‘

P R I M A R Y WAT E R F O R
G E N E R AT O R C O O L I N G
IN THERMAL POWER PLANT

TSGENCO

BY
RAMESH KOMMA
Senior Chemist /TSGENCO
KTPP-CHELPUR

KOMMA RAMESH SENIOR CHEMIST TSGENCO KTPP-CHELPUR Page 1

 NTRODUCTION

Kinetic energy from Turbine converts in electrical energy by generator

When mechanical energy do the work against electromagnetic force electricity is produced, during this
process high current flow through stator of generator and heat is generated in stator coil
Demineralized water is used to remove the heat from stator coil is called primary water or Stator
water
There are three types of cooling systems

Air cooling Below 150MW

Hydrogen cooling 150-400MW
Hydrogen & water cooling Above 400MW

In KTPP 500 and 600MW Hydrogen & water cooling system used remove the heat from stator coil
For stator water cooling the stator bars are equipped with hallow strands

SCHEMATIC DIAGRAM OF HYDROGEN AND WATER COOLING OF GENERATOR

KOMMA RAMESH SENIOR CHEMIST TSGENCO KTPP-CHELPUR Page 2

 WATER COOLING SYSTEM
MAKE UP
WATER

MAKE UP FILTER
GENERATOR

STORAGE

MAIN FILTER
TANK

PHE
DEIONIZER
PHE

2PUMPS

NaOH

NOTE :- Filters are used to remove the debris in stator water circuits that may block stator coil because
stator coil hallow conductors are typically 1 to 3mm wide and 3500 to 12000mm long they are packed in to
the stator bar with numeric bends

Deionizer used to remove dissolved solids in stator water, in this deionizer strong acid cation and strong base
anion resin used in 1:1 ration. The deionizer resin is replaced when primary water conductivity is raised

Plate heat exchanger are used to cool the circulating stator water which gains heat in generator

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COOLING WATER CHEMISTRY

Generator provided with hallows strands/conductors connected to common header at inlet and outlet of the
winding. The conductors and headers are commonly made up of copper

As the water enters into the hallow conductor , Copper comes in contact with water and forms cuprous oxide
( Cu2O) red colour and cupric Oxide (CuO) black colour depends on the electrochemical potential which
varies with temperature and PH of water. The copper Oxide forms passive layer on the inner surface hallow
copper conductor, the stability of the passive layer increases with increase in pH.

The copper corrosion low at high oxygen level but has the maximum in the 100 to 500ppb range. Also an
increase in PH reduces copper corrosion considerably, it suggest that alkalization of stator water could
bebeneficial. the rate of corrosion depends on PH and DO

The makeup water enters into low DO type stator water system, copper release copper oxide excess of the
solubility limit at operating temperature (85oC ). One part of copper oxide forms passive layer another part
moves in circuit and deposits at critical areas of the winding it is called plugging. The re deposition of copper
oxides causes blockage of strands. The solubility of the copper oxides depends up on PH and temperature of
water

KOMMA RAMESH SENIOR CHEMIST TSGENCO KTPP-CHELPUR Page 4

In low oxygen system and neutral PH cuprous oxide Cu2O will be predominant, while in high oxygen and
alkaline system the oxide will be mainly cupric oxide CuO

Stator Water Treatment Options

1. Low dissolved oxygen (<10ppb) and neutral PH

2. High dissolved oxygen (>200ppb) and neutral pH
3. Low dissolved oxygen(<10ppb) and at alkaline pH(8-9)
4. High dissolved oxygen (>200ppb)and at alkaline pH(8-9) not suitable for cooling due to clip corrosion

Problems In Stator Water Coil

1. Leaks in stator winding at brazed connections

2. Water box leakage combined with strand to strand leakage
3. Small leakage will not damage winding in normal operation because H2 gas pressure maintained
above the stator cooling water but causes when generator is degassed
4. Leakage in stator hydraulic components and connections
5. Clip to strand leakage due to crevice corrosion

Primary Water Parameters

pH 8 to 9

DO <100

CONDUCTIVITY
<2
at 25oC µS/cm

Total Cu µg/l <20

Total Fe µg/l <20

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