20 September 2014 PMI Revision 00 1

GENERATOR &
ITS AUXILIARY
SYSTEM
20 September 2014 PMI Revision 00 2
GENERATORS AND ITS AUXILIARY CAN BE
BROADLY DEVIDED INTO THREE SYSTEMS
A) Stator water system
B) Seal oil system
C) Gas system
D) Generator
20 September 2014 PMI Revision 00 3
STATOR WATER SYSTEM
DIFF PRESS
SWITCH
VACUUM
PUMPS
POLISH UNIT
FILTERS
COOLERS
PUMPS
GAS TRAP
FLOW
METERS
CONDUCTIVITY
EXPANSION
TANK
MAKE
UP
FSI
I
DIFF PRESS.
MAGNET
FILTER
20 September 2014 PMI Revision 00 4
Stator Water System
Stator water cooling is a closed loop system
There are two full capacity single stage centrifugal
pumps with change over facility
The pumps are driven by 3Ph. 415V A.C. motors
The stator water cooler is shell and tube type heat
exchanger
DM water flows through shell


20 September 2014 PMI Revision 00 5
Stator Water System
There are two mechanical filters and one magnetic
filters
Mechanical filters are of wire mesh type
Magnetic filter is having permanent magnet
The expansion tank is a hermetically sealed
container made of S.S.

20 September 2014 PMI Revision 00 6
Stator Water System
Float valve is there in the expansion tank to
maintain water level in the tank which act as
suction storage tank for stator water pumps
Polishing unit (mixed bed ion exchanger) is there to
maintain conductivity of stator water to desired level
20 September 2014 PMI Revision 00 7
Stator Water System
For commissioning the system the system has to
be filled up first
Prerequisites for filling the cooling circuits
a) circuit should be flushed
b) hydraulic testing
c) installation of pump and motors after O/H
d) filters cleaned and boxed up
20 September 2014 PMI Revision 00 8
Stator Water System
e) coolers and all other components are boxed up
f) ion exchanger is ready and is in service
g) all instruments and measuring devices are in
position after their callibration
20 September 2014 PMI Revision 00 9
Stator Water System
System should be lined up for filling
Complete stator water system should be filled with
DM water having required quality
All air should be vented from the system before
starting of the pump

20 September 2014 PMI Revision 00 10
Stator Water System
Take trial of the water pumps
Check the stand by pump for automatic starting
Adjust level regulator in the expansion tank
Check all the signalling devices for proper
functioning

20 September 2014 PMI Revision 00 11
Stator Water System
Check all the instruments and meters for their proper
functioning
Adjust make up water pressure around 2.0Kg/cm
2
Adjust small water flow through the gas trap
Check there is no leakage of water in the system
Take ejector into service
Take one cooler into service
20 September 2014 PMI Revision 00 12
Stator Water System
Check emergency switching in circuit of the stand
by water pump
Check high and low alarm of the expansion tank
Check high conductivity alarm and tripping
Check pump discharge pr., filter diff. pr.,
conductivity, flow, inlet winding pr., winding diff. pr.,
vacuum in expansion tank, motors current
20 September 2014 PMI Revision 00 13
SEAL OIL SYSTEM
OIL
COOLER
FILTERS
DPRV
CONSTANT PRESS. REGULATORS
WITH ORFICE PLATES
VACCUM
PUMP
BEARG
DRAINS
TG
1 2
EE
BEARING

TE
BEARING
GAS
EXHAUST
FROM GAS
SYSTEM
IOT
VACUUM
TANK
SOST
SOP
SOP-3
DC
DP
SW
TS ES
FR
FLOW M.
PS PG
20 September 2014 PMI Revision 00 14
SEAL OIL SYSTEM
Generator shaft seals are supplied with
pressuerised seal oil to prevent hydrogen escape
at the shaft
Oil pressure is kept higher than the gas pressure
There are one AC seal oil pp. and one DC seal oil
pp. which feed oil to the seal through cooler and
filter
20 September 2014 PMI Revision 00 15
SEAL OIL SYSTEM
Both the seal oil pumps are 100% capacity screw
type pump
A vacuum pump is provided to maintain vacuum in
seal oil tank
There is a additional facility to supply seal oil from
governing oil
The seal oil pressure to the seal is controlled by
DPR which maintain specified DP between oil and
hydrogen
20 September 2014 PMI Revision 00 16
SEAL OIL SYSTEM
Thrust oil is there to hold the seal ring in position
against gas pressure
Two seal oil coolers having 100% capacity is
provided to cool the oil
Duplex filter is provided in the oil line
Vacuum pump evacuates gases from SOT


20 September 2014 PMI Revision 00 17
SEAL OIL SYSTEM
Commissioning of seal oil system will be required
when the
1) generator to be filled with hydrogen or air.
2) machine to be put on barring gear
Prior to commissioning make sure that all
instruments and devices are ready for operation
after callibration, overhauling and trial.
20 September 2014 PMI Revision 00 18
SEAL OIL SYSTEM
Seal oil system has to be filled with oil
Prerequisite for oil filling
1) set all level switches
2) close all stop and non-return shut off valves
3) open all pressure gauge and pressure switches
isolating valves
20 September 2014 PMI Revision 00 19
SEAL OIL SYSTEM
4) open pressure transducer isolating valves
5) open isolating valves of impulse lines of
differential pressure regulator
6) bearing lube oil system is in service

20 September 2014 PMI Revision 00 20
SEAL OIL SYSTEM
Open isolating valve of seal oil storage tank to seal
oil system. Oil will start filling the seal oil system
Open valves in oil flow path
Take coolers and filters into service
After oil is filled up into the system level will be
visible in the gauge glass of the SOT
20 September 2014 PMI Revision 00 21
SEAL OIL SYSTEM
Take governing oil system into service
Start AC seal oil pump
To clear air locking seal oil pump should be
switched on and off till its discharge pressure
gauges shows a constant pressure
Vent DPRV-A and DPRV-B

20 September 2014 PMI Revision 00 22
SEAL OIL SYSTEM
Vent both the coolers one by one
Vent filters
Vent pressure gauges, pressure switches and
transmitters
Set seal oil pressure by DPRV-A
Stop AC seal oil pump and set DPRV-B
(<0.3Kg/cm
2
from DPRV-A)
20 September 2014 PMI Revision 00 23
SEAL OIL SYSTEM
Set thrust oil pressure (0.5 Kg/cm
2
more than seal
oil pressure)
Take vacuum pump into service and adjust SOT
vacuum as recommended
Check all the meter readings are within limit
Check seal oil flow is as per system requirement

20 September 2014 PMI Revision 00 24
SEAL OIL SYSTEM
Check automatic starting of stand by DC seal oil pump by
different interlocks including alarm
Check function of level switch of SOT, seal oil storage tank
and pre-chambers
After seal oil temperature reaches 30
0
C start cooling water
flow to seal oil cooler and adjust the flow in such a way so
that the seal oil temperature is maintained at 40
0
C



20 September 2014 PMI Revision 00 25
H2 DISTRIB
HYDROGEN
CO2
VAPOURIZER
TO
SEALOIL
DPT
H2 DRIER
HYDROGEN GAS SYSTEM
CO2

ANALYZER
DRAIN
AIR
FILTER
OP
DPI
20 September 2014 PMI Revision 00 26
GAS SYSTEM
Overhauling of gas drier has been carried and the
drier is boxed up
Check all instruments are in position after
calibration
Functionally check the gas drier system
Check the availability of adequate no of CO
2
filling
point and adequate no of co
2
cylinders


20 September 2014 PMI Revision 00 27
GAS SYSTEM
Check availability of adequate no of Hydrogen
filling points and cylinders
Functionally check the LLD system
Check whether the relief valves in the high
pressure valves are alright
Check the generator is completely boxed up
Check the seal oil system is in service
20 September 2014 PMI Revision 00 28
GAS SYSTEM
Check generator air tightness test is successfully
completed
Start purging air with CO
2
till the purity of CO
2

inside casing reaches above 95%
After CO
2
purity reaches as desired start purging
CO
2
with Hydrogen
Continue purging till hydrogen purity reaches above
98%

20 September 2014 PMI Revision 00 29
GAS SYSTEM
Pressurise generator casing with hydrogen up to its
design value
Recheck hydrogen leakages by detector
Take drier into service
Take gas coolers into service
Vent the coolers and establish flow
20 September 2014 PMI Revision 00 30
GENERATOR
Before final commissioning of Generator following
are to be ensured
a) all work on Generator has been completed
b) all electrical measurement and tests has been
completed
c) checking and setting of temperature measuring
points, protection and other signalling scheme has
been completed
20 September 2014 PMI Revision 00 31
GENERATOR
Safety precautions including fire fighting
equipments are available
Oil supply to generator bearing and seal has been
established and quality/flow of oil is as per
specification
Generator is filled with hydrogen of desired purity
and up to rated pressure
20 September 2014 PMI Revision 00 32
GENERATOR
Generator stator winding is charged with distillate of
desired quality. The other parameters of distillate is
as per norms
Generator gas coolers are charged and the
parameters are normal
Generator circuit breaker is in open condition after
testing
All switchyard equipments has been tested and
normalised

20 September 2014 PMI Revision 00 33
GENERATOR
All protection and control schemes are in service
after callibration and testing
Excitation system has been tested, normalised and
field breaker has been kept in open condition.
Mode of excitation system has been selected
(auto/man)


20 September 2014 PMI Revision 00 34
GENERATOR
After ensuring completeness of checks and
availability of all equipments the set should be
started as per starting instruction and gradually to
be brought to rated speed
During course of running up all parameters to be
noted and to be checked
20 September 2014 PMI Revision 00 35
GENERATOR
When generator reaches rated speed check the
following
a) bearing and seal temperatures
b) performance of brush gear
c) vibrations
d) any gas, oil or water leakages
e) any abnormalities in generator performance
20 September 2014 PMI Revision 00 36
GENERATOR
Switch on excitation system and check for various
parameters and functioning of excitation system
After ensuring all parameters are all right and machine
behavior is normal match the generators electrical
parameters with the grid and synchronise the machine when
permissive for the same is available
Load the machine gradually. During loading also monitor all
parameters
20 September 2014 PMI Revision 00 37