Generator PM Schedule

Sl.No. Equipment 1 Grounding Brushes 2 Liquid Level Detector

Work Required Checking for looseness, contact surface damage Checking for any oil accumulation in sight glass

Stator Slot Temperature Check for different heating with same current in all 3 RTDs three phases

Cooling Gas 4 Temperature 5 Hydrogen Pressure 6 Primary Water Flow Primary Water 7 Temperature Cold Primary Water to Cold Gas Differential 8 temperature

Checking for same temperature at all gas coolers outlet Checking for Value (should not be < 0.4 bar) Checking for Value (should not be < 0.4 bar) Checking for Value (should not be < )

Checking for Value (should not be < 5 Deg C)

Primary Water Pressure 9 before Stator Winding Checking for Value (should not be < ) 10 Coolers Vents Venting Operation Measurement of ground insulation and shaft seal insulation resistance by measuring the potential at defined points during normal running. Measurement of insulation resistance by measuring the potential at defined points during normal running. Measurement of Insulation resistance Changeover: Changeover from inservice pump to stand by pump. First start the stand-by pump manually and then stop the in-service pump manually after some time.

11 Generator EE Bearing Generator Exciter 12 Bearing 13 Rotor

14 Seal Oil Pump-1 and 2

15 DC seal oil pump

Functional Test: Start the DC SOP in parallel with inservice AC SOP. After preset time the DC SOP will stop automatically. Check for healthiness of indicators/ transmitters and pump parameters.

Changeover: Changeover from inservice pump to DC seal oil pump. First start theDC SOP manually and then stop the in-service pump manually after Changeover to DC Seal some time. Again changeover to in-service SOP 16 Oil Pump after half hour. Changeover: Changeover from inservice exhauster to stand by exhauster. First start the stand-by exhauster manually and then stop the in-service exhauster manually after some time. Repacking of bearing gresing device Venting Operation

Bearing Vapour 17 Exhausters Bearing Vapour 18 Exhausters 19 Seal Oil Cooler

20 Seal Oil Line and Valves Check for any leakage in the system Seal Oil Cooler (for wet 21 lay-up only) Changeover operation Seal Oil Cooler (for wet 22 lay-up only) Full water flushing 23 Seal Oil Filters 24 Seal oIl Filters Check for degree of contamination with filter DP. Cleaning

25 Gas System 26 Gas System 27 Gas System 28 Gas System

Check for consumption Leakage areesting Shut off valve free movement Gas supply lines and shut off valves leakage identification

29 Primary Water Pumps 30 Primary Water Pumps 31 Primary Water Pumps Primary water main 32 filters

Bearing Oil level Changeover: Start stand-by pump and stop the in service pump Bearing oil replacement Check for choking through DP across filter

Primary water main 33 filters 34 Primary water fine filter

Filter Cleaning: Take stand-by filter in service with proper venting. Isolate in-service filter and open drain and vent. Check for choking through DP across filter Filter Cleaning: Open the filter bypass and isolate the fine filter. Dismantle and replace the filter elements. Also clean sealing faces and seating rings. Check O-ring for any damage. Venting Operation Checking and recordimg for value at ion exchanger outlet and main circuit Transducer checking by means of selector switch Ion exchanger resin replacement: When condutivity downstream to ion exchanger is higher than the main circuit or > 0.5 mho/cm

35 Primary water fine filter Primary water cooler 36 vents Primary Water 37 Conductivity Primary Water 38 Conductivity Meter Primary water system ion exchanger 39 replacement Primary water alkalizer 40 unit

Check level in NaOH tank NaOH tank filling, during each tank filling the lime filter in the tank vent shall also be replaced. Also check and clean sealing faces.

Primary water alkalizer 41 unit

42 Primary Water Analysis Check for chemistry parameters Supervision for healthiness: With the help of stroboscope individual fuses of diode wheel is checked for any fuse taking radial position due to diode failure. Measure insulation resistance between exciter winding and ground &between diode heat sink and rectifier wheel

Exciter Rectifier Wheel 43 fuses

44 Exciter Winding

45 Exciter Drier Pre-filter

Checking for cleanliness.

46 Exciter Drier dust filter

Checking for cleanliness.

Exciter Drying System 47 make-up air filter Exciter Drying System 48 line filters Exciter Drying System 49 Ventilator Bearings 50 Exciter Cooler Vents

Checking for cleanliness.

Checking for cleanliness. Checking for grease condition Venting Operation

Rotor ground fault Checking for length: It can be measured by using detection system carbon gauge stick made of insulating material inserted into 51 brushes the bore of the brush holder.

Periodicit y Permit Required Daily LWC Every 3 Monthly Months

Rectification Tightening/ Replacement

Weekly

Oil draining. If quantities are beyond acceptable limit, to be analysed and attended in shutdown Nil Slot RTD calibration and compensation checking. If still problem persists, to be analysed and attended in shutdown

Nil

With cooling water cooler inlet valve full open adjust the outlet valve to achieve same outlet temperature. If problem persists, to be analysed and attended in shutdown Nil Nil Nil Nil

Nil

Nil LWC

PTW

PTW PTW

Nil

Nil

Nil

Nil LWC LWC LWC Nil Nil If filter DP is high, Filter cahngeover and filter cleaning is to be done. Nil LWC If consumption is high check flange connection, joints, screw couplings, welds, bushings etc. with soap solution for any leakage. Handy Tector can also be used for leakage detection. Nil LWC PTW PTW Oil level should be at middle of gauge glass with foam on top of it, if lesser same should be topped up. Nil Nil PTW In general it will continue for several years without considreable choking. Nil

PTW Nil

PTW Nil Nil LWC

PTW Considering the daily consumption of around 2 dm3 and tank volume, generally the filling should be required every two months. Nil

LWC Normal Values: Conductivity: <0.5, pH: 8.5-9.0, Na+: 25 250 ppb, Cu: <5 ppb, Fe: <5 ppb Nil The decision for reducing load or withdrawal of generator or continued service depends upon the number of failed fuses/ dioldes Nil

0.5

PTW The filter consits of coarse and fine filter. If choking is observed should be cleaned by air blowing and may be replaced on need basis.

LWC

The dust filters are provided at each branch inlet of exciter drier. After deenergising the filter, the filter should be dismantled, air blown or water washed and if necessary may be replaced. After reassembly, the drier should be kept in operation. LWC

If choking is observed should be cleaned by air blowing or water washing and may be replaced on need basis. If choking is observed should be cleaned by air blowing or water washing and may be replaced on need basis. Greasing every 2-3 years.

LWC

LWC LWC Nil

If length is shortened to unacceptable value, replace carbon brush. The contact face should be made suitable to slip ring contour. The carbon layer shall come before silver layer when seen in the direction of rotation of rotor. LWC

Every 6 months

Annually

Breakdow n/ Need Based

0.5 0.5 0.5

Note: If Coolers are operated for prolonged duration with lower cooling water flow than design, due to low water velocity deposits may grow over the surface. In such conditions coolers are to be flushed with full water flow and cleaned with brushes during short shutdowns. The cooler sections which do not get water for prolonged duration may result into standstill corrosion. Also, the microorganisms if any dies out due to scarcity of living oxygen. Such organisms decays out producing ammonia resulting into stress corrosion of cooler elements. Thus, coolers which are not to be used should be kept in dry condition. The lift oil pressure to the shaft journals is so adjusted that the shaft lift is limited to 50% of bearing top clearance (0.12% of the bearing diameter). At higher pressure the lift oil pressure should settle at 40-80 bar. If the value observed during normal operation is lower, it is indicative of damage in the contact surface/ bearing babbit, leaking oil pipes or defective pressure limiting check valves. If stand-by seal oil cooler is in dry stage from water side its called Dry Lay-up. The drains and vents must be kept open for such coolers. If stand-by seal oil cooler is kept flushed from water side by small flow, it is wet layup type. Such coolers should be flushed with full water every week. According to section 4.6 e in VDE 530 Part-3, not more than two cylinders shall be connected and opened during normal operation. If results of the primary water analysis do not conclude firmly, check for After cationic conductivity in main circuit. This gives indication of other unwarranted anions. The rotor ground fault detection system consists of slip ring and carbon brushes. If a ground fault occurs (as indicated by alarm) winding insulation resistance should be measurd. If the measurement is done in Rotor excited condition, handling of slip ring should be done with great care as full field voltage may be applied to the slip ring in the worst condition.

Generator Air Leakage Calculator (for Air Leak Test)

Sl. No. Prameter 1 Standard Pressure, P0 2 3 4 5 6 7 8 9 10 11 12 Standard Temperature, T0 Standard volume for 1 mole, V0 Initial Casing Pressure at start of test, P1 Initial Barometric Pressure at start of test, pB1 Initial Gas temperature at start of test, T1 Casing Volume, Vg Final Casing Pressure at End of test, P2 Final Barometric Pressure at End of test, pB2 Final Gas temperature at End of test, T2 Test conduction duration Gas Constant, R Unit Bar 0 C Lit Bar Bar 0 C m3 Bar Bar 0 C Hrs m3barK-1mol-1 Value 1.01324 0 22.4 4 1 30 30 3.9 0.9 32 72 0.00008314

13

Initial number of gas moles in Casing, n1

Nos.

5954.408287

14

Final number of gas moles in Casing, n2

Nos.

5678.748467

15

Number of gas moles lost during test

Nos.

275.6676414

16 17

Corresponding Gas Volume lost during test at STP m3 Gas Leakage/ Hr Note: dm /Hr
3

6.174955166 85.7632662

Any gas leakage more than 2.4 m3 /24 Hr or 100 dm3/hr deems the leakage test unsuccessful and calls for leakage identification usi solution at prospective locations viz. flange connections, joints, screw couplings, welds, bushings, etc. After arresting the leakage the test conducted again till completion criterion is met. It is important to understand that the regular leakage of gas takes place through electrica meter and seal oil waste gas system and minimum loss of gas should always be there in system. Thus, any leakage of less than 1.5 m or 62.5 dm3/ hr is considered to be sufficiently tight system. Important:

1. Test with Air, Test Pressure = Operating Pressure, Minimum Test Duration 48 Hrs, Class 0.6 precision pressure gauge for casi pressure measurement

2. The primary water system should also be included in test with waste gas valve closed and primary water tank at atmospheric pr The pressure gauge in the waste gauge to be replaced by more sensitive U - tube type gauge. Any increse of pressure at waste gas lin is indicative of primary water system leakage in generator. The same should be arrested.

Leak Test)
Remarks

Using ideal gas equation for initial condition: pB1)*Vg = n1R*(273+T1), this gives n1 = 1/R*(P1+ pB1)*Vg/(273+T1) Using Ideal Gas Equation for final condition: pB2)*Vg = n2R(273+T2), this gives 1/R*(P2+ pB2)*Vg/(273+T2)

(P1+

(P2+ n2 =

So, ( n1 - n2) =Vg/R* [(P1+ pB1)/(273+T1) - (P2+ pB2)/(273+T2)], But, for STP conditions, P0*V0 = R*(273+T0), So, 1/R = (273+T0)/(P0*V0) Putting this in equation, n1 - n2 = Vg*(273+T0)/(P0*V0)*[(P1+ pB1)/(273+T1) - (P2+ pB2)/(273+T2)] Number of moles lost * Volume of Gas at STP (n1 n2)*V0 = Vg*(273+T0)/P0*[(P1+ pB1)/(273+T1) - (P2+ pB2)/(273+T2)] Gas volume lost in dm3 / duration of test in Hrs

s the leakage test unsuccessful and calls for leakage identification using soap crew couplings, welds, bushings, etc. After arresting the leakage the test shall be understand that the regular leakage of gas takes place through electrical purity should always be there in system. Thus, any leakage of less than 1.5 m3 / 24 hr

m Test Duration 48 Hrs, Class 0.6 precision pressure gauge for casing

h waste gas valve closed and primary water tank at atmospheric pressure. sensitive U - tube type gauge. Any increse of pressure at waste gas line gauge ame should be arrested.