GENERATOR &

ITS AUXILIARY
SYSTEM

June 23, 2022 PMI Revision 00 1

• GENERATORS AND ITS AUXILIARY CAN BE
BROADLY DEVIDED INTO THREE SYSTEMS
• A) Stator water system
• B) Seal oil system
• C) Gas system
• D) Generator

June 23, 2022 PMI Revision 00 2

 STATOR WATER SYSTEM
EXPANSION FLOW
TANK METERS
GAS TRAP
DIFF PRESS
SWITCH
MAGNET
FILTER FILTERS

FSI
DIFF PRESS. I

CONDUCTIVITY
POLISH UNIT
MAKE
UP
COOLERS

PUMPS
VACUUM
PUMPS
June 23, 2022 PMI Revision 00 3
 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

June 23, 2022 PMI Revision 00 4

 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.

June 23, 2022 PMI Revision 00 5

 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

June 23, 2022 PMI Revision 00 6

 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

June 23, 2022 PMI Revision 00 7

 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

June 23, 2022 PMI Revision 00 8

 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

June 23, 2022 PMI Revision 00 9

 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 signaling devices for proper
functioning

June 23, 2022 PMI Revision 00 10

 Stator Water System
• Check all the instruments and meters for their proper
functioning
• Adjust make up water pressure around 2.0Kg/cm2
• 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

June 23, 2022 PMI Revision 00 11

 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

June 23, 2022 PMI Revision 00 12

 SEAL OIL SYSTEM
FLOW M.
EE PS PG
BEARING FROM GAS
TE SYSTEM
BEARING TS ES
GAS
EXHAUST FR
TG DPRV
SOST BEARG
DRAINS

IOT
DP
SW
VACCUM VACUUM FILTERS
PUMP TANK
SOP-3
SOP 1 2 DC
OIL
COOLER

CONSTANT PRESS. REGULATORS

WITH ORFICE PLATES
June 23, 2022 PMI Revision 00 13
 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

June 23, 2022 PMI Revision 00 14

 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

June 23, 2022 PMI Revision 00 15

 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

June 23, 2022 PMI Revision 00 16

 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.

June 23, 2022 PMI Revision 00 17

 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

June 23, 2022 PMI Revision 00 18

 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

June 23, 2022 PMI Revision 00 19

 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

June 23, 2022 PMI Revision 00 20

 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

June 23, 2022 PMI Revision 00 21

 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/cm2 from DPRV-A)

June 23, 2022 PMI Revision 00 22

 SEAL OIL SYSTEM
• Set thrust oil pressure (0.5 Kg/cm2 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

June 23, 2022 PMI Revision 00 23

 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 300C 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 400C

June 23, 2022 PMI Revision 00 24

 HYDROGEN GAS SYSTEM

ANALYZER
H2 DISTRIB
CO2 TO
SEALOIL
DPT
H2 DRIER

FILTER DPI
OP
VAPOURIZER
CO2

HYDROGEN
AIR

DRAIN
June 23, 2022 PMI Revision 00 25
 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 CO2 filling
point and adequate no of co2 cylinders

June 23, 2022 PMI Revision 00 26

 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

June 23, 2022 PMI Revision 00 27

 GAS SYSTEM
• Check generator air tightness test is successfully
completed
• Start purging air with CO2 till the purity of CO2
inside casing reaches above 95%
• After CO2 purity reaches as desired start purging
CO2 with Hydrogen
• Continue purging till hydrogen purity reaches above
98%

June 23, 2022 PMI Revision 00 28

 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

June 23, 2022 PMI Revision 00 29

 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

June 23, 2022 PMI Revision 00 30

 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

June 23, 2022 PMI Revision 00 31

 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

June 23, 2022 PMI Revision 00 32

 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)

June 23, 2022 PMI Revision 00 33

 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

June 23, 2022 PMI Revision 00 34

 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

June 23, 2022 PMI Revision 00 35

 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 generator’s 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

June 23, 2022 PMI Revision 00 36

 THANK YOU

June 23, 2022 PMI Revision 00 37