25

3. HYDROGEN COOLING AND SEAL OIL SYSTEM/STAGE – I

3.1 HYDROGEN COOLING SYSTEM OF GENERATOR

The 210 MW Generator is cooled by Hydrogen in stator. H2 is cooled by cooling

condensate flowing in the gas coolers.

3.2 ADVANTAGES OF HYDROGEN COOLING

 Windage and ventilating losses are reduced due to the low gas density.
 An increased output per unit volume of active material because of the high thermal
conductivity and high heat transfer co-efficient of hydrogen.
 The life of the insulation on the stator winding is increased because of absence of oxygen,
moisture and corona discharge.
 The reduction of windage noise, dirt and moisture because of lesser density of gas and closed
recirculation
 Because of the hydrogen atmosphere inside the generator the chances of fire is reduced, as
the hydrogen cannot support combustion or oxidization.
3.3 HYDROGEN GAS SYSTEM

Gas system is provided for the following reasons.

 To provide means for putting hydrogen in or taking hydrogen out of the generator using
CO2 as a scavenging medium.
 To maintain the gas pressure.
 To indicate the conditions of gas pressure, temperature, purity and the presence of liquid
by alarms.
 To dry the gas and remove vapour which might get into the generator from the seal oil.
3.4 GAS SUPPLY (Fig.1)

The gas either H2 or CO2 is distributed uniformly to the various compartments of the

generator by means of perforated pipe of the manifolds located in the top and bottom of the

housing.

3.5 GAS DRIER (Fig. 2)

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A gas drier with activated alumina absorbent material filled is connected across the

generator blower. Gas is circulated through the drier. The absorbent material will take up about

1kg of water, after that disconnecting the drier from the machine and then heating with a built in

electric heater can dry it out. Before and during the drying process air is forced through the drier

by a small blower to remove the moisture. A thermostat protects the drier against over heating.

The dryness of active material can be determined by the colour of absorbent material as seen

through the window in the bottom of the drier. The colour will be light blue, when dry and

grayish pink, when saturated with moisture.

3.6 LIQUID DETECTOR

Float-operated switches in small housing are provided under the generator frame and

under the main lead box to indicate the presence of any liquid, which might be due to leakage

from H2 coolers openings, are provided in each frame ring at the bottom of the frames to drain

the liquid collected to these water detectors. Each detector is provided with a vent return line to

the frames so that drain line from the frames will not become gas bound. Isolating valves are

provided in both the vent and drain lines to inspect the float switches. A drain valve is provided

for removal of accumulated liquid.

3.7 GENERATOR HYDROGEN PURITY INDICATING TRANSMITTER

The purity of the gas in the generator is determined by use of the hydrogen purity

indicating transmitter and the purity meter blower. The purity-indicating transmitter is a

differential pressure instrument which measure the pressure developed by the purity meter

blower. An induction motor loaded very lightly so as to run at constant speed, drives the purity

meter blower and circulates the gas drawn from the generator. Thus the pressure developed by

the purity meter blower varies with pressure, temperature and purity of the gas. The purity-

indicating transmitter is provided with automatic compensation for pressure variations.

The purity meter has two scales, one at upper and another at lower. The lower scale is

calibrated in terms of purity and is associated with the pressure compensated pointer. The upper
 27

scale indicates gas density (relative to air at 100%) and is associated with the uncompensated

pointer. Only the lower scale is visible. Upper scale is used for calibration purpose. The lower

scale is divided into three sections. In the approximate centre of the scale there is a point marked

air-100. This pointer is used for calibrating the gauge with out removing the gas from the

generator. The left hand end of dial shows percentage of CO 2 in the mixture of CO2 and air. This

scale is used during scavenging operation when CO2 is being admitted into the generator. The

right hand side of the dial shows percentage of H 2 present in the mixture of H2 and air. This scale

is used to determine the purity of H2.

The hydrogen purity-indicating transmitter produces a pneumatic output signal. This

output signal is then converted in to electric signal. It is carried to a remotely located receiver

provided with a dial on the Hydrogen control panel. Two switch assemblies are provided with

purity-indicating transmitter. These are used for “Hydrogen purity High or Low” alarms when

the differential pressure varies.

3.8 GENERATOR BLOWER PRESSURE GUAGE AND HYDROGEN

PRESSURE INDICATING TRANSMITTER

A dual pressure gauge is provided on the hydrogen control panel, which indicates both

the pressure developed by the blower on the generator rotor and the hydrogen pressure in the

generator housing. The range of blower pressure gauge scale is 0-400cm of water. This portion

of the instrument is connected directly to the generator housing and reads the differential

pressure across the blowers on the rotor. This pressure can be used as a check on the purity

meter or it can be used as a purity indicator when the purity meter is not available. The hydrogen

pressure portion of the instrument has a range of 0-7 Kg/cm 2 and is connected directly to the

generator housing to indicate the pressure of hydrogen. The transmitter produces a pneumatic

output signal and then it is converted in to an electric signal. This is carried into a remotely

located receiver, which is provided with dials. High and Low pressure alarm switches are

provided in the hydrogen control panel.

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3.8.1 HYDROGEN TEMPRATURE ALARMS

Hydrogen cold gas thermostats and the resistance temperature detectors are located in a

generator to provide an alarm if hydrogen temperature raises above normal.

3.8.2 PRESSURE REGULATORS AND GAUGES

The generator is equipped with a hydrogen pressure control, which has a pressure

regulator and a pressure gauge for the gas going to the generator. The top gauges indicate the

machine gas pressure and also setting of the regulator on the hydrogen control panel. The

bottom gauge indicates the amount of pressure available from the hydrogen supply system.

3.8.3 HYDROGEN GAS COOLERS

The hydrogen is cooled by passing it through coolers where the gas gives up its heat to

the cooling water in the finned tubes of the coolers.

3.9 SEAL OIL SYSTEM (Fig.3)

3.9.1 GLAND SEALS (Fig. 4)

Gland seals, which are supplied with oil under pressure, are used to prevent the escape of

the gas along the rotor shaft. Oil is supplied in two annular grooves in the gland-sealing ring.

From these grooves the oil flows both ways along the shaft through the clearance space

between the shaft and the inner diameter of the gland ring. As long as the oil pressure in the

circumferential groove exceeds the gas pressure in the machine, oil will flow towards the

hydrogen side of the seal and prevent the escape of hydrogen from the generator. The purpose

of having two seal grooves in the gland rings is to provide separate hydrogen side and airside

seal oil system. When the feed pressure is in these two system are properly balanced there will

be no flow of oil in the clearance space between the two feed grooves. Oil which is supplied

from the hydrogen side of the seal oil system will flow inwards along the shaft towards the

inside of the generator and oil which is supplied by the air side of the system will flow

outwards along the shaft towards the bearing. The oil in the space between the two feed

grooves will remain relatively stationary due to pressure balance between the two systems.
 29

The gland oil is fed to the feed grooves through passages in the supporting brackets.

The gland ring is provided to restrict the flow of oil through the seal. This gland ring can move

radically with the shaft, but is restrained from rotating by a pin to the supporting structure. Oil

leaving the gland seal rings is caught in chambers of each side of the seal from which it is

drained back to the gland seal oil system.

3.9.2 OIL SUPPLY

The function of the seal oil system is to lubricate the seal and prevent hydrogen escaping

from generator, with out introducing an excessive amount of air and moisture into the

generator. This oil which is in contact with air or hydrogen absorbs appreciable volume of gas

and will absorb moisture, if water vapour is present. If oil with air and water absorbed in it is

pumped into the hydrogen compartment, some of the air and moisture will come out of the oil

and contaminate hydrogen in the generator. Therefore it is necessary to add fresh gas to the

generator to maintain the purity. Contaminating air and moisture are kept out of the

generator by separating the airside of the seal oil system from the hydrogen side of the seal oil

system. When this is done, hydrogen side oil is returns to the hydrogen side of the seal ring in

the generator, thus preventing the escape of absorbed hydrogen to the outside atmosphere. The

airside seal oil returns to the airside of the seal ring, thus preventing the release of absorb air or

moisture with the hydrogen compartment at the generator.

The seal oil is supplied to the airside of the gland seal rings at a pressure of 0.84 Kg/cm 2

above the generator gas pressure. The hydrogen side seal oil is maintained at the same

pressure by means of pressure equalizing valves. As a result, the interchange of air side and

hydrogen side oil at the gland rings is held to a minimum, the air side seal oil flowing only to

the air side and the hydrogen side seal oil flowing only to the hydrogen side. While the

interchange of seal oil at the gland seal rings is held to a minimum, the variation in pressure

over a long period of time may result in a gradual increase or decrease in amount of oil in the

two sides of the seal oil system. A hydrogen side drain (Fig .5) regulator is provided for
 30

adding or removing of oil from the hydrogen side of the seal oil system. This chamber has two

float valves; one will introduce oil into the chamber from the airside of the system. If the oil

level gets low, the other float valve allows the oil from the chamber, to flow to the airside of

the system if the level gets high. The quantity of oil in the hydrogen side of the gland seal

system is kept constant and the oil levels are properly maintained.

3.9.3 DEFOAMING TANKS

Oil returning from the hydrogen side of the gland seal ring goes to two de-foaming tanks,

where most of the gas comes out of the oil. These de-foaming tanks are located in the bearing

brackets of the generator. The oil levels in the de-foaming tanks are maintained by overflow

connection, one de-foaming tank is provided for each seal. Trap is provided in the drain line

between the two tanks so that the difference in the pressure at the two ends of the generator

will not cause circulation of oil vapour through the generator

3.9.4 SEAL OIL PUMPS

The airside seal oil pump receives its oil supply from the combined bearing and airside

seal oil drain. It pumps part of this through a seal oil cooler to the air side of the seal ring and

returns part of it back to the suction side of the pump through a differential pressure regulator.

This pressure regulator maintains the differential pressure at 0.84 Kg/cm2 between the airside

seal oil pressure and hydrogen pressure. (Fig.6) The back up pump is also provided. The

hydrogen side seal oil pump receives its supply from the hydrogen side seal oil flow chamber. It

pumps part of this through seal oil cooler to the hydrogen side of the seal ring. A pressure-

equalizing valve is provided in the hydrogen side to feed the line at each end, which maintains

the (Fig.7) hydrogen side seal oil pressure at the same value as the airside seal oil pressure. A

bypass line is provided around the pump which allows that portion of the oil not required by the

pressure equalizing valve to return to the suction side of the pump.

3.9.4 SEAL OIL BACK UP

 31

The seal oil back up from the main bearing oil feed system is normally closed. If the air

side seal oil pump fails or if the seal oil pressure at the seal decreases to 0.56 Kg/cm 2 above the

H2 pressure, the back up regulator valve will open automatically and provide oil pressure for the

seals. The back up pressure may be supplied from several sources. When bearing oil flows to

the seals through the seal oil back up, the excess oil will overflow through the seal oil return line

into the main bearing oil frame.

The main oil pump on the turbine pump shaft is the primary source of seal oil back up

when the turbine speed is 75% or full speed. When the turbine oil reservoir is equipped with a

turbine governor auxiliary oil pump, this pump will be actuated by turbine controls, and it will

supply seal oil back up when the turbine speed is less than 75%. When the airside seal oil

pressure at the seal drops to 0.35 Kg/cm2 above gas pressure, a switch will close and

automatically starts the airside seal oil back up pump. The pump will continue to operate as it is

held in by an interlock in the control and can be stopped only by the push button. When this

pump starts, “seal oil pressure low ” and “seal oil back up pump Running” signal will appear.

When this appears, the H2 pressure in the machine should be decreased to 0.14 Kg/cm2 gauge or

less. Amount of gas pressure that can be maintained in the generator depends not upon pressure

being developed by the source of seal oil pressure then operating, but depends upon the pressure

available from the next backup source of seal oil pressure.

The generator may also be operated with H 2 with out the H2 seal oil pump. Under this

condition the seal oil from the airside feed groove will flow in both direction along the shaft.

Charging of hydrogen is required to maintain the H 2 purity since airside oil flowing into the H 2

side of the sealing will bring air and moisture into contact with the H 2 inside the machine and

will remove some of the H2 from the generator by absorption into the oil.

3.9.5 GENERATOR BEARING DRAIN LOOP SEAL

A loop seal is provided in the bearing drain line before it enters the turbine bearing oil

drain system .It will prevent the entry of hydrogen into the main oil reservoir, if seal fails. A vent
 32

to the atmosphere is provided on the upstream or inlet side of the loop so that only hydrogen

flowing through the bearing drain will be carried out of the system before sufficient pressure can

be built up to blow the oil out of the loop seal and allow the hydrogen to reach the drain oil

reservoir. Since this loop seals presents an obstruction to oil flow in the bearing drain system, the

vapour extractor in the main oil reservoir is not able to ventilate that part of the generator bearing

oil drain system on the upstream side of the loop seal. Therefore, an additional vapour extractor

assembly consisting of extractor, control bypass and check valve are provided as a part of the

loop seal assembly to provide the negative pressure in the generator drain system on the

upstream of the loop seal required for normal operation.

3.10 OPERATION OF THE SEAL OIL SYSTEM

The operation of the seal oil system involves initial commissioning operation, adjustment

of parameters after commissioning, normal operation when the unit is running and some of the

abnormal operations. It also involves the routine checkups and inspection of the systems.

3.10.1 INITIAL OPERATION OF OIL SYSTEM

The seal oil system will be filled automatically from the turbine oil system as described

before when the bearing oil is being circulated. When the seal oil system is put into operation

for the first time it may be necessary to add additional oil to the turbine oil system in order to

supply the oil required to fill the defoaming tanks, the hydrogen side seal oil drain regulator to

the current levels.

1. Set the relief valve No.258 on the airside seal oil pump so that it will open on low
pressure by screwing out on the adjustment until it is almost all the way out. This will
prevent damaging the pressure gauges by high pressure in the event that the other valves
in the pump discharge are incorrectly set when the pump is started.
2. Set the differential seal oil pressure regulator No.256 to open with minimum differential
pressure between the oil and gas pressure. Releasing the spring pressure on the regulator
may do this. Loosen the vent in the bellows to allow oil to drip out during preliminary
operation at the seal oil unit. This will get rid of any entrapped air and will ensure stable
 33

operation of the regulator. After the pump has been started, tighten the plug after
approximately one litre of oil has leaked out from the plug.
3. Close valves Nos.263, 265 & 266 to isolate the main turbine oil system back up from the
rest of the seal oil system during the part of preliminary operation.
4. Start the airside seal oil pump. This provides oil pressure at the shaft seals.
5. Oil will now flow through valve No.232 into the hydrogen side drain regulator.
6. The de-foaming tanks will now fill up to the level of overflow connections.
7. Excess oil in the deforming tanks flows to the hydrogen side drain regulator. The
hydrogen side drain regulator maintains a steady quantity of oil in the gas side seal oil
system. Valve Nos.231 & 232 will maintain the normal level. If the level becomes high,
float valve No.231 opens and allows the excess oil to flow out. If the level becomes low
float valve No.232 opens and the oil flows from the airside seal system into the chamber.
Jacks are provided in the valves No.231 & 232 so that they can be opened or closed
manually in case of emergency.
8. Close valve No.254, and close the differential pressure regulator No. 256.
9. Screw down on the adjustment of the relief valve No.258 until the pressure on the
discharge of the airside seal oil pump is 7 Kg/cm2.
10. Open valve No.254.
11. Valve No.238 should be partially closed to prevent hunting of the differential pressure
regulator No.256 and approximately one-half turn open is the proper setting for this
valve.
12. Adjust the differential pressure regulator No.256 to maintain the airside seal oil pressure
at the seals at 0.84 Kg/cm2 above the hydrogen pressure (with cold oil, setting will be
approximately 1.05 Kg/cm2).
13. Set the relief valve No.243 and the hydrogen side seal oil pump similar to relief valve
No.258.
14. Start the hydrogen side seal oil pump. This will provide oil to the hydrogen side of the
shaft seals.
15. Close the valves 211, 218 & 242 and screw down on the adjustment of the relief valve
243 until the hydrogen pressure at the hydrogen side seal oil pump discharge is 7 Kg/cm2.
16. Open valves 211, 218 & 242.

17. Adjust pressure-equalizing valves 210 & 217 to give +50mm (or) 50mm of water on the
pressure gauge associated with each equalizing valve and this adjustment is made by
means of the adjusting screw on the bottom of the valve.
 34

18. Pressure equalizing valve 210 & 217 will now maintain the hydrogen side seal oil
pressure at the shaft seals at the same pressure as the airside seal oil pressure.
19. If a pressure reducing valve 291 is provided to reduce the pressure of the back up oil from
the main oil reservoir, it should be adjusted as follows .Set the pressure reducing valve
291 to the closed position and start the high pressure auxiliary pump. Adjust the relief
valve 280 to hold the value at 10.5 Kg/cm 2 when the pressure-reducing valve is set for
maximum pressure. When the shaft pump is operating at a speed greater than 75% of
normal operating speed, it will provide the necessary seal back up. Adjust the pressure-
reducing valve 291 to the value 8.7 Kg/cm2.
20. Open valves 263 & 265.

21. Stop the airside seal oil pump. Start the high-pressure auxiliary pump.

22. Adjust the back up regulator 264 to maintain the airside seal oil pressure at the seals at
0.56 Kg/cm2 above the hydrogen pressure.

23. Check the operation of back up pressure switch PSA/542/414 which should close when
the turbine oil back up pressure drops to a value equivalent to 6 Kg/cm 2 (gauge) at the
seals. Close valve 265 Block regulator 264 in open positions and the throttle valve 265
until the pressure at the seals is 6 Kg/cm2. Adjust pressure switch PSA/542/414 to close at
this point. Release regulator 264. Open above valve 265. Stop the high pressure
auxiliary oil pump.
24. Start the airside seal oil pump.

25. The seal oil back up supply from the pumps should be checked individually to assure
their availability and correct functioning in the case of emergency.
26. Turning gear oil pumps supply only 0.35 Kg/cm2 pressures of the seals. This is
insufficient to maintain 0.56 Kg/cm2 differential pressures. Therefore when these pumps
are operating such that turbine is at standstill or on turning gear and high-pressure
auxiliary oil pumps is out of service. When this differential pressure drops to0.35 Kg/cm 2,
switch PSA/542/424 will automatically close and start the airside seal oil back up pump.
Check the proper functioning of this differential pressure switch and back up pump by
opening valve 273, close valve 248 temporarily and then read pressure gauge. Slowly
crack open valve 274. The DPSA/542/424 should operate when the pressure gauge
decreases to 0.40 Kg/cm2 from the initial reading. Close valve 274 and open valve 248.
Stop the airside seal oil back up pump.
 35

27. Check the operation of differential pressure switch DPSA/542/414. This switch closes
when pressure differential across the air side seal oil pump decreases to 0.35 Kg/cm 2
(gauge) and actuate the “air side seal oil pump off” alarm.
28. Stop the H2 side seal oil pump. Pressure switch DPSA/542/434 should close. This
switch should close when the difference between discharge and suction pressure of the H2
side seal oil pump decreases to 0.35 Kg/cm 2 (gauge) and actuate the “H2 side seal oil
pump off” alarm.
29. Start H2 side seal oil pump. The seal oil supply system is now in normal operation.
3.10.2 ADJUSTMENTS WHILE RUNNING

Final adjustments should be made after the generator is synchronized and the seal oil

temperature after the seal oil coolers is between 27C and 50C.

1. Re adjust the differential seal oil pressure regulator 256 if necessary to maintain
differential pressure 0.84 Kg/cm2. This adjustment should be made at low hydrogen
pressure. At high hydrogen pressure, blower may develop as much as 0.15 Kg/cm 2
pressure. The gas and oil sensing lines to the seal oil pressure regulator come from high
pressure zone of the generator. Therefore the operation of the regulator is not affected by
the gas pressure, however the gas pressure line from the generator to the gas pressure
gauges come from a low pressure zone of the generator. At low pressure, the observed
differential between the air pressure gauge and oil pressure gauge may be 0.84 Kg/cm 2.
While at high pressure the apparent differential pressure will be 0.99 Kg/cm 2. This is not
the true difference since the gas pressure in the high-pressure zone of the generator has
gone up to 0.15 Kg/cm2 more than the gas pressure in the low-pressure zone of the
generator.
2. Stop the air side seal oil pump and check the setting of the back up pressure regulator 264
which should open when the seal oil pressure at the seals decreases to 0.56 Kg/cm 2 above
the hydrogen pressure. This regulator should maintain the differential pressure. Check
the airside seal oil back up pump to make sure that it starts automatically when the
differential pressure switch DPSA/542/424 closes.
3. When the generator is operating at maximum pressure and maximum oil temperature,
throttle valve 242 until seal oil differential pressure gauges no longer give steady
readings. If seal oil differential pressure (oil to gas) is not with in plus or minus 50mm of
water, readjust regulator 210 &217 to obtain this value.
3.10.3 NORMAL OPERATION
 36

 Seal oil pressure must be maintained at the seals when hydrogen is in the generator or
when the shaft is running.
 The hydrogen pressure may be varied upto3.12 Kg/cm 2. The seal oil pressure is
maintained at 0.84 Kg/cm2 above the hydrogen pressure when air side oil pump and back
up pump is in operation, and at o.56 Kg/cm2 above the hydrogen pressure when the seal
oil pressure is being supplied by the turbine oil back up system is 0.21 Kg/cm 2
differential is required to maintain a seal when running.
 The temperature of the seal oil leaving seal oil coolers should be maintained between
27˚C and 50˚C.
 The vapour extractors should be operated continuously when the generator is filled with
hydrogen as these vapour extractors ventilate the bearing brackets and bearing oil drain
system.
 The filter should be turned until free every eight hours. At least once in every 12 months
filters should be drained through the pipe plug in the bottom when the system is
shutdown.
 When the air side back up pump starts, the auxiliary in the main oil reservoir should be
started or the pressure in the generator should be decreased to less as the next back up
pressure available is from the low pressure pumps.
 The generator can be operated without hydrogen side oil pump.
 The hydrogen should be purged from the generator before the main oil reservoir is
drained.
3.10.4 OPERATION WITHOUT HYDROGEN SIDE SEAL OIL PUMP

The hydrogen side seal oil pump supplies oil to the hydrogen side of the shaft seal at

pressure equal to the oil on the airside of the shaft seals. Therefore interchange of airside and

hydrogen side gland seal oil is minimized. The air brought into the machine due to this

interchange will not adversely affect the purity of hydrogen since hydrogen is added to make up

normal gas leakage. The hydrogen side seal oil pump can be bypassed any time for maintenance.

When the pump is not in service, the flow of airside seal oil to the hydrogen side seal oil is

greatly increased. So, a certain amount of hydrogen is removed from the generator by absorption.

The purity may be decreased to 90% to conserve hydrogen. This will increase the density of the

gas slightly. With the generator running at the rated speed, approximately 20M3 of hydrogen per
 37

day will maintain the purity at 90% during bypassing operation. At standstill the flow of seal oil

will be less, therefore the hydrogen required to maintain the purity will be decreased when the

seal oil system is operated without hydrogen side seal oil pump, the air side seal oil will flow

through the seal in to the defoaming tank and into the hydrogen side drain regulator. When this

operation occurs at low gas pressure the oil level in the hydrogen side drain regulator may rise.

During operation at higher gas pressures, the gas pressure forces the oil down to the normal

level. The oil fluctuates to provide sufficient head for the oil to flow through the valve 231.

3.10.5 OPERATION WITH GENERATOR SHUTDOWN

Hydrogen may be left in the generator during shutdown if the seal oil pressure is

maintained and the vapour extractors are in operation. If it is necessary to shutdown the turbine

oil pumps, close valves 263 & 265 to prevent the seal oil from leaking back into the turbine oil

reservoir through the back up regulator and there by causing loss of oil pressure to the seals. The

generator bearing feed and drain lines must be free from oil flow from the bearing oil pump,

through the generator bearing and into the loop seal. If the back up seal oil pump starts under

this condition, valves 263 and 265 should be opened and the H2 pressure should be reduced to

0.14 Kg/cm2 or less as the next back up pressure available from the low pressure turbine pumps.

If the turbine pumps cannot be started, the hydrogen should be purged out.

3.10.6 STARTING SEAL OIL PUMPS

Before starting any of the seal oil pumps, be sure that each has an adequate supply of oil

so that pumps will not run dry. This would result in destructive wear between the various

rotating stationary parts. The sequence of starting is (a) air side seal oil pump (b) H 2 side seal

oil pump.

3.11 INSPECTION AND MAINTANANCE OF SEAL OIL SYSTEM

3.11.1 SEAL OIL PUMPS (AIR SIDE & HYDROGEN SIDE)

The seal oil pumps have a special double helical rotor, which eliminates end thrust and

trapped liquid. The large surfaces of helical rotors provide high efficiency and long life. The
 38

sealing of the drive shaft on the seal oil is achieved by means of a bellow type mechanical seal

subject to the suction pressure on the pump only, which results in leakage. The mechanical seal

consists of a spring, spring holder, synthetic rubber bellows holding ring, carbon seal and

floating seal. The synthetic rubber bellows is secured to the shaft by the shoulder of the holding

ring, which also secures the bellows and carbon seal in such a way that the seal is spring loaded

against sealing surface of the stationary iron seat. If any leakage of oil is detected the

mechanical seal should be replaced.

3.11.2 SEAL OIL BACK UP REGULATOR

Since the back up regulator 264 is normally required it is advisable to check it once a

month to ensure that it will operate correctly when needed.

 Read the seal oil pressure gauge at valve 236.

 Slowly throttle valve 254. When the pressure gauge readings decrease to 0.28 Kg/cm 2
from its initial reading, the back up regulator 264 should start to open.
 Continue to throttle valve 254 slowly. If the seal oil pressure continues to drop, it
indicates that the back up regulator needs to be readjusted.
 With the backup regulator 264 set to hold the seal oil pressure at 0.56 Kg/cm 2 above gas
pressure, slowly close 254. The seal oil pressure should not decrease; when the valve 254
is fully closed the seal oil pressure is being supplied by the turbine oil system.
 Stop the airside seal oil pump.
 Open valve 254.
 Check for proper operation of the airside seal oil back up pump.
 Start the airside seal oil pump.

All pressure switches should be checked for correct operation and for mechanical defects.

Each self-cleaning filter should be cleaned at regular intervals. A handle wheel controls the

cleaning operation and it does not require any housing. The dirt removed is collected at the

bottom of the filter housing, from where it can be drained by means of a valve.

3.11.3 PRESSURE EQUALIZING VALVES

Pressure equalizing valves 210 & 217 should be checked to see that they are holding the

differential seal oil pressure (air side Vs hydrogen side) to within plus or minus 50mm of H2O.
 39

3.11.4 HYDROGEN SIDE DRAIN REGULATOR

Hydrogen side drain regulator should be drained and the cover removed, so that any

accumulation of sludge or other foreign materials can be cleaned out.

3.11.5 SEAL OIL COOLERS

The cooler tube bundles should be removed and inspected for cleanliness. The tube
should be cleaned if required, vent the coolers on the oil side by loosing the pipe plug provided
for this purposes.

3.12 OPERATION OF HYDROGEN GAS SYSTEMS

When hydrogen mixes with oxygen, an explosive mixture is formed which will explode

violently when ignited. So the hydrogen should not be allowed to mix with oxygen or air in the

generator when filling up. So, CO2 is used as a medium for charging the generator with

hydrogen or scavenging.

3.13 GAS CHANGE OVER OPERATION (Fig. 8 & Fig. 9)

Gas changing operations are preferred with the generator at stand still or turning gear. In

case of emergency these operations can be performed while the machine is accelerating or

decelerating. The generator should not be allowed to operate at normal operating speed in CO 2.

Atmospheric air contains approximately 21% oxygen by volume. At the upper end of the

explosive range (70% hydrogen & 30% air) the oxygen content of the hydrogen and air mixture

is 21% × 30% = 6.3% oxygen. Therefore before introducing hydrogen in to the generator oxygen

content should be reduced to less than 6.3% oxygen. Therefore before introducing hydrogen into

the generator, oxygen content should be reduced to less than 6.3%. Air content will be reduced to

14% having equivalent oxygen of 21% × 14% = 3% oxygen will introduce two volumes of gas.

When CO2 is introduced at the bottom of a frame with the rotor at standstill about 1 1/2 volumes

will be sufficient to remove the air since there is no much mixing of air and CO 2 under this

conditions. Purity meter connections are provided to take gas samples from either the top or

bottom of the machine. During the addition of CO 2 gas sample should be taken from the top of
 40

the machine. After 11/2 volumes of CO2 is put in the generator, the purity meter should read about

95% CO2.

A hydrogen cooled turbine generator is operated with the gas in the machine 95% H 2 or

above by volume. If 3½ volumes are introduced into the generator when it is running the

resulting mixture will be 95% H2 and 2 ½ volumes with the rotor at stand still. Connecting the

purity meter sampling lines to the bottom of the frame should check purity of gas. During the

normal operation of the H2 cooled generator the H2 purity is maintained 95% or above. When the

H2 side seal oil pump is shut down, gas must be added to maintain the pressure and to maintain

the purity. Inflow of 1M3 of air will require the addition of 24M3 of H2 to maintain the purity at

95% and 10M3 of H2 to maintain the purity at 90%. For removing H2 from the generator, CO2 is

introduced at the bottom of the housing as a scavenging gas and H 2 is driven at the top.

Sufficient CO2 is introduced to reduce the H2 content in the mixture to 5%. Two volumes of CO2

being required for scavenging at standstill condition. CO 2 purity should be 95%. After the H 2 has

been scavenged from the generator housing, it may be opened and the oil pressure may be turned

off. Hand holes in each end of the generator end should be opened and a fan directed into the

opening at one end to drive out the CO 2. This precaution is suggested to prevent inhaling of CO 2,

which might occur if an immediate visual inspection is made through hand hole.

3.14 REPLACING AIR WITH CO2

 Make certain that normal seal oil pressure is established at the seals.
 Make sure that the purity meter system is operating correctly.
 Make sure that the purity meter blower is running and that power and or air supplies to
the H2 panel have been turned on.
 Check that sufficient quantities of H2 and CO2 are available.
 Connect the purity meter sampling lines to the top manifold, open valves 34 & 36, close
valves 33&35.
 Connect vent to the top manifold by opening valve39 & closing 38.
 Isolate the H2 supply by closing valve 30.
 Connect the CO2 supply to the bottom manifold by opening valve 37.
 41

 Recheck valves 40,41&42 in the H2 panel to be sure valve 40 is closed. Valves 41 & 42
are open.
 Admit CO2 to the generator through the valve 48.Do not allow machine pressure to
exceed 0.2 Kg/cm2 gauge during the time CO2 is being admitted. The valves in the CO2
supply including valve 58 should be opened wide to prevent the valve from freezing.
Observe the frost line on the CO 2 feed line to see that it disappears at least 3m from the
point at which the CO2 feed line enters in to the generator. Observe the purity meter
indications as the CO2 is being admitted. When 1½ machine volumes have been put in to
the generator, the purity meter should read approximately 93% of the CO 2. Continue to
admit CO2 until the purity meter indicates 95% CO2.
 Close valves in CO2 supply and then close valve 58.
3.15 REPLACING CO2 WITH H2

 Connect vent to bottom manifold by opening valve 38 and closing valve 39.
 Connect purity indicator sampling lines to the bottom by opening valve 33 and 35 and by
closing 34 and 36.
 Open valves 30 and 2.
 Admit hydrogen either by opening valve 53 or by using the regulator on the hydrogen
pressure control manifold. The generator gas pressure should not be allowed to exceed
0.2 Kg/cm2 to 0.35 Kg/cm2. Continue to admit hydrogen until purity meter indicates at
least 95% hydrogen purity. This will require approximately 21/2 times machine volumes.
 Open valve 24 for approximately two minutes for purging out of the CO2 from the lead
box.
 When the desired purity level has been reached close valve 38. The machine pressure
will increase for one Kg/cm2 increase in gas pressure; one machine volume of gas will be
required.
 The pressure regulator on the hydrogen pressure control manifold may be set for the
desired machine gas pressure as follow.
1. Close valve 2, 53 and 1 and turn the ‘T’ handle of the regulator in anti clockwise
direction.
2. Open valve 54 to allow the manifold pressure to go to zero.
3. Close valve 54.
4. Open valve 1 and set the desired pressure by tuning the ‘T’ handle of the regulator
clockwise and observe the pressure gauge on the generator side.
 42

5. Open valve 2, the regulator will now allows hydrogen to flow into the generator
until the set pressure has been reached.
3.16 REPLACING H2 WITH CO2

1. Connect the purity meter sampling lines to the top manifold by opening valves 34 and 36
closing valves 33 and 35.
2. Close hydrogen charging by closing valve 30 and 2 and removing the removable link in
the hydrogen feed line.
3. Connect the CO2 feed to the bottom of the generator by opening valve 37 and closing
valve 38.
4. Connect the vent to the top manifold by opening valve 39. Hydrogen will now escape to
the vent through the line and valve 39.
3.17 REPLACING CO2 WITH AIR

 The seal oil system may be stopped provided the shaft is not running.
 Remove the manhole cover at each end of the generator. As soon as the covers have been
removed, take a gas sample with a gas analyzer. After the gas covers are removed, wait
at least for one hour before blowing dry air to one end of the generator to drive out the
CO2. Open all water detector drains.
 Ventilate for several hours after removing manhole cover, before entering into the
generator.
 When replacing the manhole covers, do not forget to close the water detector lines.
3.18 DETERMINATION OF GAS PURITY
3.18.1 FROM THE PURITY INDICATING TRANSMITTERS

Direct reading purity meter determines machine gas purity. Valves in the purity meter

circulating lines permit sampling from the top or bottom of generator. During normal operation,

the sample should be taken from bottom. The pressure head developed across the purity meter

blower is directly proportional to the density of the gas passing through the blower. Connection

from the high and low pressure sides of the blower are taken to the purity meter. The purity

meter is a differential pressure instrument, which converts the pressure head to reading on a

scale. A pressure compensating device incorporated in the purity meter allows the calibration of

the scale directly in terms of the machine gas purity.

 43

3.18.2 FROM THE BLOWER PRESSURE GUAGE

Generator blower pressure is indicated by a differential pressure gauge in the hydrogen

control cubicle. The blower pressure gauge may be used to check the purity meter since both

gauges operate in the same principle. If the purity meter is out of service and generator is running

at rated speed the machine gas purity may be obtained as described below. The readings of the

blower pressure gauge and the upper scale of the purity meter are both proportional to machine

gas density. They are therefore proportional to each other for the same hot gas temperature. The

constant may be obtained by direct measurement at a number of typical hot gas temperatures.

There after for a given hot gas temperature either gauge reading may be transferred to the other

gauge reading by multiplying or dividing by the constant.

Density = Blower pressure × constant

(or)

Blower pressure = Density / Constant.

Since a straight-line relationship exists between upper scale (density) of the purity meter

and blower pressure readings, a chart may readily be prepared. A series of straight line will go

through the origin and some other point for a given hot gas temperature. These curves may be

obtained when the purity meter and the blower pressure instrument both are in operation.

3.18.3 USING PORTABLE INSTRUMENT

Gas purity may be checked with portable instruments. Oxygen and CO 2 content may be

determined by means of the standard apparatus.

3.19 NORMAL OPERATING PURITY

During normal operation of the generators with both airside and hydrogen side seal oil

pumps in operation, the hydrogen purity can be maintained at 95% or greater. If the hydrogen

side seal oil is not in service, hydrogen purity should be maintained at 90% to avoid excessive

use of hydrogen.

3.20 POSSIBLE CAUSES OF LOW PURITY

 44

(1) Incorrect setting of the pressure equalizing valves.

(2) Malfunctioning of the hydrogen side drain regulator.
The pressure equalizing valves 210 & 217 should maintain at a differential pressure with

in plus or minus 50mm water column between airside and hydrogen side. If one or both of these

valves are not operating correctly, air may enter in to the generator through the airside seal oil.

Float valves 231 &232 maintain the oil level in the hydrogen side drain regulator with in certain

limits. If valve 232 does not function properly when the oil level rises, airside oil is forced into

the tank. The level is maintained since valve 231 is open when the oil level is high and allows the

extra oil to be forced into the loop seal.

3.21 TESTING GENERATOR AND GAS SYSTEM FOR LEAKS

The Generator and gas system should be tested at 1.05 and 3.12 Kg/cm 2 with air to check

for any leaks. This test should be made with oil circulating through the seals of hydrogen side

seal oil pumps in service. The allowable leakage is 0.5M 3 per day at 1.05 Kg/cm2 and 1.06M3 per

day at 3.12 Kg/cm2. Dry air should be used for the pressure test.

Leak Detection:

If the leakage rate is not with in the specified limits in systematic search for leaks should

be made either with soap or either liquid solutions or by means of leak solutions or by means of

leak detectors with “From 12”. The use of odorants such as either is not permitted. Liquid soap

solution provided a quick and simple method of leak detection and evolution. They are not

suitable for inaccessible parts or for very small leaks. Solutions of industrial or domestic liquid

soap with the addition of glycerin as a thickening agent are satisfactory.

The location of leak may be determined by injecting “From 12”gas into the generator at

the rate of approximately 1Kg / 28M3 of machine volume. “From 12” is inert, nontoxic and

readily available. Very small quantities “From 12” at leakage points can be detected with the aid

of suitable halide detectors.

3.22 LEAKAGE SOURCES SEARCH PROCEDURE AND CORRECTIVE

ACTION
 45

(a) GENERATOR FRAME AND LEAD BOX

Check bearing brackets and lead box joints, lead bushings, gas cooler flexible end, piping

connections, and instrument boards. Tighten bolts in sequence such that loads on gasket or other

joints are evenly applied.

(b) VALVES AND PIPE LINES

Check all gas valves and piping associated with the gas supply including water detectors

and the hydrogen and carbon dioxide manifold.

(c) VENT VALVES AND VAPOUR EXTRACTORS

Leakages or losses through vent lines from the generator or vapour extractors can be

checked at the vent outlets on the powerhouse roof. When checking vents, use an activated

charcoal filter in the suction side of the detector to remove oil vapour. There should be no

leakage from the main oil reservoir and generator vents, but there may be some from the

generator bearing loop seal vent. If leakage is detected at the loop seal vent, investigate the

bearing drains.

(d) BEARING DRAINS

Access to each drain is made through a pipe plug in the drain line or slightly below floor

level. Use an activated charcoal filter and stop the vapour extractor during the search. Leakage

into the bearing cavities is due to faulty joints between the gland seal and bearing brackets. It

may also be due to faulty oil seal or due to an excess of hydrogen side seal oil pressure over

airside oil pressure. Tighten the gland seal brackets. Check the differential pressure at seals and

check the difference between hydrogen side and airside seal oil pressure.

(e) GAS DRIER

Check all flanges and openings in gas drier tank including the entry points for heater

leads and thermostat. Check also the three way valves which are a frequent source of leakage.

(f) HYDROGEN GAS CONTROL PANEL

 46

Check all joints instrument canes and purity meter blower for leaks. Do not use liquid

solution on electrical leads.

3.23 CALCULATION OF GAS LEAKAGE

To obtain accurate leakage tests, it is necessary to correct the observed pressure drop for

changes in temperature and atmospheric pressure.

L = 6552 × V / H [(P1 + B1) / (273 + T1) - ( P2 + B2) / (273 + T2) ]

L = Leakage in m3 per day at standard conditions for the entire test period.
P1 = System pressure at the beginning of the test.
B1 = Barometric pressure at the beginning of the test.
T1 = System temperature at the beginning of the test.
P2, T2, B2 = Pressure, Temperature and Barometric readings at the end of the test.
V = Static gas volume of the system in m3.
H = Test period in hours.
(Temperature in degrees centigrade and pressure in Kg/cm2).

3.24 OPERATION OF THE SIGNAL SYSTEM

3.24.1 HYDROGEN PURITY – HIGH OR LOW

The low hydrogen purity signal is given by an alarm contact system in the purity

indicating transmitter and indicates that the hydrogen purity in the generator is lower than 90%.

This signal indicates low hydrogen purity, which may be a result of improper operation of the

pressure equalizing valves, or the hydrogen side drain regulator. The high hydrogen purity signal

is given by an alarm contact in the purity indicating transmitter and indicates that the purity

meter pointer is above 100% mark. If the meter indicates a higher purity, either the pointer or the

meter has struck or the purity meter blower has stopped.

3.24.2 HYDROGEN PRESSURE – HIGH OR LOW

The high hydrogen pressure signal is given by a signal contact on a pressure switch

mounted in the generator panel. It indicates the pressure of hydrogen in the generator is higher

than the operating pressure by 0.2 Kg/cm 2. The low hydrogen pressure switch located adjacent to

the first. It indicates that the hydrogen pressure has dropped to 0.15 Kg/cm 2 below the operating
 47

pressure. The alarm may also be given if there is a sudden large drop in load and the water

supply to the coolers is not decreased. The resultant rapid drop in temperature will cause the

hydrogen to contract and reduce the pressure in the machine. If this low-pressure alarm is

sounded, the gas supply system should be checked.

3.24.3 WATER DETECTORS - HIGH

Two liquid detectors are located at the bottom of the generator and one at the bottom of

the generator lead box. The water detector high signal indicates that one of these three detectors

has become filled with water or oil. A float-operated switch on the detector gives the signal. The

detector at the hydrogen cooler would be the first to be filled if water were leaking from the

coolers. A secondary cause for an alarm would be an overflow of the oil from the gland seal oil

system. At the exciter end of the generator, the water detector high signal indicates that the

detector at the bottom of the main lead box was full of oil, which had overflowed from the seal.

At the water detector, at the centre of the generator, and alarm would indicate that an overflow of

liquid from either end of the machine had reached that point. The three detectors may given

pressure signal by making contact on a second alarm separately or may be paralleled to give one

alarm. Opening the valve at the bottom and draining each detector will show whether the liquid

is water, or oil or a mixture.

3.24.4 HYDROGEN TEMPERATURE – HIGH

It is given by making of contacts on the hydrogen cold gas thermostats and by resistance

temperature detectors in the generator. These contacts should be set at a few degrees above the

maximum temperature when the generator carrying full load and the cooling water is at its

maximum expected temperature. This signal may be due to overload, low hydrogen purity or

high water temperature in the coolers.

3.24.5 HYDROGEN SUPPLY PRESSURE - LOW

 48

This signal indicates that the pressure of hydrogen at the header is low. It is given by

making a contact on a pressure switch located on the hydrogen pressure control manifold. This

signal will appear when the pressure decreases to 5.25 Kg/cm2 gauge.

3.24.6 DEFOAMING TANK LEVEL HIGH

This signal indicates that the oil level in one of the defoaming tanks is too high and is

given by signal contact on the float switches located in both the collector end and the turbine

end-defoaming tank. This alarm will sound when the oil level rises above the overflow

connection, a condition which might be due to an excessive oil flow from the seals, a clogged

overflow or drain line or the improper functioning of the float valve 231 in the hydrogen side

drain regulator. If this alarm is sounded, the oil level in the defoaming tanks should be checked

immediately, since if the level gets too high the oil will back up through the seals in the

generator. Float valve 231 & 232 are provided with jacks by which they can be opened manually

in case of emergency. The defoaming tanks are provided with drain valves through which excess

oil can be drained. Care should be taken in the operation of these valve as the defoaming tanks

contain hydrogen at the same pressure as the gas in the generator.

3.25 SEAL OIL PRESSURE LOW

This signal indicates that the seal oil pressure at the seals has dropped to 0.35 Kg/cm 2

above the gas pressure. It is given by making of a contact on a differential pressure switch

located on the seal oil supply unit. If this alarm appears while the turbine is in service, the turbine

oil back up system should be checked, as it may not be functioning properly. Either the turbine

oil back up pumps are not producing their normal pressure or regulator 264 is not operating

correctly as this regulator should maintain 0.56 Kg/cm 2 differential pressure. This regulator can

be bypassed by opening valve 266, if it is found that the trouble is in the regulator.

This differential pressure switch also activates the seal oil back up pump at the same time

as the alarm is given. This pump restores the differential pressure of the seal oil to 0.84 Kg/cm 2

above the gas pressure. If it is found that the cause of the trouble lies in the turbine oil back up
 49

pumps and at least one of these pumps cannot be taken into normal service immediately, the

hydrogen pressure in the generator should be reduced to 0.14 Kg/cm2 or less as the only back up

for this seal back up pump are the motor driven low pressure oil pumps which can deliver only a

limited pressure.

3.26 AIR SIDE SEAL OIL PUMP OFF

“The air side seal oil pump-off” signal indicates that the power supply to the motor is cut

off. The signal is given by a contact on a differential pressure switch across the airside seal oil

pump on the seal oil supply unit. This contact closes and the alarm is given when the pressure

across the pump decreases to the 0.35 Kg/cm 2. When this alarm is given, the contactor of the seal

oil pump motor circuit should be inspected.

3.27 SEAL OIL TURBINE BACK UP PRESSURE LOW

This signal indicates that the turbine oil back up pressure has dropped below the setting

of pressure switch (PSA/542/414), which should close at 4.9 Kg/cm 2. This signal indicates that

high pressure oil is not available from the pump on the turbine shaft or from a turbine auxiliary

oil pump.

The alarm should occur only when a turning gear oil pump is lubricating the turbine

generator unit. If the air side seal oil pump fails and the air side seal oil back up pump controlled

by pressure switch (dpsa/542/424) starts while alarm is on, the turbine auxiliary oil pump (or the

back up pump on the main oil reservoir) should be started. This will provide the necessary back

up pressure for the airside seal oil back up pump. If the turbine auxiliary oil pump (or back up

pump on the oil reservoir) cannot be started immediately and the turbine back up pressure in the

turning gear oil pump, the hydrogen pressure in the generator should be reduced to 0.14 Kg/cm 2

gauge or less.

3.27 HYDROGEN SIDE LEVEL LOW

This signal indicates that the oil level in the hydrogen side seal oil drain float chamber is

too low and is given by making of a contact of a float switch located in the chamber. This low
 50

level may be due to improper functioning of float valve 231. If this alarm appears, the action of

this valve should be checked immediately since if it struck in the open position, the oil will drain

from this chamber and the seal would be lost, allowing the hydrogen in the generator to escape

into the bearing and seal oil system, there by causing a dangerous condition. This float valve 231

is provided with jack by which it can be closed manually in case of emergency.

3.28 HYDROGEN SIDE SEAL OIL PUMP OFF

This signal indicates that the hydrogen side seal oil pump is not operating. A differential

pressure switch connected across the inlet and outlet of the pump, when the differential pressure

drops to 0.35 Kg/cm2 gives the signal. The generator can be operated without this pump, but the

hydrogen consumption of the unit will be increased due to the contaminated airside seal oil

flowing in the hydrogen side of the seal rings.

3.29 AIR SIDE SEAL OIL BACK UP PUMP RUNNING

This signal indicates that the seal oil back up pump is running. This signal is given either

by an interlock switch in the contactor for the motor drive for this pump, or by a differential

pressure switch connected across the inlet and outlet of the pump. The switch closes when the

pump starts, the turbine auxiliary pump (or the seal oil back up pump on the main oil reservoir)

should be started immediately to serve as a source of high pressure seal oil backup. If high-

pressure backup cannot be provided and if the airside seal oil pump cannot be restored, the

hydrogen pressure should be reduced to 0.14Kg/cm2.

3.30 GLAND SEAL OIL AIR SIDE HIGH OR LOW

This signal indicates that the differential pressure between the airside and hydrogen side

of the seal oil at the generator bearing is beyond the limits. In case that both the differential

pressure switches (DPSA/542/434 and DPSA/542/444) should alarm, and the valve 242 should

be re adjusted. So that, through the pressure equalizing valves 210, 217, the difference in
 51

pressure between the airside and hydrogen side of the seal oil at the generator bearings is

restored to the normal limits. In case only one of the two differential pressure switches should

alarm, its corresponding pressure equalizing valve should be checked.

3.31 AIR SIDE (HYDROGEN SIDE) FILTER DIFFERENTIAL PRESSURE

HIGH

The filters on airside and hydrogen side of the seal oil system are equipped with

differential pressure switches, which will alarm and the filters should become chocked. In case of

alarm the filter should be taken out of service and cleaned.

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