected at the inspection.
The main purpose of an inspection of the gas system
is to restore a satisfactory gastightness. All pipe
connections of the gas system should be checked for
leaks [1] before the unit is shut down. All leaks should
be marked and corrected during the inspection.
In addition, the scope of inspection work depends
on the intervals between inspections, the scope of the
work performed during the preceding inspection and on
the time available. During a full-scale inspection the parts
listed under items a, b and c should always be replaced.
Depending on the inspection conditions, the following
work should normally be performed.
a) Remove and clean the dust filters in the CO2/H2 purity
b)
c)
d)
e)
transmitter. If required, insert a new sintered bronze

filter.
The throttle element should be unscrewed, cleaned
and reinserted.
Check and, if required, replace the pressure reducer
diaphragms.
Check all valves of the gas system for leaks. If
required, replace the diaphragms and valve inserts.
Check the gas dryer for leaks at the changeover
valve assembly and, if required, replace the gaskets.
Perform functional check of the fan and heater.
Replace the absorbent material of the dryer.
Drain the heat transfer liquid from the CO2 vaporiser.
Disassemble the CO 2vaporiser. Replace old gaskets
with new ones and reassemble the CO 2 vaporiser.
Fill the CO 2 vaporiser with heat transfer liquid until

the liquid level is observable in the riser of the
expansion vessel. Then functionally check the CO 2
vaporiser.
After completion of all inspection work on the gas
system, the gas system and generator should be leak
tested. For this test, the main gas and measuring gas
pipes at the generator should be closed. The waste gas
valves should then be closed, followed by filling the
gas system, including the connected equipment, with
hydrogen or air. During the filling procedure, the valves
at the gas valve rack (except for the waste gas valves)
should be open continuously to ensure that all
components are included in the leakage test. The test
pressure should correspond to the rated gas pressure
of the generator. The air of gas supply should be shut
off when the test pressure has been reached.
Subsequently, the pressure drop in the system should
be monitored for a period of 24 hours. The gas system
can be considered sufficiently tight when the pressure
drop during a 24 hour test with compressed air does
not exceed 0.15 bar. When this test is performed with
hydrogen filling, the permissible pressure drop is 0.57
bar. It should be noted, however, that these values
exclusively apply to the gas valve rack and the
connected pipes up to the next shutoff valve. A check
by means of a leak detector should be performed when
higher pressure drops are observed at the leakage test.
On sealing of the leaks, the leakage test should be
repeated until satisfactory results are obtained.
On completion of the inspection work, the electrical
purity meter system should be calibrated with pure CO 2
and H2.

[1] 2.5 0310
Leakage Tests
BHEL, Haridwar
2.5-7200-10550/1
0209E
Turbogenerators
Inspection
difficult to determine in advance. The operating log
should be checked to determine what faults need to be
corrected.
The following inspection work should normally be
performed after draining of the primary water circuit :
1
1.1 Main Filter

Open the filter housing and remove the insert. The
magnet bars should be taken out of the filter insert.
The filter insert should be brushed and rinsed with a
suitable cleaning agent, using a brush of medium
hardness. After cleaning, blow out the strainer with
compressed air from the clean side for removal of the
dirt retained in the filter cloth.
As filter cleaning agent, only fully demineralized
water, condensate or air should be used, since these
cleaners will not contaminate the primary water.
After cleaning of the individual components of the
filter insert and filter housing, install the insert with new
seals and insert the magnet bars. Reinstall the filter
cover, making sure that the filter insert is tightly seated
and that the cover gasket is properly positioned.
1.2 Fine Filter
The cartridge in the filter should be replaced at each
overhaul[1].
2
Ion Exchanger
Depending on the condition of the ion exchanger
resins, they should be replaced by new or reactivated

resins. The replacement of the resins should be done in
accordance with a separate instruction [2].
3
Valves
Inspect all valves for proper operation.

During a large-scale inspection, the packings of the
valves should be replaced.
4
Level Monitoring System
The probe rods in the primary water tank should be

removed, cleaned and reinstalled using new seals.
5
At each inspection, the transmitters of the

conductivity meter system should be removed, cleaned
according to a separate instruction [2] and reinstalled
using new seals.
6
Controllers and Contacts
Check the thermostats and pressure switches for

proper operation.
All checking, cleaning and reconditioning work
should be performed with utmost care to ensure reliable
operation of the entire primary water system for a
prolonged period of time. After recommissioning of the
primary water system, all control and alarm equipment
should be subjected to a functional test.

[1] 2.4 4740 Primary Water Filters
[2] 2.3 9782 Conductivity in Primary Water System
BHEL, Haridwar
2.5-7300-10550/1
0209E
Turbogenerators
Primary Water Pumps
Inspection
Electric Motors for Primary Water Pumps
After 8,000 operating hours, the bearings of the

electric motors should be removed, cleaned and packed
with high melting point grease. Worn bearing should be
replaced by new ones.
Measure the installation resistance between the
windings and ground with a 500 V megger. If the
insulation resistances do not comply with the related
equipment manuals, the motors should be dried for
several hours in an oven at approx. 70C (160F).
Check the coupling between motor and pump and
replace worn parts.
BHEL, Haridwar
Primary Water Pumps
2.1 Bearings
The primary water pumps are equipped with
lubricated bearings. The oil level in the bearings can be
checked at an oil slight glass. After approx. 3000 hours
of operation, the oil should be changed. For this purpose,
only a good quality oil (SAE 20/30) should be used.
During intermediate inspections, the bearings should
be checked. Worn out bearings should be replaced.
When replacing the bearings, the seal rings should also
be replaced. The bearing caps should be remounted
using new gaskets (0.1 mm = 0.0004 in. thick).
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.
2.5-7320-10550/1
0209E
Turbogenerators
Inspection
The upper water channels should be removed and
their location marked after the cooling water inlet and
outlet valves are closed. The tube bundles should be
withdrawn and the tubes cleaned internally using
special brushes [1]. Deposits on the primary water side
of the tubes should be removed with a water jet. Care
should be taken that all deposits on the tubes and water
channels are completely removed. Take care that the
protective coating on the tubes is not damaged during
cleaning, as this would promote corrosion. If corrosion
or damage to the protective coating is detected, the
effected area should be cleaned and protective coating
reconditioned or replaced. The drain and vent ports in

the water channels should be inspected for freedom
from deposits and dirt. The vent and drain should be
cleaned thoroughly and checked for operation.
For reassembling the tube exterior, the tube bundle
should be immersed in a suitable cleaning agent.
Cleaning by means of steam, with solvent added, is
also possible. The tube interior and exterior should be
well rinsed with water and dried after each cleaning.
Only new gaskets and packings should be used for
reassembly.

[1] 2.3 5003
BHEL, Haridwar
2.5-7330-10550/1
0209E
Turbogenerators
Inspection
Treatment and Cleaning of Pipes

in Primary Water Circuit
General
The pipes of corrosion-resistant resistant chromenickel steel used in the primary water circuit of watercooled generators are welded according to the TIG
method with SAS 2/G, using argon (99.9 %) as shielding
gas.
Any required pipe bends should be made only by
cold bending on the pipe bending machine or pipe elbows
should be welded in.
Q
Treatment of welds
After welding, the welds should be treated as

follows:
Q
Fusion check
(surface penetrant test)
The fusion check to be carried out on each weld
according to the surface penetrant method.
Mechanical treatment or cleaning of pipes tarnished
by welding.
Even when using a shielding gas, the pipes tarnish
BHEL, Haridwar
up to 20 mm from the weld. On completion of the

welding work, the tarnished portions of the pipes
should be cleaned mechanically on the outside and
as far as accessible, on the inside, too. Use only
brushes of corrosion resistant chrome-nickel steel
for such mechanical cleaning work. For grinding
work use only new grinding wheels or wheels that
have been in contact with corrosion-resistant
materials only.
Flushing the pipes welded at the power plant.
Prior to assembly, all pipes welded at the power
plant should be flushed with hot water at 80C or
with Chlorothene NU at ambient temperature.
Following this, all parts should be dried by blowing
them out with water and oil-free compressed air. All
pipe lines not required for immediate service should
be closed at the ends.
Flushing the Complete Piping System
Prior to commissioning the complete piping system

should be flushed in completely assembled condition.
2.5-7381-10550/1
0209E
Turbogenerators
Inspection
1
General
Prior to startup of the turbine-generator, the complete

piping system should be flushed. Any dirty and dust
particles in the system in spite of the extreme care taken
in the installation will thus be retained in the main filter.
It is assumed that all pipework is in clean condition
and that all pipe sections replaced during the inspection
have been subjected to the treatments and checks
specified elsewhere in this manual [1].
2
Q
Q
Q
Q
Check to ensure that primary water pumps are ready

for operation. Heat water by simultaneously placing
both primary water pumps in operation after filling
of primary water circuit.
Flushing the Complete Piping System
stator winding
terminal bushings.
generator main leads (if provided).
generator main circuit breaker (if provided).
Fill system with cold or hot deionate (up to 50C) via

the filler valve in accordance with the instructions for
filling the primary water circuit.
Ensure that pressure in primary water tank does not
exceed the full-scale value of pressure gauges
(MKF91CP001 and MKF91CP501. For this reason, keep
drain valve MKF91AA505 open during filling and flushing
procedures and adjust the filling rate accordingly.
Initial flushing should be performed for 8 to 12 hours
at a water temperature of 45 to 50C. Vibrate all piping
and welds to facilitate removal of dirt.
Then drain all flushing water from the circuit. Open,
clean and reassemble main filter.
Repeat flushing procedure until no dirt particles are
collected in the filter.
Close above components by fitting closure discs.
Preparatory Work
Prior to flushing, the following work should be

performed:
Q
Flushing External Part of

Install bypass pipes between inlet and outlet of
Close all equalizing valve assemblies upstream of

volume flow measuring devices.
Remove all orifices and screens, if provided.
Ensure that tank MKF60BB001 is not filled with resins
and has been drained.
Remove filter element from filters MKF60BT001.
Isolate N 2 supply line and vent gas line by closing
shutoff valves MKF91AA502 and MKF91AA506.
Preparing Primary Water Circuit for Leakage

Te s t
After the last flushing procedure and filter check, all

filters should be reassembled using new gaskets.
Reinstall orifices and screens prior to performing
the leakage test. Remove bypass pipes.
Perform leakage test according to the instructions
given in the turbogenerator manual [2].

[1] 2.5 7381 Treatment and Cleaning of Pipes in Primary
Water Circuit
[2] 2.5 7384 Leakage Test of External Primary Water
Circuit.
BHEL, Haridwar
2.5-7382-10550/1
0209E
Turbogenerators
Inspection
1
General
A leakage test of the external primary water circuit

is required after a major overhaul of the unit. This test
serves to inspect all components of the system for leaks.
2
Preparatory Work
The external primary water circuit is normally cleaned

before the leakage test is performed [1]. Since the test
is restricted to the external circuit, the stator winding
and the terminal bushings with the phase connectors
should be and must remain isolated from the external
primary water circuit by means of closure discs.
During the leakage test, pressure gauge MKF91CP501
in the waste gas pipe should be replaced by a pressure
gauge of accuracy class 0.6 with a range of not less
than 10 bar.
All other pressure gauges and pressure transmitters
with a range of less than 10 bar should be isolated from
the primary water circuit by cleaning the respective
valves.
All shutoff and gas valves in the primary water
circuit should be opened.
3
Filling the Circuit
The circuit should be filled with deionate via the

filler line (shutoff valve MKF60AA504) and properly
vented, making sure that all drain valves have been
closed prior to filling.
Observe water level I the primary water tank during
the filling procedure. Water level in primary water tank
should be approximately 300 mm. Ensure that all water
lines connecting to the primary water tank are filled
Leakage Test of External

with water.
4
Applying the Test Pressure
Admit nitrogen at a gauge pressure of 10 bar to

provide a gas cushion above the water level in the
primary water tank. The test pressure is to be applied
from a nitrogen bottle connected to the gas pipe to the
primary water tank via a pressure reducer. Before
applying the test pressure, close shutoff valve
MKF91AA508 and open shutoff valve MKF91AA502.
Pressure rise in circuit can be read at pressure gauge
MKF91CP501. Close shutoff valve MKF91AA502 when
gauge pressure in circuit amounts to 10 bar.
5
Leak Detection
Inspect all flanged, bottle and welded joints in primary

water circuit as well as the respective shutoff valves
for leaks while maintaining constant pressure. Repair
any leaks detected and repeat the leakage test.
6
Terminating the Leakage Test
The primary water circuit may be considered as

sufficiently tight when no leaks are detected by visual
examination and when no pressure drop is observed at
pressure gauge MKF91CP501 during a test period of 10
minutes (after thermal equilibrium has been reached).
Drain external primary water circuit after completion of
the leakage test, remove all closure discs and promptly
reasonable the primary water circuit.
Place primary water system in operation immediately
after the system has been restored to its previous
condition.

[1] 2.5 7382 Flushing External Primary Water Circuit.
BHEL, Haridwar
2.5-7384-10550/1
0209E
Turbogenerators
Inspection
1
General
The scope of work to be performed during an

inspection depends mainly on the equipment on which
defects have been detected since the last inspection. It
will therefore be necessary to extract from the operating
log all deficiencies to be corrected during the inspection.
In accordance with the inspection schedule [1], the
following inspection work should be performed.
2
Hydrogen Leakage Test
Excitation System
Exciter
see the respective instructions [2].

5
Drying the Windings
After a prolonged shutdown of the exciter, a

reduction of the insulation resistance may be caused
by the formation of a moisture film on the surface of the
winding. Such a moisture film can be removed by drying
the main exciter rotor. This should be done by placing
an air dryer into operation, which was installed as
additional precaution against corrosion.
Prior to removing the hydrogen gas from the

generator casing, the dc field connections should be
leak tested.
To do this, check the coupling between the generator
and exciter and the terminal bolts between the rectifier
wheels with a potable leak detector.
6 Checking the Diodes, Fuses and Rectifier

Wheels
The drive motors of the actuators for the emergency

cooling flaps should be subjected to a thorough
functional test. The drive motors of the actuators for
the emergency cooling flaps should be subjected to a
thorough functional test. Perform the maintenance work
in accordance with manufacturers special instructions.
The filter mats of the makeup air filters should be
cleaned or replaced. To enable their reuse, slightly
contaminated filter mats should be beaten out.
Otherwise, the filter mats should be washed in cold to
lukewarm (30C maximum) suds (e.g. Pril). When placing
the filter mats in the suds, make sure that the air inlet
side points downward. After washing, the filter mats
should be rinsed with clean water.
Dismantling and Cleaning the Exciter
Remove exciter rotor. The coupling flange at the rotor

should be checked both at the guide flange and at the
coupling bolt holes. Check coupling bolts for proper
condition and take dimensions.
Check field connection for gas tightness. To do this,
a cover with top-mounted pressure gauge should be
attached to the coupling flange and sealed gas tight.
The space inside the cover should then be pressurized
at a gauge pressure of 6 bar via the compressed air
connection. With gas tight lead, no pressure drop is
permissible within a period of about six hours.
Any accumulations of dirt in the ventilating air ducts
of the rotor, at the diodes, fuses and heat sinks must be
removed. Cleaning should be done very carefully to avoid
damage to the numerous insulated parts. It is, therefore,
recommended to remove these contaminations with a
brush, cloth (non-linting) and a vacuum cleaner.
Particular care should be exercised when cleaning the
porcelain bodies of the diodes.
4
Measuring the Insulation Resistances of the

Windings
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,
BHEL, Haridwar
For details, see the respective instruction [3].

7
Emergency Cooling and Makeup Air Filters
Bearing and Labyrinth Rings
Check the insulation of the bearing, pipe connections

and, labyrinth rings. For details see the respective
instruction [4].
If the bearing babbitt is found grooved, our erection
engineer should be consulted regarding further use of
the bearing.
The strips of the labyrinth rings should be checked
for proper condition and replaced, if required.
9
Checking the Contact Pins and Plug-In Socket

Strips
The contact pins and plug-in socket strips should be

checked for proper mechanical condition. If the silver
2.5-9000-10550/1
0209E
plating of the contact pins shows signs of arc erosion,

the contact pins require reconditioning and re-plating. A
check should be made to ensure that the projecting
contacts of the plug-in socket strips are spirally
distributed on the entire circumference of the contact
sleeve.
10 Checking the Condition and Performance of
the Ground Fault Detection System
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. After complete
assembly of the exciter, the complete ground fault
detection system should be subjected to a functional
test.
11 Cleaning the Exciter Coolers
Remove the coolers and perform the same cleaning
procedure as described for the hydrogen cooler.
1
2
3
Insulation
Contact sleeve
Plug-in contact strip
Fig. 3
Section Through Contact Sleeve
Also refer to the Following Information
2.5-9000-10550/2
0209E
[1] 2.5 1090 Inspection Schedule Excitation System

[2] 2.5 3300 Insulation Resistance Measure-ments on
[3] 2.5 9010 Checking the Rectifier Bridge Circuit
[4] 2.5 0300 Checking the Bearing and Shaft Seal
Insulation
Turbogenerators
Inspection
Regular inspection work should include checking the
insulating sections, between the diode heat sinks and
rectifier wheels [1]. Leakage paths may be formed at
these points as a result of dirt deposits, rendering the
fuses connected after the diodes ineffective in the event
of a failure.
In the event of a diode losing its blocking capability,
an interruption of the respective bridge arm by the fuse
Excitation System
Checking the Insulation Resistance
of Heat Sink Insulation
would then no longer be ensured, resulting in a phaseto-phase fault in the main exciter circuit.
After removal of the fuses, the insulation resistance
between points a and b or a 1 and b 1 respectively, can
be measured by means of a megger, applying a voltage
of 500 to 1000V. The insulation resistance between the
heat sink and rectifier wheel should not be less than 10
M ohms.

[1] 2.5 9011 Checking the Insulation at Rectifier
Wheels
BHEL, Haridwar
2.5-9010-10550/1
0209E
Turbogenerators
Excitation System
Checking the Insulation at Rectifier Wheels
Inspection
10 1
Current path
1
2
3
4
5
6
7
8
9
10
Fuse
Heat sink
Diode
Rectifier wheel (-ve polarity)
Terminal bolt
Tension bolt
Hot air outlet
Rectifier wheel (+ve polarity)
AC lead
DC lead
Detail X
4,8
BHEL, Haridwar
2.5-9011-10550/1
0209E

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OPERATION & MAINTENANCE

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

Stator End Shields . . . . . . . . . . . . . . . . .

Tripping Scheme for Generator Electrical

Seal Oil System

Measuring Devices and Supervisory

Primary Water System

Voltage and Frequency Deviations . .

Supervision of Generator during Standstill

Seal Oil Pumps . . . . . . . . . . . . . . . . . . .

Maintenance and supervisionIntroduction. . . . . . . . . . . . . . . . . . . .

Leakage Tests of Generator and Gas System 2.5-0310

This manual contains information on

maintenance personnel are fully familiar with

Notes on the Use of the Mannual

The turbogenerator instruction manual consists

For the user of the manual, the identification

Each section contains a number of separate

Manual section number

The manual contains a Table of Contents together

2.0 - 0040 - 00009 / 1

The Turbogenerator set has been designed and

Operation Beyond Contract

increase in Copper temperature, thermal expansion

Safe Disposal of Turbogenerator Items

exposure of fluoro-elastomers like O-rings, rubbers etc.

The materials, which are scrapped during

Guidelines given in the following paragraphs can

May be disposed as scrap material for recycling and

A proper system of waste disposal should also be

These items can be disposed/recycled/ reused as

Generator is manufactured mainly from three

To be recycled after cleaning as far as possible. After

Residue of fluoro-elastomer products, obtained by

Rating Plate Data for Generator

Project name: NCTPP Stage-II DADRI Unit-1

BHARAT HEAVY ELECTRICALS LTD

Type: THDF 115/59

Coolant: Hydrogen & Water

Gas Pressure : 3.5 Kg/cm2 (g)

Spec. IS: 5422

Generator Cross Section

General Outline Drawing

Exciter Outline Drawing

General Design Features

Design and Cooling System

The two-pole generator uses direct water cooling

The following additional auxiliaries are required for

The heat losses arising in the generator interior are

Hydrogen Cooling Circuit

The hydrogen is circulated in the generator interior

For direct cooling of the rotor winding, cold gas is

Cooling of Stator Core

For cooling of the stator core, cold gas is admitted

the heat from the core. To dissipate the higher losses in

Primary Cooling water Circuit in the Generator

The treated water used for cooling of the stator

cooled water flow is divided into two flow paths as

Generator Cooling Gas Circuit

General Design Features

The stator frame consists of a cylindrical section

General Design Features

Stator bars, phase connectors and bushings are

Micalastic High-Voltage Insulation

O&M Manual 500 MW TurboGenerator

O&M Manual 500 MW TurboGenerator