AMERICAN NUCLEAR INSURERS ANI/MAELU TECHNICAL GUIDELINE, Electrical Generators and Generator Support Systems Revision 0 AMERICAN NUCLEAR INSURERS TOWN CENTER, SUITE 300 S 29 SOUTH MAIN STREET WEST HARTFORD, CT. 06107-2445 (203) 561-3433 August 1994 (Our inspections, and reports and other communications we issue, are for our insurance purposes only. We do not undertake to render any service to or on behalf of our Insureds or others orto determine or warrant the safety or healthfulness of any property or operation, or compliance with any law, rule, regulation or specification. We do not authorize anyone to rely on us for the safety of persons or property ‘This Guideline refers to some kinds of damage for which no coverage is afforded under the ANIMAELU policies and which are therefore not of direct insurance interest to ANVMAELU. However, in certain situations they could lead to other kinds of loss or damage which may be covered, and they are mentioned for this reason,ANUMAELU Generator Guideline August, 1994 Revision 0 Table of Contents Page General Background i Insurance Risk Significance vi Inspection Guidelines and Loss Prevention Recommendations 1 Main Generator 1 0. Generator Support Systems 5 A. Introduction 5 B. Hydrogen Cooling System 7 C. Stator Cooling Water 9 D. Hydrogen Seal Oil 10 EB. Isolated Phase Bus Duct Cooling 12 References 15ANIMAELU Generator Guideline August, 1994 Revision 0 General Background Electrical Generator failure data (Ref. 1) indicates the following mechanical and electrical root causes of generator problems: Design or manufacture 45% Operational 33% Windings 18% External 4% ‘The location of generator damage is as follows: Stator windings 33% Rotor windings B% Stator core 3% Casings 3% Other rotating components 38% Design or manufacturing faults may result from routine design and material faults as well as limitations associated with the state of the technology at the time of manufacture, particularly winding insulation. Fastening methods of internal components and retaining rings, fan blading, bearings and end turns are also common locations of mechanical failure. ‘The type of electrical failures that are most common result from insulation overheating and surges due to lack of proper protective devices. Mechanical failures are more numerous than electrical failures (Ref. 2), but either type can result in a total loss of the generator and may result in a fire. Operational faults include both operator error and lack of proper maintenance, while most winding faults (rotor and stator) are attributed to insulation breakdown. The condition of the generator should be constantly monitored and appropriate action should be taken to prevent or minimize possible damage. Abnormal operating conditions can be identified using the following parameters. Ideally, these parameters should be periodically monitored and trending accomplished by the system engineer. Increased surveillance should be accomplished when monitored parameters exceed normal ranges. Required action limits should be established and procedurally defined. Instrumentation should be periodically calibrated and trip devices (if provided) functionally tested. ‘The parameters to be monitored are: + Stator voltage and current + Field voltage and current + Megawatts and megavars + Power factor + Vibration (end turn, bearings) + Field ground detection + Field temperature Page iANIMAELU Generator Guideline August, 1994 Revision 0 + Hydrogen pressure, moisture and purity + Dew point + Differential pressures (stator water to H, gas, H; cooler cooling water to Hy gas, seal oil to H, gas) + Hydrogen temperature + Cooling water temperature to and from hydrogen coolers + Hydrogen temperature to and from coolers + Frequency + Stator cooling water flow, pressure and temperature (liquid cooled stator) + Stator RTD temperature + Stator cooling water conductivity + Stator slot gas discharge temperatures (gas cooled stator) In terms of operational events, generator problems are the fifth most prevalent cause of nuclear plant outages. North American Electric Reliability (NERC) Council data (Ref. 3) for the years 1985-1989, shows that on average, there were 0.35 generator related forced outages per year at nuclear units. This total of 0.35 is broken down into the categories: generator, 0.06; exciter, 0.08; cooling systems, 0.08; controls, 0.09; and miscellaneous 0.04. The other systems causing high numbers of forced outages are: steam turbine, 0.73, reactor coolant, 0.78, feedwater, 0.46, and steam generators and supply, 0.39. The total number of forced outages per unit was 4.8 during this period. Updated information for the years 1987-1991 (Ref. 4) shows a slight drop in forced outage rate due to generators to 0.33, but does not include a breakdown by sub-system, ‘The NERC data is also broken down by type and size of reactor. When examined in this manner, the plants with the most generator problems are the large PWRs and the mid size BWRs (see table). Generator Forced Outage Rate By Type and Size of Unit (Years 1987 - 1991) Reactor Size Reactor Type 400-799 MW 800-999 MW 1000 + MW BWR 0.19 0.41 0.22 PWR 0.20 0.29 0.41 Nuclear plant electrical generators are complex machines which produce considerable heat and large magnetic, vibrational, and torsional forces. To protect against the excessive heat and resultant damage to insulation, multiple cooling systems are necessary. Hydrogen cooling is typically used for the rotors and may be used for stators. Water cooling of stators is used to Page iiANIMAELU Generator Guideline August, 1994 Revision 0 attain higher heat transfer capabilities. The large forces produced require the use of high strength materials, supports and braces, especially at the stator end windings, and special alloy retai rings at the rotor end turns. Electrical protection throughout the generator is provided by high strength, high resistance insulation and multiple sensing systems which detect insulation breakdown and faulting. Stator fault protection, turn-to-turn or phase-to-phase, is provided by stator ground fault protection or differential relays. Stator bar insulation is a hard thermosetting resin containing compacted mica platelets and flakes with a glass cloth backing for mechanical strength. An overview of generator hazards and protection features is presented in Ref. 2. ‘The major hazards are: Most generator electrical hazards (transients and faults) cause sudden increases in stator currents with subsequent excessive temperature. Also common to these hazards are severe mechanical shocks caused by increased mechanical (magnetic) forces which could cause damage to end turns, blocking, winding insulation and possible shocks to the turbine-generator coupling and shaft. Stator Overheating is caused by overload, cooling system failure, or short-circuiting. Overheating will deteriorate insulation and lead to faulting. As protection in hydrogen-cooled stators, resistance temperature detectors (RTDs) are used to measure conductor temperatures and hydrogen gas temperatures. Core monitors (ionization detectors) are also used to detect insulation breakdown caused by thermal decomposition of organic materials by sensing particulates in the normally clean continuous hydrogen sampling stream. In water-cooled stators, thermocouples are used to measure stator coil water inlet and discharge temperatures and detect differences between the top and bottom coils. Stator Ground Faults are caused by deteriorating stator winding insulation either by aging, overheating, or mechanical deterioration such as insulation migration or stator bar vibration, Overvoltage relays with time delays to prevent trips on transients are typically employed for stator ground fault protection. Stator Phase-to-Phase Faults between any two phases in the winding can result in extensive damage to the winding and stator. ‘These faults are usually caused by mechanical damage to insulation similar to that causing ground faults or by vibration at the end windings. Protection is provided by differential relays which detect current differences between the neutral and lead lines of each phase. Field Ground Faults can cause electrical imbalances. One such fault will cause no problems since the circuits are isolated, but two faults may cause a short and cause unbalanced radial forces in the rotor which are detected by the bearing vibration monitors. When a double ground exists, part of the field windings will be shorted through the shaft causing magnetic or thermal imbalances. Loss of field detection can Page iANIMAELU Generator Guideline August, 1994 Revision 0 not be depended upon to detect double rotor grounds or shorted rotor turns because these may result in only a small change in reactive power output which would be compensated for by voltage regulation. A single fault can be detected by a field ground voltage relay and alarm. It is advisable to identify and correct the trouble. Loss of Field or excitation would cause rotor overheating unless the generator output breakers are opened expeditiously. The degree of heating is a function of the initial load, the manner in which the field is lost and overspeed (generator operation as an induction motor). Armature current increases as terminal voltage decreases and is accompanied by high rotor currents. High rotor currents result in high temperatures particularly across the wedges and retaining rings. Overheating of the end portions of the stator core may also result (low excitation). A loss of field relay should be provided which will remove the generator from service by tripping the generator output breakers open. Unbalanced Armature Current produces negative sequence currents in the stator which induce circulating currents on the surface of the rotor and in the rotor wedges. The currents are at twice the frequency (120 Hz), and magnitude depends on the degree of imbalance and armature currents. Localized heating is produced at the wedge joints, retaining ring fits, and rotor surfaces. These should be protected against by a negative sequence relay (current imbalance). ‘Synchronization Errors occur when the generator is out of phase with the system. These cause high torques in the stator which can lead to extensive mechanical damage depending on the degree of phase error. This is protected against by a synchronism check relay. Generator design standards do not require that a machine be able to withstand the currents and mechanical forces created during incorrect phasing or synchronizing, therefore it is important that this relay be periodically surveyed and maintained. Mechanical Hazards Retaining Rings are highly: stressed components which are subject to loosening at operating speed or fracturing due to stress corrosion cracking (18Mn-SCr) which may lead to insured loss. Water leakage can cause stress corrosion and needs to be guarded against by inspection of fittings, maintaining of differential pressures and moisture elimination. Every effort should be made to prevent exposure of 18Mn-SCr retaining rings to moisture or high dew points when the generator is operating, shutdown or during dismantle. To avoid stress corrosion cracking failure generator manufacturers recommend that 18 Mn-SCr retaining rings be replaced with 18 Mn- 18Cr retaining rings. Fatigue crack growth rates are also reported to be lower with 18Mn-18Cr retaining rings. Inspections should be used to detect relative motion or evidence of pitting and corrosion cracking. The two most common methods of NDE for retaining rings are fluorescent dye penetrant and ultrasonic testing. To examine the interior surface of the retaining rings with fluorescent dye penetrant, removal of the rings is required. Page ivANIIMAELU Generator Guideline August, 1994 Revision 0 Cooling Fan Fractures caused by resonant vibration have occurred. Blade and attachment degradation or discontinuities should be looked for during periodic NDE (magnetic particle or dye penetrant examinations). Distortion of the gas flow passages should also be evaluated. End_Windings bracing or supports can be loosened and weakened by generator vibration and forces caused by system faults. This weakening can then cause insulation wear leading to more severe faults. Looseness should be looked for during inspections. Operational vibration monitoring is also provided or backfit to some designs. Hydrogen Seals should be thoroughly inspected during dismantle inspections of the generator. The seal should be completely disassembled, cleaned and refurbished as necessary. Reassembly should ensure proper axial and radial clearances. Stator Winding Leaks have occurred in liquid cooled generators (usually detected during high pot testing) resulting in water penetration of the stator bar groundwall. Vendor recommendations pertaining to capacitance mapping tests of the end arms of each box on both ends of the generator during dismantle inspection should be adopted. Periodic vacuum decay and pressure decay testing of the winding circuit are also recommended. A weekly check of hydrogen flow in the stator cooling water tank vent should also be adopted. Consideration needs to be given to removing the generator from service if hydrogen flow exceeds 200 ft/day (measured at the stator cooling water tank vent). In a recent article on generator refurbishment, Moore and Ulm (Ref. 7) list the major issues facing the generator owner. The issues ar + Stator insulation degradation + Rotor insulation degradation + Stator end winding looseness + Stator core looseness + Rotor tooth top cracking + Rotor copper dusting + Retaining ring stress corrosion cracking Page vANIMAELU Generator Guideline August, 1994 Revision 0 Insurance Risk Significance ‘The main electrical generator represents one of the most highly valued insured individual pieces ‘of equipment. Improper or inappropriate operation, maintenance, or testing can result in high dollar losses due to damage. Hathaway (Ref. 5) lists a number of U.S. utility generator losses both for nuclear and fossil plants, The nuclear plant events are: Monetary Loss (Million $, Date Event Description Corrected to 1993) 1986 Phase to ground fault in stator windings. 8.60 Surplus stator used. 1984 Electrical fault caused severe damage. 12.00 Generator completely rewound. 1979 Generator stator damaged 8.30 This same reference lists very significant fossil unit losses in the U.S which included: an explosive hydrogen ignition, an operational error which isolated the generator from the distribution system, a maintenance error on a hydrogen seal oil filter which led to a fire, and two retaining ring failures. Total damages for these events were estimated to be $140.7 million in 1993 dollars. Two recent foreign nuclear plant events also reported by Hathaway are a 1992 hydrogen fire at a plant in France and a motorization event in the Ukraine which also caused Generator failures which resulted in insurance losses include: Date Event Description 1976 Seal oil entered generator during startup. Insulation breakdown. 1983 Stator wedge contacted rotor and shorted, carbon residue contaminated all stator cooling ducts, rotor rewound. 1986 Internal fault caused checking, arcing, with carbon and water found. Page viANIMAELU Generator Guideline August, 1994 Revision 0 Several other large damage events have occurred, but were under the policy deductible. These events included: Date 1980 1985 1988 Event Description Loosening of core laminations from vibration caused ground fault, Generator ground damaged insulation, requiring major rework. Ground fault in C-phase windings caused by moisture permeation. Some additional (more recent) events include: Date 1990 1990 1991 Event Description Excessive end tum vibration caused failure of the stator cooling water inlet header box with generator tripping on the running ground fault relay. Testing showed a low natural resonant vibration frequency. Generator synchronized out-of-phase due to breaker closure malfunction. A turbine overspeed event with blade separation and severe vibration caused failure of generator hydrogen seals and seal oil. Ignition followed and lasted for about 20 minutes. Page vitANIMAELU Generator Guideline August, 1994 Revision 0 Inspection Guidelines and Loss Prevention Recommendations IL Main Generator General A comprehensive review of main electrical generator performance should be periodically conducted to including: A. Instrumentation calibration reports Electrical test reports Generator maintenance repair/overhaul reports Circuit breaker and relay maintenance, calibration, and coordination reports Infrared thermal imaging reports Non-destructive examination test reports Technical information bulletins Work requests Surveillance test results for protective systems rroO™moo® Operating Inspections These should include the generator output breakers used for synchronization of the generator as well as associated instrumentation used by operators to synchronize the unit (as applicable). Periodic inspections should include: + A visual inspection of the overall installation and operation of the generator, generator protection system and associated circuit breakers. + A check of instrumentation for loading, temperatures, pressures and vibrations. + Identification of any unusual noises and/or vibrations. + Areview of general housekeeping in the surrounding area, Evidence of excessive dirt, dust, moisture, oil, fumes or inadequate ventilation should be noted. + A condition check of foundation and hold-down bolts. + A check for evidence of sparking or chattering of brush assemblies, if applicable. + An inspection for evidence of sparking and wear of slip rings. + Monitoring of the lube oil system (pressure, temperature and flow). Page 1ANIMAELU Generator Guideline August, 1994 Revision 0 + Evaluation of oil condition. + Evaluation of seal oil, stator cooling and hydrogen cooling (pressure, temperature and flow). Control valves should be calibrated in accordance with a formal program and subject to periodic preventative maintenance. + A check that calibrations of protective devices and instrumentation are up to date. + Manufacturer's operating parameters should not be exceeded. + Installed protection for a specific generator (e.g., circuit breakers, relays, fuses) should be tested periodically in accordance with a formal program. Dismantle Inspections The main electrical generator should be internally examined every five years, not to exceed three refueling outages. For a complete inspection, the end bells and the rotor should be removed from the stator. Care should be exercised during rotor removal and replacement to avoid damaging core punchings, stator windings, bearings, collectors, rotor fans, bearing journals or retaining rings. The rotor should be protected from moisture and a tool/materials control policy utilized to prevent foreign material from being left in the generator. Enclosed environments should be dehumidified and fire resistant. Since tool/material control is considered common practice, formal procedures do not provide significant added assurance to the insurer. The ANI/MAELU Account Engineer is available to evaluate tool/material control during site visits timed to evaluate the overall condition of the generator. A check for loose or missing stator wedges. Examination for burns, wear, or unusual igns of damage. A check of loose coils in the slot. + Evidence of moisture, dirt, abrasions, oil or grease on the stator (armature) winding or main terminal connections should be noted. Stator structural parts should be inspected for evidence of hot spots or damaged punchings. Insulated bolts should be tested for deterioration, Verification of clamping fixture tightness, should also be performed. + Accheck of insulation surfaces for cracks, flaking, powdering, tape migration and signs of corona. + Inspection of blocking ties and coil support rings in the stator. + Inspection of stator iron for hot spots or mechanical damage. + Inspection of stator for loose through-bolts or core iron. + A bearing check for effects of wear, temperature and/or lubrication. Page 2ANIMAELU Generator Guideline August, 1994 Revision 0 Shaft ground testing. Fan blower non-destructive examination (NDE) and proper installation. Boroscopic examination of the shaft performed per manufacturer's requirements with review of results. Retaining rings and end discs non-destructive examination (NDE) and inspection for evidence of moisture, stains, pitting and hot spots. 18 Mn-SCr retaining rings should be completely examined (interior and exterior surface) or replaced with 18 Mn-18 Cr retaining rings. If inspections are performed: + Perform complete ring inspections every 5-6 years, + After inspections, repair rings so that no cracks remain (engineering evaluations may be needed to ensure ring repairs will not impair ring integrity). + Reinspect rings after repair work. + Keep rings free of moisture (high dew points) and corrosive materials at all times (operations, shutdown, dismantled long-term storage, painting, etc). An examination for hot spots, movement or distortion of field coils and end winding blocking on the rotor should be performed. Ventilation ducts, wedging and contact surfaces between wedges, retaining ring and rotor body should be examined. Rotor surfaces such as journals and coupling surface should be inspected for wear or pitting. The collector rings and field leads should be cleaned and inspected and hydrogen seal integrity verified. Check the shaft for scoring; rubbing, discoloration, excessive wear and oxidation. A coupling check for elongation or gauling of bolt holes and inspection for cracking between bolt holes. The rotor should be properly laid up, with proper protection from moisture and contaminants upon removal. Special protection from moisture should be taken when the rotor is removed from the generator. Maintenance performed on generator main leads per manufacturer's recommendations. Materials handling equipment should be functionally tested and should meet specifications for the lifts to be performed. Page 3ANI/MAELU Generator Guideline August, 1994 Revision 0 + The stator lead box and terminal bushing should be thoroughly inspected for cracks and looseness. Cooling passageways should be visually inspected and signs of deterioration (if any) of insulation and blocking evaluated. + A complete inspection of hydrogen seals should be conducted. This includes dismantle, cleaning and refurbishing or replacement (if necessary). Shaft and seal ring wearing surfaces should be carefully inspected for pitting, alignment and wear. + Bearing babbitt surfaces should be inspected and bonding verified. ‘The assembly should be checked for tightness and alignment. + All generator monitoring and protective instrumentation should be checked and calibrated (as necessary). + The hydrogen gas system including temperature control valves(s), dryers, core monitors and control equipment and alarms should be inspected and/or functionally checked and adjusted (See Section I1.B). + The stator liquid cooling system including pumps, temperature and pressure control valves, ion exchangers, and heat exchangers should be inspected, cleaned and preventatively maintained. The entire system should be functionally tested, including instrumentation checks/calibrations with alarm verifications (See Section II.C). + The hydrogen seal oil system including pumps, filters, heat exchangers, pressure reducing and/or regulating valves, float trap, defoaming tanks, vacuum tank etc. should be inspected. The entire system should be functionally tested including instrumentation checks/calibration with alarm verification. Automatic features to maintain seal oil pressure (pump starts - backup regulators) should be functionally tested (See section II.D). + The isolated phase bus duct cooling system including fans, motors, and heat exchangers should be inspected. The entire system should be functionally tested including instrumentation checks/calibrations with alarm verification (see Section I.E). + Alignment checks should be performed if the 1 disassembly. ignment was altered during Electrical Te The following electrical tests should be conducted on the main electrical generator every refueling to verify insulation performance, winding, and other structural integrities. Resistance of windings - a general guideline for minimum insulation resistance values = | megohm per thousand working volts + one megohm @ 40° C using a 500 volt test potential (minimum is one megohm). Page 4ANIMAELU Generator Guideline ‘August, 1994 Revision 0 Insulation Resistance - a rule of thumb is that each 10° C rise in insulation temperature reduces resistance by half. A reference value for shellac insulation is one megohm per KV of operating voltage. DC _Commutator Resistance Values - A bar to bar measurement of resistance which tests for shorted turns. Readings should be uniform from bar to ba Dielectric Absorption (of windings) - A curve of resistance vs time. A constant test potential applied for 10 or 15 minutes. This test is to detect possible grounds and assess the level of contamination and moisture. The resistance of a clean, dry winding will continue to rise as the test potential is maintained becoming steady after approximately 10 minutes. A wet or dirty winding will reach steady state value sooner. ‘The ratio of the 10 minute reading to the | minute is called the Polarization Index. Polarization Index - Minimum values are: 1.5 for Class A insulation (organic) 2.0 for Class B insulation (inorganic) Potential Tests - In addition to the above, the high pot may be performed. This is a severe go-no-go test which may be destructive and which proof tests insulation but generally does not measure leakage current. Fire Protection Fire protection guidelines for nuclear plant turbine generator sets are presented in Section C.1.1 of the ANI Fire/All-Risk Guidelines. Page $ANIMAELU Generator Guideline August, 1994 Revision 0 II. Generator Support Systems A. Introduction ‘The generator support systems are integral components required for proper and reliable ‘generator operation. These systems generally include: + Hydrogen gas and associated hydrogen cooling + Stator cooling water (liquid cooled stators only) + Hydrogen seal oil + Isolated phase bus ducts and associated cooling + Generator excitation (voltage regulation) Generator support systems are designed to operate at varying differential pressures. The seal oil system operates at the highest pressure as its function is to assure the hydrogen cooling gas does not leak out at the sealed rotor penetrations of the generator. Additionally, the system seals moisture and air out of the generator. This is important for both generator cooling, maintenance of hydrogen purity, moisture control and fire prevention. Caution should be used in setting the seal oil pressure regulating valve to ensure that neither an overpressure nor underpressure condition exists relative to generator gas pressure, A seal oil overpressure condition results in oil flow past the seal rings on the generator rotor into the generator. The generator is typically equipped with liquid level detectors that annunciate alarms on high level (il intrusion into the generator due to overpressure or water leakage due to tube failures in hydrogen coolers or stator cooling water leaks). An underpressure condition results in hydrogen leakage into the atmosphere surrounding the generator and a potentially explosive/flammable environment can result. Indicators and alarms for generator hydrogen seal oil pressure annunciate on underpressure. Seal oil overpressure is detected using level switches indicating oil leakage into the generator. Operation of the generator without an operating seal oil system is prohibited due to the inability to maintain hydrogen pressure for cooling and lubrication of the hydrogen seal and hydrogen leakage past the generator seal resulting in an explosive/flammable environment. The hydrogen gas system should operate at a slightly lower pressure than the seal oil system. Forced circulation of hydrogen is accomplished by rotor mounted fans. Generator electric power output is proportional to hydrogen pressure (cooling) and power factor. A generator capability curve provides design generator operating parameters for various hydrogen gas pressures inside the generator. Operation of the generator at significantly reduced hydrogen pressures is against manufacturer's recommendations. In general, operation in excess of generator capability curves causes conditions which may exceed design. The purity of the hydrogen gas is also a limiting factor to generator operations. Hydrogen purity should be maintained above 98% for optimum thermal efficiency (90- 96% is generally allowable). Insulation deterioration is detected with a properly Page 6ANIMAELU Generator Guideline August, 1994 Revision 0 operating generator core monitor which continuously samples the hydrogen environment in an operating generator. The core monitor uses an ionization detector to detect insulation breakdown. Protection of the generator from moisture is imperative to prevent detrimental effects on insulation and highly stressed metal parts and components (fans, retaining rings). Sources of moisture are typically hydrogen cooler leaks, water vapor entrained in seal oil and hydrogen, poor maintenance during disassembly, and stator cooling water leaks, With hydrogen temperature below the dew point (unit shutdown) condensation will occur in a generator having a high water vapor content. Generators designed with liquid cooled stators employ a stator cooling water system. Low conductivity cooling water is supplied to the stator windings and the rectifier banks in the exciter. The operating pressure of the stator water system should be lower than the hydrogen gas system. This prevents water leakage into the generator in the event of a leak developing internal to the generator frame. Generators are designed so that the normal leakage path would be hydrogen gas into the stator water cooling system. Operation of a water cooled generator stator is not recommended without an operating stator cooling water system. Typically a generator runback and/or trip occurs on a low pressure or low flow condition. The isolated phase bus duct system isolates the three AC phases of the generator and connects the phases to transformers (main transformer for distribution to offsite loads, auxiliary transformer for distribution to inplant loads and generator protective metering transformers) for voltage adjustment and power distribution. ‘The system typically is equipped with forced air ventilation (closed or open loop) with heat exchangers cooled by closed cooling water or nonvital service water for heat removal. Large commercial generators are typically limited in generator electrical power production in the event of a loss of bus duct ventilation or cooling. Limiting components may include the bus ducts, main transformer or auxiliary transformer. The generator excitation system typically provides automatic and manual voltage control under varying reactive/inductive electrical loading. This is accomplished by furnishing direct current (or rectified AC) to the rotating field windings thereby controlling generator output voltage and power factor. Generator capability at varying hydrogen pressures and power factors (leading and lagging) is limited by field heating, armature heating and armature core end heating. Stator cooling water is used for rectifier and high voltage bushing cooling in some commercial installations. Hydrogen Cooling System The hydrogen cooling system is used to remove the heat produced by generator current flow. Advantages of using hydrogen include lower windage friction losses, superior coolant properties resulting in 20% less generator structural material, and a clean, dry operational atmosphere preventing insulation oxidation and moisture induced arcing. The disadvantages of using hydrogen are its explosive/flammable Page 7ANIMAELU Generator Guideline August, 1994 Revision 0 potential when mixed with air and due to its low density, high leakage potential ‘These disadvantages require makeup, periodic leak testing, and operational care when purging or adding hydrogen to the generator. Operations, surveillance, and periodic maintenance of the hydrogen cooling systems require qualified personnel using approved procedures and calibrated equipment and instruments. Because of the high hydrogen leakage potential: + Periodic hydrogen leak testing should be performed, and + Hydrogen leakage rates should be tended and evaluated (especially after dismantle inspections). Because of the high potential for explosive/flammable concentrations during hydrogen/air purges: + Gas exchange evolutions should be procedurally controlled and performed by qualified personnel, + A calibrated, properly operating Hair/CO, analyzer should be used to monitor vent paths to determine atmospheric conditions within the generator, and + The analyzer should be calibrated with known concentrations of H,/air/CO, prior to gas exchange evolutions. Because of the potential for hydrogen cooler tube wear and control valve degradation: + Hydrogen cooler performance should be evaluated periodically and trended to determine the need for cleaning/maintenance. + The hydrogen coolers should be periodically cleaned and subjected to NDE evaluations with NDE results tended. The exterior of the tubes should be inspected for lead carbonate deposits which are symptomatic of excessive moisture in the hydrogen. + The hydrogen cooling water temperature control valve (and actuator) should be periodically maintained and tested. ‘This component should have a demonstrated history of reliable operations during steady state operation and variations in generator load. + Hydrogen cooler cooling water flow rates should be operated at design flows to prevent tube corrosion and fouling (low flow) and tube erosion (high flow) which may lead to insured loss. Because of the potential for moisture to enter the hydrogen system: Page 8ANIMAELU Generator Guideline August, 1994 Revision 0 (NOTE: The most limiting situation occurs with the generator coldest and at design pressures. Allowable dew points are specific to each generator and environmental/climatic conditions.) + Hydrogen cooler temperature control valve operation should be set to maintain generator cooling gas relative humidity at the metal surfaces below 40%. + The hydrogen dryers should receive preventive maintenance on a regular frequency. Hydrogen dryers are considered an important system especially when supporting generators with 18 Mn-SCr retaining rings. + Floating a hydrogen bottle or even the entire hydrogen bank on the generator through a pressure regulator is not the preferred arrangement from an insurance perspective. The preferred arrangement is to normally makeup for hydrogen leakage from the valving that is outdoors at the hydrogen storage facility. Advantages to this include recording the delta pressure, recording consumption which would result if leaks are in the system, and in the event of a generator hydrogen fire, the source is isolated outside the fire zone. + During an outage, when the generator is open for maintenance, a blank flange should be inserted or a spool piece should be removed in the hydrogen supply line to the generator. This ensures hydrogen can not leak into a generator where it could cause an explosive mixture. + Annunciator inputs associated with the hydrogen dryer(s) should be functionally tested and calibrated including annunciator verifications. + There should be annunciator procedures for each annunciator input outlining operator actions in response to abnormal operating conditions. + Instrumentation monitoring hydrogen dryers’ operating parameters should be calibrated on a routine basis. + Operator rounds should include verification of normal operations including channel checks of instruments (where possible). To ensure adequate operational reliability of the hydrogen cooling system; * Local and main control room annunciator inputs and indicators should be functionally tested and periodically calibrated including annunciator verification. + Operator rounds should include verification of normal operations including channel checks of instruments (where possible). Page 9ANIMAELU Generator Guideline August, 1994 Revision 0 + Hydrogen pressure, purity, and the core monitor should be periodically checked during operator rounds. These parameters should be alarmed at a constantly attended location (control room). C. Stator Cooling Water The stator cooling water system provides cooled, demineralized and filtered water to the generator for removal of heat from the generator stator. The system is required for operation of generators employing a liquid cooled stator design. The system is closed loop with closed loop cooling or non-vital service water used as the ultimate heat sink via heat exchangers. Loss prevention considerations address system failure scenarios that could threaten design operating parameters for the generator. These include inadequate cooling, conductivity excursions, and leakage of stator water into the generator. Periodic evaluation and trending of stator water makeup should be conducted to enhance leak detection capability. + The temperature and pressure control valves and actuators (if provided) should be subject to periodic preventative maintenance. Stator water pressure should be maintained in the generator below hydrogen pressures. Cooling water to the stator cooling heat exchangers should be maintained at lower pressure than the stator water. This ensures that upon a tube leak stator water leaks to the cooling water side of the heat exchanger. The level switch in the stator water tank would annunciate a low level due to the tube leak. If leakage of cooling water to stator water occurs, conductivity excursions will occur and should result in alarms. + All annunciators and indicators (local and control room) should be periodically calibrated, and functionally tested including alarm verification. + There should be annunciator procedures for each annunciator input outlining operator actions in response to abnormal system operations. + Operator rounds should include verifying the following parameters for normal system operation. (Including channel checks of instruments where possible). Examples include: Flow Conductivity Discharge pressure Filter status and differential pressure(s) Demineralizer flow and differential pressure(s) ‘Temperature Tank level Page 10ANIMAELU Generator Guideline August, 1994 Revision 0 + Pump performance should be monitored and trended. + Periodic cleaning and NDE (with comparisons to baseline) should be performed on stator cooling water heat exchangers. In lieu of eddy current testing of stator cooling water heat exchanges tubes, pressure or vacuum testing is considered acceptable, + The following normal/abnormal conditions should be addressed procedurally: System startup System shutdown Pump start testing (automatic pump starts) Pump operational rotation High conductivity High temperature Low flow/pressure High and low tank level Evolutions involving removing or placing demineralizers in service Evolutions involving removing or placing stator cooling water heat ‘exchangers in service with the main generator on-line System draining + strainers should be periodically inspected and cleaned (if installed). + Periodic demineralizer resin and filter changeouts should be accomplished. + All. generator protection circuits involving stator cooling water should be periodically calibrated and tested. + In the heat exchangers it is desirable to maintain stator water at a higher pressure than cooling water (closed loop cooling or non-vital service water) to prevent significant conductivity excursions if tube leaks should occur. + In the generator it is desirable to maintain stator water at a lower pressure than hydrogen. In the event a stator leak should develop, hydrogen would leak into the stator cooling water rather than stator water into the generator. Hydrogen Seal Oil ‘The hydrogen seal oil system provides temperature controlled, filtered and conditioned oil to the main generator to seal air and moisture out and hydrogen in the generator. The system is required for operation of the generator. The designs of the seal oil system are quite different for Westinghouse and General Electric generators; however; loss control philosophy is consistent for both designs. Loss control considerations address system failure scenarios that could threaten design operating parameters for the generator. This is accomplished by maintaining the reliability of redundant Page 1ANIMAELU Generator Guideline August, 1994 Revision 0 features. Due to the explosive/flammable nature of hydrogen air mixtures, personnel actions to mitigate property loss are of considerable interest to the insurer in the event of a loss of seal oil + The loss of seal oil should be addressed procedurally and provide plant personnel with detailed guidelines. (Procedure(s) should exist to cover the range of equipment malfunctions including a total loss of pumping capacity). + Temperature and pressure control valves (regulators) should be subject to periodic preventive maintenance and calibration. + Relief valves installed to protect equipment should be periodically tested. + Check valves which are important to supply sources of oil to the system should be tested. + Seal oil coolers (if provided) should be cleaned and subject to NDE and compared to baseline measurements. + Airfnydrogen detraining sections and/or float traps, drain regulators and defoaming and vacuum tanks should be subject to periodic visual inspection, cleaning and maintenance (as necessary). + Automatic functions such as pump starts, alternate oil supplies and/or automatic regulator operation should be verified operational during periodic surveillance tests. + The generator seals should be inspected during periodic generator dismantle inspections. + Operator rounds should include verification of normal system operations and channel checks of instrumentation (where possible). + Generator purge operation should require seal oil operational verifications as a prerequisite. + All annunciators and indications (local and control room) should be subject to periodic calibration including alarm verification. + Annunciator procedures should exist for each annunciator in the seal oil system. The procedure should outline automatic and manual operator action in response to abnormal system operation. + Pump performance should be monitored and trended. Page 12ANIMAELU Generator Guideline August, 1994 Revision 0 + The following normal/abnormal conditions should be addressed procedurally: System startup System shutdown Pump start testing Pump operational rotation Surveillance tests Seal oil low pressure Seal oil high temperature High and low tank levels Loss of seal oil E. Isolated Phase Bus Duct Cooling Isolated phase bus ducts are used to isolate each AC phase and connect the generator to transformers (main, auxiliary and generator protection) for subsequent voltage stepup (main transformer(s)) for distribution to the electrical grid, stepdown (auxiliary transformer) for in-house loads with generator operating and generator metering and protection circuits (powered by various transformers). Due to the high currents in the conductors which are housed within the bus ducts, the heat generated (I? R losses) must be removed. For large commercial generators the system is typically equipped with fans (single or dual 100% redundant) for air filtering and cooling. The generator, main transformer(s), and/or auxiliary transformer(s) load may be limited by bus duct ventilation availability. Typically, design features for the bus ducts address permissible time of maximum load operation on main transformer(s), generator, auxiliary transformer and bus ducts on a loss of forced ventilation. Operational restrictions including derate of the generator on a loss of bus duct ventilation is not uncommon. A backup (100% redundant) fan is often supplied to prevent the need for generator derating on a single fan failure, thereby increasing the reliability of the generator. Automatic start of the standby fan may also be provided. The use of finned heat exchangers (air to water heat exchange) and filters are also typical. The heat exchangers are generally cooled by closed cooling water or non-vital service water. These provide heat removal while the filters remove airborne particulate. Dual fan/heat exchanger/filter design is the most desirable for large commercial generators. The bus ducts interface with the generator at the bushing box. The bushings isolate the hydrogen environment in the generator from the air in the bus ducts. Some bus duct systems have hydrogen monitors which provide alarms when bus duct hydrogen concentration increases and cooler leak detection may also be provided. These features positively impact reliability. The bus duct ventilation system may be operated in a recirculation (closed loop) mode or open mode where air is exchanged and utilized from the outside environment. Operation in a closed-loop mode is more desirable to prevent contamination of the bus with airborne dust and/or particulate. Alarms are typically provided to notify operators of misoperation or abnormal conditions. ‘The bus ducts are typically Page 13ANIUMAELU Generator Guideline August, 1994 Revision 0 provided with local temperature indicators at various locations to allow for local verification. + Fans, motors, filters and heat exchangers should be subject to periodic preventative maintenance. + All annunciators (local and control room) and instrumentation (except local temperature indicators within the bus ducts) should be subject to periodic calibration including alarm verifications (if applicable). + Annunciator procedures should address automatic actions and manual operator actions in response to abnormal system conditions. + System performance should be monitored and trended. + Operator rounds should include normal operational verifications of the bus duct cooling system. + Procedures should exist which address both normal and abnormal operations including: System startup + System shutdown + Fan automatic start testing + Fan operational rotation + High temperature/low flow + Loss of bus duct cooling/ventilation Page 14ANIMAELU Generator Guideline August, 1994 Revision 0 References General References: IEEE Std 67-1990, IEEE Guide for Operation and Maintenance of Turbine-Generators, June 1990, American Nuclear Insurers, Fire/All-Risk Guidelines, August, 1992. Spe ferences 1 2. 6. Allianz Handbook of Loss Prevention, Allianz Versicherungs AG, 1987, Pg. 43. Factory Mutual Engineering Loss Prevention Data Sheets. Generating Availability Report 1985-1989, North American Electric Reliability Council, August 1990. Generating Availabil July 1990. y Report 1987-1991, North American Elect Reliability Council, Leonard Hathaway, Editor, A 28-Year Study of Large Losses in the Gas and Electric Utility Industry, Marsh & McLennan, December, 1993. Standard Handbook for Electrical Engineers, Donald G. Fink & H. Wayne Beaty Editors, Twelfth Edition, McGraw Hill, 1987. Moore, William G. and Ulm, Stephen F., Evaluation Methodology for Generator Refurbishment Decisions, PWR-Vol. 13, Design, Repair, and Refurbishment of Steam Turbines, ASME 1991 Generator Retaining Ring Moisture Protection Guide EPRI TR-102949, Project 2719 Final Report September 1993. Page 1S