Professional Documents
Culture Documents
0$,17(1$1&(
0$18$/
)25
0:785%2*(1(5$725
:,7+
:$7(5&22/('67$725:,1',1*
',5(&7+<'52*(1&22/('52725:,1',1*
3URMHFW0:<(5$0$586736
%+(/:RUN2UGHU1RV3
3
&XVWRPHU065$,&+8532:(5&253/7'
+$5,':$5
%+$5$7 +($9< (/(&75,&$/6/,0,7('
+HDY\ (OHFWULFDO(TXLSPHQW3ODQW
23(5$7,21 0$,17(1$1&(
0$18$/
)25
0:785%2*(1(5$725
:,7+
:$7(5&22/('67$725:,1',1*
',5(&7+<'52*(1&22/('52725:,1',1*
3URMHFW0:<(5$0$586736
&XVWRPHUM/S RAICHUR POWER CORP.LTD
%+(/:RUN2UGHU1RV3
3
+$5,':$5
%+$5$7 +($9< (/(&75,&$/6/,0,7('
+HDY\ (OHFWULFDO(TXLSPHQW3ODQW
Turbogenerators
Table of Contents
Introduction
Introduction Tab 1
.
.
.
Safety Instruction Tab 2
.
.
e Siemens AG 2011 --
.
Design Data Tab 3.1 .
PrimaryWater
Primary WaterSpecification..........................................................................................................2.1-1639-0002/1
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1639--0002/1
0114E
0106E
0106E
Specification
Gas of Ion Exchange Resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1639--0002/2
Specification..........................................................................................................................2.1-1640-0002 0114E
0106E
0898E
Turbine
AdditiveOil Specification...............................................................................................................2.1-1680-0001
Specification for Alkalizer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1639--0002/3
0114E
0710E
1101E
Approved
Gas Specification Oils..................................................................................................................2.1-1681-0001/1-2
Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1640--0002
0114E
0109E
0898E
Turbine Oil Specificaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1680--0001 0710E
Approved Turbine Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1681--0001/1-2 0109E
Siemens AG
BHEL,Haridwar MK &MAB 2.0--0010--12580 / 1
Energy Sector 0212E
0114E
Dimensions and Weights Tab 3.4
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1670--12580 0114E
0212E
Generator Outline Drawing, Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--3102--160533 Index-A
Index A
.
.
Description of Components and Auxiliary Systems Tab 4 .
.
.
MK - Abstract Tab 4.1 ..
Design and Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1100--0051/1--2 0901E
0114E
Generator Cooling Gas Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1150--0012 0212E
0114E
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1210--0020 1008E
0114E
Stator Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1230--0012 1008E
0114E
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1300--0030 0901E
0114E
Hydrogen Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1440--0026 1008E
0114E
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1450--0001 1010E
0114E
Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1460--0011 1008E
0114E
.
MKA06, MKA07 - Shaft Seal Tab 4.2 .
Description of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--6000--0008 1008E
0114E
Shaft Seal -- Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--6001--0013 0901E
0114E
Insulation and Sealing of Seal Ring Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--6005--0002 1008E
0114E
.
..
MKA10 ... MKA37 - Stator Tab 4.3 .
.
Stator Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2100--0036 0111E
0114E
Outer Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2110--0014 0911E
0114E
Core and Winding Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2130--0016 1208E
0114E
Stator Bearing Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2150--0021/1--2 1008E
0114E
Hydraulic Testing and Anchoring of Stator Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2190--0017 1008E
0114E
Stator Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2200--0024/1-2 1008E
0114E
Mounting of Stator Core and Winding Assembly in Stator Casing . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2201--0038 0911E
0114E
Stator Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2300--0030 1208E
0114E
Connection Diagram of Stator Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2301--0080 0110E
0114E
Stator Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2303--0075 0901E
0114E
Micalastic High Voltage Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2320--0014/1-4 1008E
0114E
Construction of High-Voltage Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2321--0011 1208E
0114E
Stator Winding -- Corona Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2330--0004 1008E
0114E
Coil and End Winding Support System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2340--0018 1008E
0114E
Stator End Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2341--0113 0106E
0114E
Electrical Connection of Bars and Phase Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2350--0024 0701E
0114E
Electrical Bar Connections and Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2351--0010 1208E
0114E
Terminal Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2370--0030 1008E
0114E
Cooling of Terminal Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2371--0035 0210E
0114E
Water Cooliing System -- Ststor Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2380--0006 1008E
0114E
.
..
MKA40 - Rotor Tab 4.4 .
.
Rotor Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3000--0033 1008E
0114E
Cooling of Rotor Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3100--0020 1008E
0114E
D-Cooling System for Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3101--0034 1008DE
0114E
Rotor Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3300--0015 1008E
0114E
Rotor Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3301--0037 0210E
0114E
Rotor End Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3310--0075 0901E
0114E
Arrangement of Damper Bar in Rotor Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3333--0013 0210E
0114E
Rotor Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3350--0003 1008E
0114E
Field Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3370--0016 1010E
0114E
Mechanical and Electrical Connection of EE Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3373--0021 0210E
0114E
Radial Blower .(Rotor
. . . . . .Fan)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3600--0001 0210E
0114E
Rotor Fan and Fan Baffle Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3603--0021 0210E
0114E
..
MKA70 - Cooler Tab 4.5 ..
..
Hydrogen Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--4000--0033 1008E
0114E
Siemens AG
BHEL,Haridwar 2.0--0010--12580 / 2
Energy Sector 0212E
0114E
MKD - Bearing Tab 4.6
Generator Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--5000--0024/1-2 1008E
0114E
Generator Bearing -- Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--5001--0036 1008E
0114E
Measuring of Bearing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--5003--0013 1008E
0114E
Generator Bearing Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--5005--0018 1008E
0114E
Generator Bearing -- Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--5007--0012 1008E
0114E
.
MKW -- Seal Oil System Tab 4.7 .
Seal Oil Diagram -- Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--7111--12580/1--2 0811E
0114E
Seal Oil Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--2603--148221 Index DD
Index
.
..
MKG -- Gas System Tab 4.8
..
Gas Diagram -- Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--7211--12580/1--2 0811E
0114E
Gas Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--2604--148222/001 Index DD
Index
Gas Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--2604--148222/004 Index CC
Index
.
MKF -- Primary Water System Tab 4.9 .
Primary Water Diagram -- Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--7311--12580 0811E
0114E
Primary Water Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--2605--148223 Index CD
Index
.
MKQ -- Waste Gas System Tab 4.10 .
Waste Gas Diagram -- Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8311--12580 0811E
0114E
Waste Gas Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--2604--148222/002 Index CC
Index
.
BHEL,Haridwar
Siemens AG 2.0--0010--12580 / 3
0212E
0114E
Contract Drawings Tab 7
Generator Cross Section --- Longitudinal Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ---0090---160441 Index A
Index A
Generator Cross Section --- Lateral Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24---0090---160642 Index A
Index A
Generator Cooling Gas Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ---0090---160443 Index A
Index A
Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24---0128---148718 Index A
Index A
Generator Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24---3102---160533 Index A
Index A
Operation Tab 9 .
.
Turning and Running Up Tab 9.1
.
Preparations for Starting --- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 ---5000---0002 0806E
0114E
Hints for Cooler Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---5003---0006/1-2 0210E
0114E
Turning Gear Operation and Runup of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 ---8010---0012 0210E
0114E
Simplified Generator Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---8011--- 0027 0210E
0114E
Startup, Voltage Regulation With Automatic Control --- Static Excitation System . . . . . . . . . . . . . 2.3---8030---0021 0806E
0114E
Operation Under Load Tab 9.2 .
On-Load Running, Voltage Regulation With Automatic Control --- Static Excitation System . . . . 2.3---8130---0026 0209E
0114E
On-Load Running, Changeover of Automatic Voltage Regulator from Automatic to Manual --- .
Static Excitation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---8150---0021 0709E
0114E
On-Load Running, Changeover of Automatic Voltage Regulator from Manual to Automatic --- .
Static Excitation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---8160---0019 0709E
0114E
Generator Load Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---8170---0050 0210E
0114E
.
Shutdown Tab 9.3 .
Shutdown of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 ---8310---0012 0610E
0114E
Generator Shutdown Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---8311---0025 0709E
0114E
Unloading and Shutdown, Voltage Regulation With Automatic Control --- ..
Static Excitation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---8330---0024 0806E
0114E
.
Standstill Tab 9.4 .
Supervision of Generator During Standstill --- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 ---8400---0030 0709E
0114E
Supervision of Generator During Standstill --- Slipring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---8900---0020 0901E
0114E
.
Trouble-Shooting Tab 10 .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---9000---0001 0808E
0114E
.
MKA10 ... MKA37 --- Stator .
Stator and Generator Supervisory Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 ---9200---0031/1-3 0710E
0114E
MKA40 --- Rotor .
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---9310---0001 1208E
0114E
MKA70 --- Cooler .
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 ---9440---0030/1-2 0511E
0114E
MKD --- Bearings .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---9450---0001 ..
0710E
0114E
.
Maintenance Tab 11 ..
.
..
.
Maintenance in Operation Tab 11.1
Maintenance and Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 ---4200---0001 0710E
0114E
Survey on Maintenance and Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 ---4205---12580 0212E
0114E
MKA10 ... MKA37 --- Stator .
.
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4---4210---0061/1-2 0210E
0114E
.
MKA40 --- Rotor .
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4---4310---0003 0710E
0114E
.
Siemens AG
BHEL,Haridwar 2.0 --0010 --12580 / 4
Energy Sector 0114E
0114E
Maintenance at Generator Standstill Tab 11.2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0010--0008 0909E
0114E
.
MK - Abstract .
Determination of Dewpoint Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0019--0001 0109E
0114E
Packing, Transport and Storage of Generator Rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0030--0003/1-4 0710E
0114E
Checking Desiccant in Packing of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0032--0001 0109E
0114E
Insulation Resistance Measurements on Rotor Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0033--0002 0909E
0114E
Preparation of Machinery Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0200--0001 0210E
0114E
Checking the Insulation for Protection From Shaft Currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0300--0002/1-3 0210E
0114E
Flushing the Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0320--0001/1-2 0310E
0114E
Measures to prevent Corrosion During Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1003--0021 0504E
0114E
Preventive Measures to Avoid Moisture Condensation -- Survey . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1005--0003 0109E
0114E
Inspection Schedule -- Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1010--0005/1-2 1110E
0114E
Inspection Schedule -- Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1020--0022 0302E
0114E
Inspection Schedule -- Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1030--0025 0408E
0114E
Inspection Schedule -- Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1040--0016 0109E
0114E
Inspection Schedule -- Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1050--0005 0109E
0114E
Inspection Schedule -- Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1060--0002 0109E
0114E
Inspection Schedule -- Generator Supervisory Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1080--0005 0109E
0114E
Measures for Preservation of Generator During Standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1100--0025 0109E
0114E
MKA06, MKA07 - Shaft Seal .
Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--6000--0005 0114E
0109E
Insulation and Sealing of Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--6110--0002/1-2 0114E
1010E
.
MKA10 ... MKA37 -- Stator .
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2000--0016 0114E
0409E
Check List for Works on Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2001--0001 0109E
0114E
Cementing the Joints of Profiled Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2120--0001 0109E
0114E
Generator Drying System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2155--0002 0109E
0114E
Mounting of Inner Labyrinth Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2162--0004/1-2 0109E
0114E
Fitting New Seal Strips to Labyrinth Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2163--0001/1-3 0710E
0114E
Insulation Resistance Measurements on Stator Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2300--0004/1-2 1194E
0114E
Drying the Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2310--0014 0806E
0114E
Electrical Tests on Stator Winding With vacuum Impregnated MICALASTIC .
High-Voltage Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2320--0001/1-3 0409E
0114E
Treatment of Bolted Contact Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2350--0001 0109E
0114E
.
MKA40 -- Rotor 0114E
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--3000--0016 0310E
0114E
Insulation Resistance Measurements on Rotor Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--3300--0004 0310E
..
MKA70 -- Cooler 0114E
Hydrogen Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--4000--0020 0909E
..
MKD - Bearings
0114E
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--5000--0009 0109E
Siemens AG
BHEL,Haridwar 2.0--0010--12580 / 6
Energy Sector 0212E
0114E
Exciter Table of Contents
General
1 General
Table of Contents.............................................................................................. ELR-1.0-0001-0209/14 (
Preface.............................................................................................................. ELR-1.1-0001-0001 (
Addresses ......................................................................................................... ELR-1.2-0001-0001 (
General safety instructions ............................................................................... ELR-1.3-0001-0001/14 (
2 Technical Data
2.1 Identification
Identification Data ............................................................................................. ELR-2.1-0001-0209 (
Rating Plate Data .............................................................................................. ELR-2.1-0002-0209/12 (
Siemens AG
BHEL,Haridwar ELR-1.0-0001-0209 / 1
Energy Sector 11(
Exciter Table of Contents
General
3.1 General
General Technical Description.......................................................................... ELR-3.1-0001-0209/14 1(
3.2 Cooler
Cooler Technical Description......................................................................... ELR-3.2-0001-0209 (
'U\HU
'U\HU7HFKQLFDO'HVFULSWLRQ(/5(
'U\HU'UDZLQJD(
0HDVXULQJ'HYLFHVDQG6XSHUYLVRU\(TXLSPHQW
%HDULQJ9LEUDWLRQ7HFKQLFDO'HVFULSWLRQ(/5(
6KDIW9LEUDWLRQ7HFKQLFDO'HVFULSWLRQ(/5(
6KDIW9LEUDWLRQ'UDZLQJ$(
Copyright Siemens AG 2011 - All Rights Reserved
*URXQG)DXOW'HWHFWLRQ(/5(
6WURERVFRSH(/5(
5HVLVWDQFHWHPSHUDWXUHGHWHFWRU(/5
7KHUPRFRXSOH(/5(
5 Troubleshooting
General ............................................................................................................. ELR-5.1-0001-0209 (
Ground Fault Detection..................................................................................... ELR-5.2-0001-0209 (
Exciter Temperatures........................................................................................ ELR-5.3-0001-0209 (
Cooler................................................................................................................ ELR-5.4-0001-0209/12 (
Fuses on the Exciter ......................................................................................... ELR-5.5-0001-0209/13 (
Stroboscope ...................................................................................................... ELR-5.6-0001-0209/12 (
Dryer ................................................................................................................. ELR-5.7-0001-0209 (
BHEL,Haridwar
Siemens AG ELR-1.0-0001-0209 / 2
Energy Sector (
Exciter Table of Contents
General
6 Maintenance
6.1 General
General ............................................................................................................. ELR-6.1-0001-0209 (
Standstill during Maintenance, Long-term Storage .......................................... ELR-6.1-0002-0209 (
6SHFLDO$VVHPEO\,QVWUXFWLRQV011
6SHFLDO$VVHPEO\,QVWUXFWLRQV(/5(n Ex
Pilot Exciter Housing......................................................................................... ELR-8.4-0001-0209/12 1011
Main Pole Coil .................................................................................................. ELR-8.5-0001-0209/12 1011
Terminals and Line Connections Main and Pilot Exciter .................................. ELR-8.6-0001-0209/14 1011
End Shield (DE and NDE)................................................................................. ELR-8.7-0001-0209/12 1011
Seal........................................................................... ELR-8.8-0001-0209/12 1011
Sealing (NDE) ........................................................................................... ELR-8.9-0001-0209/12 1011
Cover (Main Exciter Air Guide) ......................................................................... ELR-8.10-0001-0209/12 1011
RR Air Guide Cover .......................................................................................... ELR-8.11-0001-0209/12 1011
Temperature Measuring Point Bearing............................................................. ELR-8.13-0001-0209/12 1011
Ground Fault Detection..................................................................................... ELR-8.14-0001-0209/12 1011
Stroboscope ...................................................................................................... ELR-8.15-0001-0209 1011
Fuse Monitoring 1 (Stroboscope) ..................................................................... ELR-8.16-0001-0209/12 1011
Coupling bolt ..................................................................................................... ELR-8.17-0001-0209/12 1011
RR Heat Sink ................................................................................................... ELR-8.18-0001-0209/12 1011
RR Wheel (Assembly)....................................................................................... ELR-8.19-0001-0209/12 1011
Siemens AG
BHEL,Haridwar ELR-1.0-0001-0209 / 3
Energy Sector (
Turbogenerators
Preface
Introduction
Siemens AG
BHEL,Haridwar MK &MAA 2.0--0030--0001
Energy Sector 0E
Turbogenerators Notes on the Use of the
Introduction Technical Documentation
The Operating and Maintenance Manual comprises Each section contains a number of separate documents.
several folders containing the following sections: Please check your manual against the Table of Contents,
and notify (see 2.0--0050) if you should identify any
1 Introduction mismatches or have any other queries regarding your manual.
2 Safety Instruction
Identification Number
3 Technical Data
This identification number is sufficient reference for locating
3.1 Design Data
a particular document within the manual. However, when
3.2 Limit and Setting Values
ordering documents, the complete document identification
3.3 Specifications
code must be quoted.
3.4 Dimensions and Weights
4 Description of Components and Auxiliary Systems Document Number
4.1 Abstract The document number comprises the identification number
4.2 Shaft Seal detailed above, a variant number, a page number and a date
4.3 Stator reference number complete with language code.
4.4 Rotor The page number is omitted from single-sided documents.
4.5 Cooler
4.6 Bearing
4.7 Seal Oil System Identification number
4.8 Gas System
Variant number
4.9 Primary Water Sytem
4.10 Waste Gas System Page number
All Rights Reserved
9 Operation
Date
9.1 Turning and Running Up
9.2 Operation under Load
9.3 Shutdown Supplements
9.4 Standstill The contents of this manual are subject to a continual
Copyright
Spare Parts
The part numbers indicated in the documents contained in
this manual are not suitable for ordering spare parts. Please
order your spare parts in line with the instruction detailed in the
Spare Parts section of this manual.
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MK &MAA 2.0--0040--0041
Energy Sector 0511E
0114E
Turbogenerators
Addresses
Introduction
or:
Siemens AG
Energy Sector Siemens AG
Standort Muelheim Energy Sector
Generator-Dokumentation Standort Muelheim, Hafen
Postfach: 10 17 55 45473 Muelheim a.d. Ruhr
45466 Muelheim a.d. Ruhr Germany
All Rights Reserved
Germany
Muelheim (Ruhr) -Speldorf, Anschlussgleis
Telefon: +49 208 456-5118
Telefax: +49 208 456-2021
E-Mail: Generator.Doku@siemens.com If you have any queries regarding the correct address or
e Siemens AG 2008 --
Siemens AG maintains representatives in all major cities in Company, department and name of individual in charge.
Germany and in nearly every part of the world. For spare parts
and the services of personnel, as weIl as technical questions, In addition, the following information should be included in
contact our local representatives. the shipment:
Postfach 10 17 55
For LCL shipments and railway express:
45466 Muelheim a.d. Ruhr
Germany
Siemens AG
Distribution: UNRESTRICTED
Energy Sector
for packages and parcels:
Standort Muelheim, Hafen
Rheinstrae 100 Rheinstrae 100
45478 Muelheim a.d. Ruhr 45478 Muelheim a.d. Ruhr
Germany Germany
Siemens AG
BHEL,Haridwar MK &MAA 2.0--0050--0001
Energy Sector 0E
Turbogenerators KKS
Introduction Power Plant Identification System
Category 0
A Equipment units
B Components (such as vessels or pipe)
Category 1
(broken down into 4 function keys) C Direct measuring circuits
Category 2
(broken down into 3 equipment T: (Equipment Unit Keys 2)
units keys) This letter is used to identify Equipment Unit Key 1.
As a rule the following combinations of letters are used:
3MKD11 CT014A
AA Valves (including actuators)
AC Heat exchangers
3: (Category 0)
AN Compressors and fans
This number identifies the actual unit in power plants com-
AP Pumps
prising more than one unit. This identifier is not used for single-
AT Cleaning and drying equipment as well as filters, strainers
unit power plants, and is not required for system diagrams, lists
and separators
and descriptions.
BB Tank
It is not defined by the KKS but can be selected freely, e.g.
BP Orifices
in line with the actual unit designation.
BR Piping and tubing
CF Flowmeters
M: (Function Key 1) CL Level measuring instruments
Distribution: UNRESTRICTED
This letter identifies the main machine set. CM Humidity and moisture measuring instruments
CP Pressure gauges and transducers
MK: (Function Key 1 + 2) CQ Instruments used for measuring the quality of a fluid
This letter code identifies the generator. All generator com- (e.g. gas purity meters)
ponents and auxiliary systems use this identifiers for Function CT Temperature measuring instruments
Keys 1 and 2. CY Vibration measuring instruments
Siemens AG
BHEL,Haridwar MK &MAA 2.0--0060--0001 / 1
Energy Sector 0E
014: (Equipment Unit Keys n) A: (Equipment Unit Key 3)
This 3-digit number is a serial number used to distinguish In cases where measuring units are equipped with several
components with identical Function Keys (1 through 4) and sensors, the individual sensors are distinguished by means of
Equipment Unit Keys (1 and 2). It is possible to allocate specific this letter.
number ranges to specific functions.
Number
Valves: AA ... Pipes: BR ... Measuring Circuits: C. ...
consecutively
001 - 050
Valves, general
051 - 100
Main pipes
101 - 150 Binary and analog measuring
Valves in main pipes Control valves
151 - 190 circuits
Table 1 KKS Numbering System for Valves, Pipes and Measuring Circuits
Siemens AG
BHEL,Haridwar 2.0--0060--0001 / 2
Energy Sector 0E
Turbogenerators Symbols for Supply Circuits
Introduction and Supervisory Equipment
M Control valve,
Piping motor-operated
Shutoff valve,
Liquid
solenoid-operated
Control valve,
Combustible gas
hydraulically or pneumatically operated
Electric heater,
Exhaust to atmosphere above roof CO2 flash evaporator
Copyright
Liquid tank
Valves and Fittings
Gas bottle
Shutoff valve
Screw pump
safety function
Siemens AG
BHEL,Haridwar MK &MDB 2.0--0070--0001 / 1
Energy Sector 0E
Treatment Systems Meanings of Identification Letters and
Symbols to DIN 19 227, Part 1
Q Quality variables
Mixed-bed filter
(e.g. O2 or conductivity)
Limit of supply
Component limit
Siemens AG
BHEL,Haridwar 2.0--0070--0001 / 2
Energy Sector 0E
Generator General Safety Information
Safety Information for SGen5 Generators
WARNING
fatal injuries during the work or in subsequent operation.
The information and instructions shall therefore be ob-
served and implemented exactly as described.
All Rights Reserved
CAUTION
e Siemens AG 2010 --
Siemens AG
BHEL,Haridwar MKA 2.0--0100--0003 / 1
Energy Sector MKC 01E
The use of these pictograms is explained below:
DANGER
Observe instructions!
Electrical shock hazard All of the information given in this documentation is import-
ant for safety, including information which is not explicitly iden-
tified through signal words and symbols. Examples of informa-
tion which is not explicitly identified include information on
technical limits or approved consumables. This information
which is not explicitly identified must be also observed and im-
plemented exactly as described. Failure to comply with these
instructions can lead to severe or even fatal injuries during the
work or in subsequent operation.
Explosion hazard
4 Organizational Notices
Siemens AG
BHEL,Haridwar 2.0--0100--0003 / 2
Energy Sector 01E
Turbogenerators
Safety Equipment for Hydrogen Operation
Safety Instructions
system should be tripped (cf. Section 2.3--9640 Gas Pressure vents the formation of explosive hydrogen-air mixtures even
and Volume Flow Rates). The turbine trip is activated upon under faulted conditions when hydrogen degasses from the
tripping of the fire protection valve and/or the fast hydrogen de- oil.
pressurization system. 5 Hydrogen Bottle Supply
Following activation of the fast depressurization system To avoid any undue hazard to the plant by the hydrogen
(comprising two solenoid valves in the vent gas system plus supplies, the volume of hydrogen that can be stored inside the
the fire protection valve) the generator hydrogen pressure is turbine buildings is limited to 80 m3 (s.t.p.). Only two hydrogen
reduced to near-atmospheric pressure within 5 to 10 minutes. bottles may be opened at any one time during normal opera-
Depressurization via the fire protection valve alone is slightly tion (this does not apply to gas filling).
e
slower.
Copyright
BHEL,Haridwar MKG
Siemens AG MKQ &MDB 2.1--8310--0004
Energy Sector MKW 0E
Technical Data
BHEL,Haridwar MK &MDA
0114E
Turbogenerators
General and Electrical Data
Technical Data
General
Job name 2 x 800 Yeramarus Therminal Power Station
Generator type Sgen5--3000W (125/67)
Year of manufacture 2011
2014
Stator serial no.
12580
Rotor serial no.
Shaft identification no. 9U938
Current 20.122 A
Voltage 27 kV r 5%
Speed 50 s-1
Frequency 50 Hz
-- All Rights Reserved
Siemens AG
BHEL,Haridwar MK &MDA 2.1--1607--12580
Energy Sector 0811E
0114E
Turbogenerators Technical Data
Technical Data Reactive Capability Curve
Siemens AG
BHEL,Haridwar MK &MEC 2.1--1611--12580
0811E
0114E
Energy Sector
Design Data
Turbogenerators
Permissible Loading at Rated P.F.
Technical Data
During Voltage and Frequency Deviations
+5%
Voltage deviation
1 2 5 10 min Duration at rated MVA
Voltage deviation
-- All Rights Reserved
* During the two hours following a fault, generator may be operated only in range permissible for continuous operation with rated MVA.
Siemens AG
BHEL,Haridwar MK &MDA 2.1--1612--0002
Energy Sector 0203E
0114E
Distribution: UNRESTRICTED Copyright e Siemens AG 2011 -- All Rights Reserved
Energy Sector
BHEL,Haridwar
Technical Data
Turbogenerators
101
Siemens AG
8
6
4
3
i22 t = 8 s
100
MK
6
&MDA
3
2
Design Data
10-1
i2 = 0.08 continuous
8
6
Unbalanced Load-Time Curve
4
3
3 4 6 8 100 2 3 4 6 8 101 2 3 4 6 8 102 2 3 4 6 8 103
Time t in s
0114E
2.1--1614--0062
0411E
Distribution: UNRESTRICTED Copyright e Siemens AG 2005 -- All Rights Reserved
Energy Sector
l 6.5
Technical Data
l rated
BHEL,Haridwar
Turbogenerators
Siemens AG
6
5.5
MKA
3.5
&MDA
3
2.5
2
Current Overload Capability
1.5
1
0 20 40 60 80 100 120
time in sec
0114E
2.1.--1615--0002
1205E
Turbogenerators Design Data
Technical Data Permissible Synchronizing Criteria
Generator Generator
+10 _
Angular error in
leading, subsynchronous _ leading, supersynchronous
+7
+5
All Rights Reserved
--5
_
Angular error in
Generator Generator
lagging, subsynchronous lagging, supersynchronous
--10
Distribution: UNRESTRICTED
BHEL,Haridwar
Siemens AG MK &MDA 2.1--1617--0001
Energy Sector 1205E
0114E
Distribution: UNRESTRICTED Copyright e Siemens AG 2011 -- All Rights Reserved
Energy Sector
U . frated
Technical Data
Urated f
Turbogenerators
BHEL,Haridwar
Siemens AG
1.5
1.4
1.3
MKA
1.2
&MDA
1.1
SGen5--3000W
with Overvoltage
1.0
0 10 20 30 sec.
0.5 1 2 3 4 5 min.
Limited Duration of Open-Circuit
5 10 20 30 min.
After an overfluxing operation with U/Urated . frated/f >1.1 there must be a phase of at least 15 min. with
U/Urated . frated/f < 1.1 before a further no load operation is conducted with U/Urated . frated/f >1.1 .
0811E
0114E
2.1--1618--12580
Turbogenerators
Cooler Data
Technical Data
Siemens AG
BHEL,Haridwar MK &MDA 2.1--1620--12580
Energy Sector 0114E
0811E
Turbogenerators Operating and Setting Values
Technical Data General
Strict observance of the operating and setting values is a the specific site conditions, such as static head in case of pres-
prerequisite for reliable operation of the turbogenerator. sure measuring points or thermal characteristics in case of
Separate tables are provided for the various design groups temperature measuring points. These calculated values are
of the generator and its auxiliaries. They show the transmitters intended as guiding values for making the preliminary settings
activating the controls and alarms as well as the transmitters during initial commissioning of the unit.
acting on the generator protection circuits. These settings require certain corrections to account for
The Remark column contains additional information on the actual conditions. The final settings obtained after startup
controls, temperatures and pressures. and initial load operation, if not coincident with the table values,
All operating and setting values refer to rated output of gen- are to be promptly submitted to SIEMENS AG Energy Sector
erator and maximum cooling water temperatures under (address, see 2.0--0050) for revision.
steady-state conditions. Revised pages will then be sent to the holder of the
The operating and setting values initially specified in this Technical Documentation Generator (instruction manual)
manual are based on experience under due consideration of as updates.
All Rights Reserved
e Siemens AG 2008 --
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MK &MDA 2.1--1630--0006
Energy Sector 1008E
0114E
BHEL,Haridwar 2.1-1632-12580/1
0114E
BHEL,Haridwar 2.1-1632-12580/2
0114E
BHEL,Haridwar 2.1-1632-12580/3
0114E
BHEL,Haridwar 2.1-1633-12580
0114E
BHEL,Haridwar 2.1-1633-12580
0114E
BHEL,Haridwar 2.1-1636-12580
0114E
BHEL,Haridwar 2.1-1638-12580
0114E
Turbogenerators Lists
Technical Data Measuring Point List
All Rights Reserved
e Siemens AG 2011 --
Copyright
Distribution: UNRESTRICGTED
Siemens AG
BHEL,Haridwar MK &MDA 2.1--1635--12580 / 1
Energy Sector 0811
0114E
Turbogenerators Lists
Technical Data Measuring Point List
All Rights Reserved
e Siemens AG 2011 --
Copyright
Distribution: UNRESTRICGTED
Siemens AG
BHEL,Haridwar MK &MDA 2.1--1635--12580 / 2
Energy Sector 0114E
0311
Turbogenerators Lists
Technical Data Measuring Point List
All Rights Reserved
e Siemens AG 2011 --
Copyright
Distribution: UNRESTRICGTED
Siemens AG
BHEL,Haridwar MK &MDA 2.1--1635--12580 / 3
Energy Sector 0311
0114E
Turbogenerators Lists
Technical Data Measuring Point List
All Rights Reserved
e Siemens AG 2011 --
Copyright
Distribution: UNRESTRICGTED
Siemens AG
BHEL,Haridwar MK &MDA 2.1--1635--12580 / 4
Energy Sector 0311
0114E
Turbogenerators Lists
Technical Data Measuring Point List
All Rights Reserved
e Siemens AG 2011 --
Copyright
Distribution: UNRESTRICGTED
Siemens AG
BHEL,Haridwar MK &MDA 2.1--1635--12580 / 5
Energy Sector 0311
0114E
Turbogenerators Lists
Technical Data Measuring Point List
All Rights Reserved
e Siemens AG 2011 --
Copyright
Distribution: UNRESTRICGTED
Siemens AG
BHEL,Haridwar MK &MDA 2.1--1635--12580 / 6
Energy Sector 0311
0114E
Turbogenerators Lists
Technical Data Power Consuming Device List
All Rights Reserved
e Siemens AG 2011 --
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MK &MDA 2.1--1637--12580 / 1
Energy Sector 0811
0114E
Turbogenerators Lists
Technical Data Power Consuming Device List
All Rights Reserved
e Siemens AG 2011 --
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MK &MDA 2.1--1637--12580 / 2
Energy Sector 0311
0114E
Turbogenerators Specifications
Technical Data Primary Water Specification
The water used must not contain any contaminants that H Ammonia : Minimum; test with Nesslers solution
might have a harmful effect on the materials used in the as a reagent must not cause a
primary water system. For this reason, the water shall meet the change in color
following quality criteria:
H Cu, dissolved : Less than 20 ppb
H Fe, dissolved : Less than 20 ppb
H Conductivity : $10mmoh/cm, preferably 0.5mmho/cm
H Dissolved solids : The water must not contain chemi-
H pH : 6 -- 8 cals from treatment processes, such
as hydrazine, morpholine, levoxine,
H Dissolved O2 : Minimum, preferably less than 100ppb phosphates, etc.
H Dissolved CO2 : Minimum; downstream of a strongly If the water to be used does not meet these quality criteria,
H Chlorides : acidic cation exchanger, a conductiv- Siemens AG / PG -P261 -- Werk Mlheim * shall be notified for
H Others anions : ity of 0.2 mmho/cm is permissible their evaluation and approval.
-- All Rights Reserved
e Siemens AG 2006
Copyright
Distribution: UNRESTRICTED
* Address: Siemens AG
Power Generation
Postfach 10 17 55
D -- 45466 Mlheim a.d. Ruhr
Siemens AG
BHEL,Haridwar MKF &MEC 2.1--1639--0002 / 1
Energy Sector 0106E
0114E
Turbogenerators
Gas Specification
Technical Data
Siemens AG
BHEL,Haridwar MKG &MDA 2.1--1640--0002
Energy Sector 0898E
0114E
Turbogenerators
Turbine Oil Specification
Technical Data
Introduction Requirements
This specification covers the requirements to be met by the In conformity with DIN 51519, oils of the ISO viscosity
turbine oils used for SIEMENS turbine-generator units. classes ISO VG 32 and ISO VG 46 shall be used.
The turbine oil shall contain no additives having an adverse
effect on the materials used in the oil system. In addition, the
WARNING additives shall be free from metal-containing organic com-
Health hazard. Turbine oil can damage your health. Avoid any pounds (e.g. zinc-containing organic compounds).
direct contact with turbine oil and thoroughly wash off any tur- The turbine oil shall give satisfactory performance without
bine oil after contact with bare skin. undergoing any adverse changes at bearing temperatures of
130 _C (266 _F) max. and oil tank temperatures of 80 _C
Dependent on the turbine speed, only turbine oils of grades
(176 _F) max.
TD 32 and TD 46 acc. to DIN 51515, Part 1 shall be used.
The turbine oil shall be suitable for being blended with rem-
These are paraffin-base mineral oils containing additives for
nants (4 vol. %, max.) of an equal-base turbine oil of a different
improved corrosion protection and resistance to deterioration.
brand. This shall not result in any harmful change in the oil
Turbine oils having a higher or lower viscosity must not be
properties.
used without the approval of SIEMENS.
Provided that the necessary hygiene precautions are taken
Special requirements must be observed in the case of
the turbine oil shall not cause a hazard to the health of the
turbine-generator units incorporating gears.
personnel handling the oil.
A list of the turbine oils permissible for the above applica-
tions is available from SIEMENS.
-- All Rights Reserved
Siemens AG
BHEL,Haridwar MK &MDA 2.1--1680--0001
Energy Sector 0710E
0114E
Turbogenerators
Approved Turbine Oils
Technical Data
Lube-oils for turbine-generator sets must be selected rately in the third column of the tables below. The oils for
taking into account the specified viscosity grade. For geared geared turbines are listed in Table 2. Note that oils for geared
turbine-generator sets it is necessary to select an oil specifi- turbines can also be used in turbine-generator sets without
cally designed for geared turbines. gearing. In such cases we recommend that Siemens AG PG,
In most cases, the ISO viscosity grade is indicated in the be consulted.
product designation. For a better overview, it is shown sepa-
Siemens AG
BHEL,Haridwar MK &MDC 2.1--1681--0001 / 1
Energy Sector 0109E
0114E
Table 2: Approved Oils for Geared Turbines ( January 2002)
Manufacturer/ Product Viscosity Manufacturer/ Product Viscosity
Supplier Designation Grade Supplier Designation Grade
TP 32 32 Mobil DTE AW 32 32
Addinol
TP 46 46 Mobil Mobil DTE AW 46 46
Power Turbo 32 32 by ExxonMobil Mobil DTE 832 32
Apar Industries Ltd.
Power Turbo 46 46 Mobil DTE 846 46
Kosmol TF 32 32 OMV turb HTU-SI 32 32
Aral OMV
Kosmol TF 46 46 OMV turb HTU-SI 46 46
Turbinol 32 EP 32 QALCO Turbine Oil T 46 46
Turbinol 46 EP 46 Aries Turbogas
BP 32
Turbinol X EP 32 32 ISO 32
Repsol
Turbinol X EP 46 46 Aries Turbogas
46
Regal EP 46 46 ISO 46
Regal Premium Savita Chemicals Daphne Super
32 46
Caltex EP 32 Ltd. Turbine Fluid AW 46
Regal Premium Wintershall Wiolan
46 32
EP 46 DW-G 32
Perfecto AWT 32 32 Wintershall Wiolan
46
Schmierstoff- DW-G 46
Perfecto AWT 46 46
raffinerie Salzbergen Wintershall Wiolan
Castrol Perfecto IP105 32 32
DWP 32
Perfecto XPG 32 32
Wintershall Wiolan
Perfecto XPG 46 46 46
DWP 46
Turbinas EP 32 32
Cepsa Turbo Oil CC 32 32
Turbinas EP 46 46
Turbo Oil CC 46 46
Teresso EP 32 32 Shell Turbo Oil S 32 32
Teresso EP 46 46
Turbo Oil S 46 46
Esso / Exxon Teresso GT EP 32 /
32 Turbo Oil GT-EP 32
by ExxonMobil Terestic GT EP 32
Regal EP 32 32
Teresso GT EP 46 /
46 Regal EP 46 46
Terestic GT EP 46
Texaco Regal Premium
Renolin TGD 32 32 32
Fuchs DEA EP 32
Renolin TGD 46 46
Regal Premium
HPC (Hindustian Turbinol XT 32 32 46
EP 46
Petroleum Corp.) Turbinol XT 46 46
Preslia 32 32
Indian Oil Corp. Servoprime 32T 32
TotalFinaElf Preslia 46 46
(IOC) Servoprime 46T 46 (Lubrifiants S.A.) Preslia GT 32 32
Preslia GT 46 46
YPF Turbina EP 32 32
Siemens AG
BHEL,Haridwar 2.1--1681--0001 / 2
Energy Sector 0109E
0114E
Turbogenerators Technical Data
Technical Data Weights
NOTE:
The weights specified above were calculated. The tolerance of the weights amounts to therefore 10%.
Siemens AG
BHEL,Haridwar MK &MDA 2.1--1670--12580
Energy Sector 0212E
0114E
Turbogenerators General Design Features
Description Design and Cooling System
The two-pole generator uses direct water cooling for the The hydrogen is circulated through the generator interior in
stator winding, and direct hydrogen cooling for the rotor a closed system by means of a single multi-stage axial-flow fan
winding, phase connectors and bushings. The losses in the which is arranged at the TE rotor end. The fan draws the hot
other generator components, such as core losses, friction and gas from the air gap and the core and delivers it to the coolers.
windage losses as well as stray losses are dissipated to the Downstream of each cooler, the gas is divided into several flow
hydrogen. paths as follows:
The generator frame is pressure--resistant and gastight and
equipped with end shields at the turbine end as well as the Flow path I routes the cold gas through ducts in the stator
exciter end. The hydrogen coolers are arranged vertically frame to the EE end-winding space where the cold gas flows
inside of the cooler section at the turbine end. along the clamping fingers before entering the axial bores in
The generator comprises the following components: the core. For this purpose, the clamping fingers and pressure
plate are designed as gas ducts to enable the cold gas to be
J Stator routed between clamping fingers and end lamination into the
Outer Casing stator core. Along its path through the stator core from the EE
Stator core and winding assembly to the TE, the gas absorbs the heat given off by the stator core
Cooler section before exiting the core at the turbine end via the ducts along
Hydrogen coolers the clamping fingers and entering the stator end--winding
End shields space from where it is returned to the coolers by the axial flow
fans.
All Rights Reserved
J Rotor
Flow path II routes the cold gas under the hub of the fan into
Rotor shaft
the rotor end--winding space for direct cooling of the TE half of
Rotor winding
the rotor winding. The rotor winding is symmetrical relative to
Rotor retaining rings
e Siemens AG 2001 --
The following auxiliary equipment is required for generator The cooling gas for the slot portion enters the hollow
operation: conductors through openings in the end winding and flows
through these conductors to the center of the rotor body. The
J Oil system hot gas is then discharged into the air gap between the rotor
body and the stator through radial openings in the conductors
J Gas system and the rotor slot wedges. The cooling gas holes are arranged
J Primary water system at different levels in the conductor assembly to give each
hollow conductor its own cooling gas outlet.The cooling gas for
J Excitation system the end winding is admitted through the end face and flows
through the conductors up to approximately the pole center,
where it passes into a collection compartment and is then
discharged into the air gap via slots in the end of the rotor body.
2 Cooling System
Flow path III routes the hydrogen to the EE rotor end-winding
The heat losses generated in the generator interior are space for direct cooling of the exciter-end half of the rotor
dissipated to the secondary coolant (such as raw water or winding. Because of the symmetrical configuration of the
condensate) via the hydrogen and primary water. cooling gas flow, the cooling is performed in the same manner
The generator is exclusively cooled by direct cooling where as for the turbine-end half of the rotor winding. The hot gas also
Distribution: UNRESTRICTED
the heat is dissipated directly to the coolant. This means that flows to the center of the rotor before being discharged to the
hot spots and large temperature differentials between adjacent air gap.
components which could lead to different thermal expansion
are largely eliminated thus minimizing mechanical stresses Flow path IV routes the cold gas through the flux shield and
particularly with regard to the copper conductors, insulation, the inner rim of the flux shield in the TE stator end-winding
rotor and the stator core. space.
Siemens AG
BHEL,Haridwar MKA &MDB 2.1--1100--0051 / 1
Energy Sector 0901E
0114E
Flow path V routes the cold gas through the flux shield in the the secondary coolant (raw water, or condensate). The pri-
TE stator end-winding space. mary water is circulated in a closed system and dissipates the
absorbed heat to the secondary cooling water. The pump is
Flow path VI routes the cold gas radially into the TE core end. supplied with cold primary water from the primary water cool-
This flow is required since the gas for axial core cooling flows ers, and delivers the water to the generator via the filter. Up-
from the exciter end to the turbine end which means that it has stream of the generator, the cooling water flow is divided into
already absorbed heat when it exits the core at the turbine end. the two following paths:
Flow path VII routes cold gas into the phase connectors and This flow path routes the water to the manifold at the exciter
terminal bushings and, via the terminal box, to the TE suction end and from there to the stator bars via insulating hoses. Each
space. stator bar is connected to the manifold by a separate hose. The
cooling water flows through the cooling ducts towards the tur-
Following heat absorption, the six flows are mixed before bine end of the generator. After exiting the stator bars, the wa-
being returned to the coolers by means of the axial flow fan. ter flows through insulating hoses to a water manifold from
where it is rerouted back to the coolers. The water flows
3.1 Coolant Temperature Control through the stator bars in one direction only, the temperature
The cooling water flow through the hydrogen coolers is rise of the coolant (and thus of the bars) is minimized which,
automatically controlled to maintain a uniform temperature in turn, means that the relative movements between the top
level for all loads and cold water temperatures. The cold gas and bottom bars due to different thermal expansions are also
temperature is used as reference variable. minimized.
4 Primary Cooling Water System The secondary water flow through the primary water cooler
is automatically controlled to ensure that the generator
The treated water used for cooling the stator winding is re- temperature is maintained at a constant level under different
ferred to as primary water system in order to distinguish it from load conditions.
Siemens
BHEL,Haridwar AG 2.1--1100--0051 / 2
Energy Sector 0901E
0114E
Turbogeneratoren Generator Khlgas-Schema
Beschreibung SGen5--3000W
Turbogenerators Generator Cooling Gas Circuit
Description SGen5--3000W
Ansicht Y Ansicht X
View Y View X
A--A B--B
Y B D A
X
C C
e Siemens AG 2012 --
C--C
Copyright
D
Distribution: UNRESTRICTED
Ursprung/Source: 24--0090--131027
Handhabung: OFFEN
Siemens AG MK &MDB 2.1--1150--0012
Energy Sector 0212DE
Turbogenerators General Design Features
Description Stator
The stator comprises a stator frame as well as the stator The inner frame of the stator comprises the core and the
core and winding assembly. winding. The supporting rings form part of the inner cage which
Manufacture of the stator frame is performed independently is suspended in the outer frame by a large number of flat
of the stator core and winding assembly production, and prior springs distributed over the entire core length. The flat springs
to installation of the winding, the core is linked to the stator are tangentially arranged over the circumference in sets of
frame by means of flat springs. three springs each, i.e. a vertical supporting spring on either
side of the core and a single horizontal stabilizing spring below
the core. As an alternative, the springs below the core can be
omitted. The springs are so arranged and tuned that forced
2 Stator Frame (Outer Frame) vibration resulting from the magnetic field will not be
transmitted to the frame and foundation.
The stator frame is a gastight and pressure-resistant
welded construction and houses the stator core, the stator 3.1 Stator Core
winding and the hydrogen coolers which are arranged The stator core is stacked from insulated electrical
vertically in a separate cooling header at the turbine end. sheet-steel laminations with a low loss coefficient and mounted
A cage of circular and axial ribs on the inside of the outer in supporting rings over insulated dovetailed guide bars. Axial
frame ensures the rigidity of the shell. End shields containing compression of the stator core is obtained by clamping fingers,
the shaft seal and bearing components are bolted to the stator pressure plates and non-magnetic through-type clamping
All Rights Reserved
frame. A high-viscosity sealant is injected in sealing grooves bolts which are insulated from the core.
to ensure that the flanged joints are sealed airtight. The pressure plates and end zones of the stator core are
The core portion of the stator frame is divided into effectively shielded against stray magnetic fields by means of
compartments which house the springs for suspending the cooled flux shields.
stator core. The cold gas for cooling the stator core and the
e Siemens AG 2008 --
exciter-end rotor winding flows through gas ducts welded to the 3.2 Stator Winding
inside surface of the shell. The stator winding is fractional pitch two-layer type winding
Feet are welded to the stator frame to support the stator on which is made up of individual bars. The bars are located in
steel beams embedded in the foundation. The stator is firmly rectangular slots uniformly distributed over the entire
anchored to the beams with anchor bolts through the feet. circumference of the stator core.
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKA10 &MDB 2.1--1210--0020
Energy Sector 1008E
0114E
Turbogenerators General Design Features
Description Stator Winding
backing material to which the mica is bonded by a small ring with pressure plates held by bolts made from high-strength
amount of epoxy resin. The number of layers and insulating material. The stator end winding and support ring
consequently the thickness of the insulation depends on the thus form a rigid short-circuit-proof structure which does not
generator voltage. Following application of the mica tape, the restrict movements of the winding due to thermal expansion
bars are dried under vacuum and impregnated with epoxy because the support ring is allowed to move axially within the
stator frame.
Copyright
Siemens AG
BHEL,Haridwar MKA20 &MDB 2.1--1230--0012
Energy Sector 1008E
0114E
Turbogenerators General Design Features
Description Rotor
1 Rotor Shaft The individual turns of the coils are insulated against each
The rotor shaft is a single-piece solid forging manufactured other by interlayers. L-shaped strips of laminated epoxy glass
from a vacuum casting. Slots for insertion of the field winding fiber fabric with Nomex filler are used for slot insulation. The
are milled into the rotor body. The longitudinal slots are slot wedges are made of high-conductivity material and
distributed over the circumference so that two solid poles are extend below the shrink seat of the retaining ring. The seat of
obtained. the retaining ring is silver-plated to ensure a good electrical
The rotor poles are designed with transverse slots to contact between the slot wedges and rotor retaining ring. This
reduce twice system frequency rotor vibrations at rated speed. system has long proved to be a good damper winding.
To ensure that only high-quality forgings are used, strength
tests, material analyses, and ultrasonic tests are performed 3 Rotor Retaining Rings
during manufacture of the rotor. The centrifugal forces of the rotor end windings are
After completion, the rotor is balanced in various planes at contained by single-piece rotor retaining rings. The retaining
different speeds and then subjected to an overspeed test at rings are made of non-magnetic high-strength steel in order to
120 % of rated speed for two minutes. reduce stray losses. Each retaining ring with its shrink-fitted
insert ring is shrunk onto the rotor body in an overhung
position. The retaining ring is secured in the axial position by
a snap ring.
2 Rotor Winding
The rotor winding consists of several coils which are 4 Field Current Lead
inserted into the slots and series-connected such that two coil The field current is supplied to the rotor winding via radial
groups form one pole. Each coil consists of several bolts and two semicircular conductors located in the hollow
2001-- All Rights Reserved
series-connected turns, each of which consists of two bores of the exciter- and generator shafts.
longitudinal and transverse turns which are connected by The field current leads are connected to the exciter leads
brazing in the end section. at the exciter- and generator shaft coupling with
The rotor winding consists of silver-bearing de-oxidized Multi-Contact plug-in contacts which allow for unobstructed
copper hollow conductors with cooling ducts. thermal expansion of the field current leads.
e Siemens AG
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKA40 &MDB 2.1--1300--0030
Energy Sector 0901E
0114E
Turbogenerators General Design Features
Description Hydrogen Cooler
The hydrogen cooler is a shell and tube type heat line. This control valve is activated by temperature transmitters
exchanger which cools the hydrogen gas in the generator. The located upstream and downstream of the cooler sections.
heat removed from the hydrogen is dissipated through the
cooling water. The cooling water flows through the tubes, whiIe
the hydrogen is passed around the finned tubes.
The hydrogen cooler is subdivided into sections which are
vertically mounted in the cooler assembly. The cooler sections
are solidly bolted in position at their upper ends and freely
movable at the lower ends.
The cooler sections are parallel-connected on their water
sides. Shutoff valves are installed in the lines upstream of the
cooler sections. All parallel-connected water paths must have
equal flow resistances to ensure a uniform cooling water supply
to the cooler sections and equal cold gas temperatures
downstream of the individual sections. The required cooling water
volume flow is adjusted by control valves on the hot water side.
Controlling the cooling water volume flow on the outlet side
ensures an uninterrupted water flow through the cooler sections 1 2 3
so that proper cooler performance will not be impaired. 1 Stator frame
To maintain the cold gas temperature at an approximately 2 Cooler
3 Cooler assembly
All Rights Reserved
Siemens AG
BHEL,Haridwar MKA70 &MDB 2.1--1440--0026
Energy Sector 1008E
0114E
Turbogenerators General Design Features
Description Bearings
1 Bearings
The sleeve bearings are provided with hydraulic shaft lift oil
during startup and turning gear operation. To eliminate shaft
currents, all bearings are insulated from the bearing cover,
respectively. The temperature of the bearings is monitored with
thermocouples embedded in the lower bearing sleeve so that
the measuring points are located directly below the babbitt.
Measurement and any required recording of the temperatures
are performed in conjunction with the turbine supervision. The
bearings have provisions for fitting vibration pickups to monitor
bearing vibrations.
Fig. 1 Bearing
All Rights Reserved
e Siemens AG 2010 --
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKD &MDB 2.1--1450--0001
Energy Sector 1010E
0114E
Turbogenerators General Design Features
Description Shaft Seals
The points where the rotor shaft passes through the stator
H2 side Air side
casing are provided with a radial seal ring. The seal ring is
guided in the seal ring carrier which is bolted to the seal ring
carrier flange and insulated to prevent the flow of shaft 16
currents. The seal ring carrier is split along its axis. The design 1
facilitates installation and ensures reliable measurement of
15 2
clearances and dielectric resistance. The seal ring is lined with
babbitt on the shaft journal side. The gap between the seal ring 3
14
and the shaft is sealed with seal oil. The seal oil is supplied to
the sealing gap from the seal ring chamber of the sealring 13 4
carrier via radial bores and an annular groove in the seal ring.
To ensure effective sealing, the seal oil pressure in the annular
gap is maintained at a higher level than the gas pressure with
in the generator casing. The oil drained on the hydrogen and
air sides of the seal rings is returned to the seal oil system 12 11 10 9 8 7 6 5
through drains in the stator end shields. ln the seal oil system
the oil is regenerated by a vacuum treatment, recooled, filtered
1 Seal ring holder (air side) 09 Seal ring
and then returned to the shaft seals. 2 Seal ring holder (H2 side) 10 Secondary seal
On the air side, pressure oil is supplied laterally to the seal 3 Seal ring chamber 11 Seal strip
4 Oil wiper ring (air side) 12 Rotor shaft
ring via an annular groove. This ensures always free 5 Groove for seal ring relief 13 Inner labyrinth ring
All Rights Reserved
movement of the seal ring in the radial direction in case of 6 Babbitt 14 Seal
7 Annular groove for seal oil 15 Insulation
higher housing hydrogen pressures. 8 Seal oil inlet bore 16 End shield
On the gas side, a secondary seal in the seal ring serves to
Fig. 1 Shaft Seal
reduce the hydrogen-side axial oil flow and to stabilize
hydrogen purity.
e Siemens AG 2008 --
Copyright
Distribution: UNRESTRICTED
MKA06
Siemens AG
BHEL,Haridwar MKA07 &MDB 2.1--1460--0011
Energy Sector 1008E
0114E
Turbogenerators
Shaft Seal
Description
The rotor shaft ends are brought out of the gastight of the seal ring carrier at the end shield. The seal oil is admitted
enclosure through shaft seals as shown on the attached into the annular groove of the seal ring via passages in the seal
drawing (see also 2.1--6001, Shaft Seal). ring carrier and seal ring. A continuous film of oil is maintained
With this type of shaft seal, the escape of hydrogen between the shaft and the seal ring. The clearance between
between the rotating shaft and the housing is prevented by shaft and seal ring is such that friction losses are minimized
maintaining a continuous film of oil between the shaft and a and an oil film of sufficient thickness is maintained without an
non-rotating floating seal ring. To accomplish this, seal oil is unnecessarily large oil flow. Temperature rise of the seal oil is
fed to the seal ring in a closed circuit at a pressure which is therefore small which contributes to reliable sealing. The
slightly higher than the hydrogen pressure. In addition, the air babbitt lining of the seal ring ensures high reliability even in the
side seal ring is supplied with jacking oil to assure free axial event of mixed friction.
movement. On the gas side, a secondary seal in the seal ring The seal oil pump delivers the oil at a pressure maintained
serves to reduce the hydrogen-side axial oil flow and to 0.7 to 1.0 bar above the generator hydrogen gas pressure at
stabilize hydrogen purity. the shaft seal by means of a differential pressure valve.
The shaft seal is characterized by its short axial length, its Higher pressure oil for ring relief is fed to the annular groove
independence from the respective axial and radial position of in the air side seal ring carrier and forced between the seal ring
the shaft and an oil supply circuit with facilities for continuous and the seal ring carrier. In this way the oil and gas pressures
vacuum treatment of the oil. More details are given in a acting on the seal ring are balanced, and the friction between
separate description (see also 2.1--7100, Seal Oil System). seal ring and seal ring carrier is reduced. The seal ring is thus
The two halves of the babbitted seal ring float on the shaft free to adjust its radial position, which is important during the
journal with a small clearance and are guided in axial direction starting period. The seal ring will adjust its position according
All Rights Reserved
by a divided seal ring carrier resistant to distortion and to the shaft position as dictated by the oil film thickness and the
bending. The seal ring is relatively free to move in the radial vibratory condition.
direction, but is restrained from rotating by use of a pin. The The seal ring need not follow the axial movement of the
seal ring carrier, bolted to the end shield, is insulated to generator shaft, which is primarily caused by the turbine
prevent the flow of shaft currents. The oil is supplied to the expansion. The design permits the shaft to slide through the
e Siemens AG 2008 --
shaft seal at two different pressures (seal oil pressure and seal ring without impairing the sealing effect.
higher pressure oil for ring relief) through the mounting flange
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKA &MDB 2.1--6000--0008
Energy Sector 1008E
0114E
Turbogenerators
Shaft Seal
Description
Drawing
H2 --side
16 Air side
1
15
2
14
3
13
4
All Rights Reserved
e Siemens AG 2001 --
Copyright
12 11 10 9 8 7 6 5
MKA06
BHEL,Haridwar
Siemens AG MKA07 &MDC 2.1--6001--0013
Energy Sector 0901E
0114E
Turbogenerators Shaft Seal
Description Insulation and Sealing of Seal Ring Carrier
5
All Rights Reserved
6
e Siemens AG 2008 --
7
Copyright
3 Seal ring
4 Antirotation device
5 Joint
6 Thrust bolt for seal
7 Seal ring carrier (bottom section)
8 Rotor shaft
9 Bearing shell support
Siemens AG
BHEL,Haridwar MKA &MDC 2.1--6005--0002
Energy Sector 1008E
0114E
Turbogenerators Stator
Despcription Stator Frame
To facilitate manufacture, erection and transport, the stator The welded stator frame consists of the cylindrical frame
consists of the following main components: housing, two flanged rings and axial and radial ribs. The cool-
ing header at the turbine end encloses the entire end-winding
J Stator frame portion of the stator up to the end wall of the slot portion. The
J Cooling header cooling header is used for routing the cold gas into the cooling
J End shields gas ducts to the exciter end.
J Terminal box The arrangement and dimensioning of the ribs are deter-
mined by the cooling gas passages and the required mechani-
The stator frame with spring-mounted core support, core cal strength and stiffness. Dimensioning is also dictated by
and stator winding is the heaviest component of the entire gen- vibrational considerations, resulting partly in greater wall
erator. A rigid frame is required due to the forces and torques thickness than required from the point of view of mechanical
arising during operation. In addition, the use of hydrogen for strength.
the generator cooling requires the frame to be pressure-resis- Two lateral supports for the spring-mounted core support
tant up to an internal pressure of approximately 10 bar (130 in the frame are located directly adjacent to the points where
psig). the frame is supported on the foundation. Due to the rigid de-
sign of the supports and foot portion the forces due to weight
and short-circuits will not result in any over-stressing of the
frame.
Manifolds are arranged inside the stator frame at the bot-
tom and top for filling the generator with argon and H2. The
connections of the manifolds are located side by side in the
All Rights Reserved
magnetic steel.
The cooling header is located at the turbine end of the sta-
tor frame. It accommodates the baffle ring, the baffle ring car-
rier and the hydrogen cooler sections. The cooler sections are
installed in vertical cooler wells. Ribs in the cooler assembly
interior serve for improved cooling gas passage and contrib-
ute towards mechanical strength and stiffness.
Siemens
BHEL,Haridwar AG MKA10 &MDB 2.1--2100--0036
Energy Sector 0111E
0114E
Turbogenerators Stator
Description Outer Casing
5
Copyright
4
6
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKA10 &MDC 2.1--2110--0014
Energy Sector 0911E
0114E
Turbogenerators Stator
Description Core and Winding Assembly
After stacking of the stator core, the insulated guide bars The supporting rings of the ends are welded to each other
are installed in the respective slots. The required stiffness is to form a skeleton frames each. They transmit the mechanical
obtained by welding supporting rings and the pressure plates forces to the outer casing via welded springs.
to the guide bars.
All Rights Reserved
e Siemens AG 2008 --
Copyright
1 2 3 4 5 6 7 8 9
1 Supporting ring
2 Mounting location for spring
3 Stator core
4 Building bar
5 Pressure palte
6 Support ring
7 Insulating cap
Distribution: UNRESTRICTED
Note: The photograph shows a typical equipment which may not correspond in all details to the specific equipment described.
BHEL,Haridwar
Siemens AG MKA20 &MDB 2.1--2130--0016
Energy Sector 1208E
0114E
Turbogenerators Stator
Description Stator End Shields
1 2 3
1 End shield flange
2 Seal oil supply line
3 Seal oil drain
1 2 3 4 5
The lower half end shields accommodate the insulated shaft seal is admitted via integrally welded pipes. The seal oil
bearing shell supports. The insulation prevents any short-cir- drained towards the air side is drained together with the
cuiting of shaft currents across the bearings. The bearing shell bearing oil. The seal oil drained towards the hydrogen side is
supports accommodate the spherical bearing shell and due to first collected in a gas and oiltight prechamber below the
their shape ensure self-alignment of the bearing with respect bearing compartment for defoaming and then passed to the
to the rotor axis. seal oil supply system.
BHEL,Haridwar
Siemens AG MKA &MDB 2.1--2150--0021 / 1
Energy Sector 1008E
0114E
The EE end shield is covered with a tapered copper shield
to prevent stray fields between stator winding and frame.
Siemens
BHEL,Haridwar AG 2.1--2150--0021 / 2
Energy Sector 1008E
0114E
Turbogenerators Stator
Description Hydraulic Testing of Stator Frame
Siemens AG
BHEL,Haridwar MKA &MDB 2.1--2190--0017
Energy Sector 1008E
0114E
Turbogenerators Stator
Description Stator Core
1 2
Siemens AG
BHEL,Haridwar MKA30 &MDB 2.1--2200--0024 / 1
Energy Sector 1008E
0114E
After compression and clamping of the core, guide bars are core, a copper rope is inserted into the groove of one of the
inserted into the slots provided in the outside surface of the bars.
core and welded to the pressure plates.
1
2
3
4
Point of contact
1 2 3 4 5
Siemens
BHEL,Haridwar AG 2.1--2200--0024 / 2
Energy Sector 1008E
0114E
Fasting of Stator Core and Framework
Turbogenerators
in Stator Frame
Description
THDF Series
2
3
4
5
6
7
8 A -- A
9 2
3
5
8
All Rights Reserved
1 Stator frame
2 Tension lock
10
3 Carrier ring
4 Shield ring
5 Dovetail support beam
e Siemens AG 2011 --
6 Pressure plate
7 Pressing finger
8 Isolated clamp bolt
9 Stator core
10 Flat spring
9
Copyright
10
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKA &MDB 2.1--2201--0038
Energy Sector 0911E
0114E
Stator Winding
Turbogenerators
Conductor Construction and
Description
High-Voltage Insulation
1
Up = pole pitch
1 Strand
Fig. 1 Lape Type Winding
Fig. 1 Stator Bar
e Siemens AG 2008 --
The slot bottom bars and top bars are displaced from each
other by one winding pitch and connected at their ends to form To ensure that the strands are firmly bonded together and
coil groups. to give dimensional stability in the slot portion, the bars are
The coil groups are connected together with phase cured in an electrically heated press. Prior to applying the bar
connectors inside the stator frame as shown in the connection insulation, the bar ends are bent with a special device which
diagram. shapes the involutes over a cone shell. This ensures a uniform
Copyright
This arrangement and the shape of the bars at the ends spacing of the bars over the entire length of the end turns after
result in a cone-shaped winding having particularly favorable installation.
characteristics both in respect of its electrical properties and In the course of manufacture, the bars are subjected to
resistance to magnetically induced forces. The bars afford numerous electrical tests for quality control.
maximum operating reliability, since each coil consists of only
one turn. This makes the turn insulation and the main insulation 3 High-Voltage lnsulation
identical. The high-voltage insulation is provided according to the
proven Micalastic system. With this insulation system, several
2 Conductor Construction half-overlapped continuous layers of dry mica/glass fabric tape
The bar consists of a large number of separately insulated are applied from end to end on the stator bars. The tape is a
strands which are transposed to reduce the skin effect losses. composite tape built up from a thin, high-strength backing
The strands of small rectangular cross-section are provided material to which the mica is bonded by a small amount of
with a braided glass fiber insulation and arranged side by side epoxy as an adhesive for further processing.
over the slot width. The individual layers are insulated from The bent bar ends are then provided with a final protective
each other by a vertical separator. In the straight slot portion the wrapping of highly flexible glass fabric tapes in order to obtain
strands are transposed by 540_. a smooth surface.
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKA34 &MDB 2.1--2300--0030
Energy Sector 1208E
0114E
Turbogenerators Connection Diagram of Stator Winding
Description SGen5-3000W
Direction of rotation
Main discharge pipe
(in generator)
TE
All Rights Reserved
e Siemens AG 2010 --
EE
Main supply pipe
(in generator)
VI VI
V V
IV IV
Copyright
III III
II II
I I
Casing C
L bottom
rear
front W2 V2 U2
W1 V1 U1
Slot 1 --42
Long = Top bar
BHEL,Haridwar
Siemens AG MKA20 &MDB 2.1--2301--0080
Energy Sector 0110E
0114E
Turbogenerators Stator Slot
Description SGen5-3000W
3
4
5
6
7
8
9
All Rights Reserved
10
e Siemens AG 2001 --
11
Copyright
12
1 Stator core
2 Slot wedge
13 3 Slide strip
4 Top ripple spring
5 Fill strip
14
6 Top strip
7 Cooling duct
8 Solid strand
9 Lateral intermediate strip
10 Top bar
11 Intermediate strip
12 Bottom bar
13 Micalastic-insulation
14 Low conductive side ripple strip
15 Low conductive equalizing strip
Handhabung: OFFEN
15
Siemens AG
BHEL,Haridwar MKA20 &MDB 2.1--2303--0075
Energy Sector 0901E
0114E
Turbogenerators
Micalastic High Voltage Insulation
Description
High-quality mica, selected epoxy resins and a matching indirect cooled generators built by Siemens AG since then
vacuum impregnation process are the characteristic features have been provided with this type of insulation, i.e. 262 turbo-
of the Micalastic insulation for large turbogenerators. A generators with a total rating of more than 90 000 MVA. Since
consistent development has led to a high quality insulation 1960 this insulation has been registered under the trade-mark
system, the reliability of which is ensured by continuous quality Micalastic by Siemens AG.
control. The stator windings of the worlds largest single-shaft
The first 10.5 kV winding of a turbogenerator to be impreg- generators with an output rating of 1640 MVA and a rated
nated under vacuum with a solventless thermosetting voltage of 27 kV were also provided with the Micalastic in-
synthetic resin was completed in 1958. All direct cooled and sulations.
All Rights Reserved
e Siemens AG 2008 --
Copyright
Distribution: UNRESTRICTED
Fig.1 Water-cooled Stator Winding of a 789 MVA Turbogenerator with Micalastic Insulation for a Rated Voltage of 21 kV.
Siemens AG
BHEL,Haridwar MKA &MDB 2.1--2320--0014 / 1
Energy Sector 1008E
0114E
Fig. 2 Construction of a Stator Bar With Internal Gas Cooling Fig. 3 Construction of a Stator Bar With Water Cooling
Method of Insulation and Impregnation the wall of the slot, the insulation in the slot section is then
For insulation with Micalastic, the conductor strands (with provided with a coat of conductive varnish.
internal gas cooling, the ventilating ducts as well) are arranged At voltages above 6 kV, a semiconductive coating is also
together to form a compact assembly and set to the required added on the slot-end sections to control the electric field and
shape. This assembly is then baked with epoxy resin to give prevent the formation of creepage sparks during high-voltage
it the mechanical strength required for further processing tests.
(Fig. 2, Fig. 3). After application of the end corona protection, the bars are
Following this, several layers of mica tape are applied ready for installation in the slots.
continuously and half-overlapped to the end-turn and slot
portions of the bar. The mica tape consists of a thin high-
strength backing material to which the mica is bonded by Tests
synthetic resin. The number of layers, i.e., the thickness of After insulation and curing, the insulation of each stator bar
insulation, is determined by the voltage of the machine. The is subjected to a high-voltage test at 150 % Up of the winding
taped bars are then dried under vacuum and impregnated with test voltage (Up = 2 x UN + 1 kV) for quality control. For as-
synthetic resin which, by reason of its low viscosity penetrates sessment of the quality of the slot insulation, the dielectric dis-
the insulation thoroughly and eliminates all voids. After resin sipation factor tan E is measured as a function of the voltage.
impregnation under vacuum conditions, the bars are pres- The dielectric dissipation factor/test voltage curve of a typical
surized in a nitrogen atmosphere. The impregnated bars with stator bar with MICALASTIC insulation is shown in Fig. 4.
direct conductor cooling are then brought to the required di- Fig. 4 shows the fluctuations due to manufacturing of the
mensions in molds and cured in an oven at high temperature. maximum increase in the dielectric dissipation factor up to
To minimize corona discharges between the insulation and rated voltage for the bars of a 21 kV winding.
Siemens AG
BHEL,Haridwar 2.1--2320--0014 / 2
Energy Sector 1008E
0114E
manner it is possible to insulate windings for voltages of over
30 30 kV efficiently and reliably.
x 10 - 3 Micalastic has a long electrical life as determined on
tan E 20 hundreds of experimental bars and substantiated on numer-
ous full-size bars (Fig. 6).
10 30
kV
0 mm
0.2 0.4 0.6 0.8 1.0 1.2 1.4
Rated voltage 20
E
Fig. 4 Dielectric Dissipation Factor of a Stator Bar With
Micalastic Insulation for 21 kV as a Function
of the Voltage 1.5 E p
10
The method of impregnation, which is exactly matched to Ep
the insulation, and the use of a special impregnating resin en- max. operating stress
able the maximum increase in dielectric dissipation factor to be
reduced considerably below the limits specified in section 33 0
1 10 102 103 104 105 106 107 108 min
of VDE 0530, Appendix X.
During insertion of the stator bars, high-voltage tests of one 1 10 100 years
minute duration are performed as follows: Time
115 % Up after installation and blocking of bottom bars Fig. 6 Electrical Life of MICALASTIC Insulation
40
20
20
5 Temperature
Siemens AG
BHEL,Haridwar 2.1--2320--0014 / 3
Energy Sector 1008E
0114E
and the copper conductor, even after 5000 heat cycles, with Micalastic is highly resistant to chemical action. Corro-
1000 cycles between 40 _C and 160 _C. sive gases, vapors, lubricating oil and weak acids or alkalis, to
Micalastic owes its insensitivity to high temperatures and which the windings of air-cooled machines may be exposed
temperature changes to the cured synthetic resin. This favor- under unfavorable conditions, do not attack the insulation; the
able performance under thermal stress is particularly advanta- impregnating resin behaves neutrally towards chemicals.
geous for machines subject to frequent load changes, e.g., Micalastic retains its outstanding properties, even after
generators driven by gas turbines or peak-load generators in years of operation. Evidence of its unchanging quality has
steam power plants. been provided by repeated tests carried out on machines over
Micalastic does not burn. The flammability is so low that an operating period of several years. Throughout the service
even on arcing it does not continue to burn once the arc is history of the first turbogenerator equipped with this insulation
extinguished. Fire extinguishing systems, such as CO2 system in 1958 there has never been a service failure originat-
systems, are therefore not necessary for machines insulated ing within the insulation system. Meanwhile 262 turbogenera-
with Micalastic. tors using the Micalastic insulation system have been
Micalastic provides protection against moisture due to its placed in operation, with an accumulated 2880 machine years
impregnation with synthetic resin which seals the winding of successful service experience.
completely.
Siemens AG
BHEL,Haridwar 2.1--2320--0014 / 4
Energy Sector 1008E
0114E
Turbogenerators Construction of High-Voltage Insulation
Description Micalastic Insulation
1 2
4
All Rights Reserved
e Siemens AG 2008 --
5
Copyright
8 7 6
Note: The number of conductors shown does not necessarily correspond to the number of conductors of the generator described.
Siemens AG
BHEL,Haridwar MKA20 &MDB 2.1--2321--0011
Energy Sector 1208E
0114E
Turbogenerators Stator Winding
Description Corona Protection
Fig. 2 Applying a Protective Sleeve of Semi-Conductive Fig. 3 Application of Graded End Corona Protection
Polyester Mat
Distribution: UNRESTRICTED
BHEL,Haridwar
Siemens AG MKA20 &MDB 2.1--2330--0004
Energy Sector 1008E
0114E
Turbogenerators Stator Winding
Description Coil and End Winding Support System
The stator windings are placed in rectangular slots which With the windings placed in the slot, the bar ends form a
are uniformly distributed around the circumference of the stator cone-shaped end winding. In order to minimize stray losses,
core. The location of the bars in the slots is detailed in Section the cone is design with as small a taper angle as possible. The
2.1--2303, Stator Slot. design of the end windings is detailed in Section 2.1--2341,
The bar is inserted in the slot. Semi-conducting side ripple Stator End Winding.
springs ensure that the bar is securely positioned in the slot, Any gaps in the end winding due to the design or manufac-
and that good contact is established between the outer corona turing are filled with curable plastic fillers, ensuring solid sup-
protection of the bar and slot wall. port of the cone-shaped top and bottom layers.
Radial positioning of the bar is done with slot wedges. Be- Clamping bolts made of high-strength fiberglass fabric as
low the longitudinally divided slot wedges a top ripple spring of well as pressure plates and spacers are used to brace the
high-strength fiber glass fabric is arranged between the filler winding bars against a rigid, tapered support ring made of fiber-
and slide strip which presses the bar against the slot bottom glass fabric. Tight seating is ensured through the use of plastic
with a specific preloading. An equalizing strip is inserted at the fillers on both sides of the bars. The fillers are cured on comple-
slot bottom to compensate any unevenness in the bar shape tion of the end winding assembly.
and slot bottom surface during bar insertion. These measures Each end winding thus forms a compact, self-supporting
prevent vibrations. The slot wedges are installed with a speci- arch of high rigidity which prevents bar vibrations during opera-
fied preload which is checked following installation. tion and can withstand short-circuit forces.
In addition, the end winding covering provides good protec-
tion against external damage. The supporting rings are posi-
tioned on brackets in such a manner that axial movement due
All Rights Reserved
1 2 3
1 2
1 Slot wedge
1 Slot wedge 2 End-winding cover
2 End-winding cover 3 Clamping bolt
Fig. 1 Stator with Complete Stator Winding Fig. 2 End-winding Cover and Support System
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKA &MDB 2.1--2340--0018
Energy Sector 1008E
0114E
Turbogenerators Stator End Winding
Description SGen5-3000W
1 2 3
All Rights Reserved
e Siemens AG 2006 --
Copyright
4 5 6 7 8 9 10 11 12 13
Siemens AG
BHEL,Haridwar MKA20 &MDB 2.1--2341--0113
Energy Sector 0106E
0114E
Stator Winding
Turbogenerators
Electrical Connection of Bars, Water Supply
Description
and Phase Connectors
1 Electrical Connection of Bars Each water box is fitted with a nozzle for connecting the
The electrical connection between the top and bottom bars hoses.
is made by means of a bolted contact surface. The exciter-end water boxes serve for water admission and
distribute the cooling water uniformly to the cooling channels
of the bar. The hot water is collected on leaving the cooling
channels in the turbine-end water boxes. The cooling water is
then discharged from the generator via the hoses and the
manifold.
During manufacturing of the stator bars, various checks are
performed to insure water tightness and unobstructed water
passages.
To ensure better accessibility, this test is performed before
the top section of the TE water boxes are welded into place.
After welding of the upper sections, all welded joints are
leaktested with helium.
The tangential air clearance between the water boxes and
bar connections within a coil group and the axial clearance
relative to the frame, end shield bearing and cooling header
which are at ground potential, is so dimensioned that additional
Fig. 1 Electrical Bar Connections and Water Supply insulation is not required. For the spaces between the individ-
ual phases insulting caps, which enclosure both the connect-
All Rights Reserved
At their ends, the strands are brazed to a connecting ing sleeve and the water boxes, are connected to the stator
sleeve, the strand rows being fanned out by means of a spacer. bars.
The contact surfaces of the connecting sleeve for the top and
bottom bars are pressed against each other by non-magnetic 3 Phase Connectors
clamping bolts. Special care is taken to obtain a flat and paral-
e Siemens AG 2001 --
Siemens AG
BHEL,Haridwar MKA20 &MDB 2.1--2350--0024
Energy Sector 0701E
0114E
Electrical Bar Connections
Turbogenerators
and Water Supply
Description
THDF, THFF Series
:
8
1
All Rights Reserved
e Siemens AG 2008 --
Copyright
2 3 4 5 6 7
9 10
Siemens AG
BHEL,Haridwar 2.1--2351--0010
Energy Sector MKA20 &MDB 1208E
0114E
BHEL,Haridwar
0114E
BHEL,Haridwar
0114E
Turbogenerators Stator
Description Water Cooling System -- Stator Winding
1 General
Two separate water cooling systems are used for the stator
winding as well as the phase connectors and the terminal
bushings (see also 2.1--1100, Design and Cooling System;
2.1--7300, Primary Water Supply).
The interconnections between live components as well as
the connections between live components and the grounded
cooling system manifolds are designed as insulated and
pressure-resistant PTFE hoses. The locknuts are secured by
means of O-rings made of Viton and Belleville washers. The
fittings are made of non-magnetic stainless steel.
and terminal bushings are arranged on the outside of the The primary water is admitted to three terminal bushings
stator frame near the terminal box. The supply pipes are linked via a water manifold, flows through the connected phase
to the primary water inlets and outlets by means of PTFE connectors and is then discharged to the outlet manifold via
hoses which are also used to route the primary water past the the opposite terminal bushings.
flexible connectors, and for linking series-connected sections The water flow through the two cooling systems is
of the phase connectors. monitored by metering the flow rate through the three phases.
Distribution: UNRESTRICTED
Siemens
BHEL,Haridwar AG MKA &MDB 2.1--2380--0006
Energy Sector 1008E
0114E
Turbogenerators
Rotor Shaft
Description
The high mechanical stresses resulting from the centrifugal selected so that the two solid poles are displaced by 180_.
forces and short-circuit torques call for a high-quality heat- Due to the non-uniform slot distribution on the circumfer-
treated steel. Therefore, the rotor shaft is forged from a vacuum ence, different moments of inertia are obtained in the main
cast steel ingot. Comprehensive tests ensure a adherence to axes of the rotor. This in turn causes oscillating shaft deflec-
the specified mechanical and magnetic properties as well as tions at twice the system frequency. To reduce these vibra-
a homogeneous forging. tions, the deflections in the direction of the pole axis and the
The rotor shaft consists of an electrically active portion, the neutral axis are compensated by transverse slotting of the
so-called rotor body, and the two shaft journals. Integrally poles.
forged flange couplings to connect the rotor to the turbine and The solid poles are also provided with additional longitu-
exciter are located outboard of the bearings. Approximately dinal slots to hold the copper bars of the damper winding. The
two-thirds of the rotor body circumference is provided with rotor wedges act as a damper winding in the area of the
longitudinal slots which hold the field winding. Slot pitch is winding slots.
1 2 3 4 5 6
All Rights Reserved
e Siemens AG 2008 --
Copyright
Siemens AG
BHEL,Haridwar MKA40 &MDB 2.1--3000--0033
Energy Sector 1008E
0114E
Turbogenerators Rotor
Description Cooling of the Rotor Winding
Each winding is divided into eight cooling zones. The first body and the stator through radial openings in the conductors
cooling zone includes the slot portion from the end to the center and the rotor slot wedges. The cooling gas holes are arranged
of the rotor body, and the second cooling zone extends across at different levels in the conductor assembly to give each
half of the end winding. These two cooling zones are repeated hollow conductor its own cooling gas outlet.
four times in a symmetrical arrangement around the rotor. The cooling gas for the end winding is admitted through the
The cooling gas for the slot area enters the hollow end face and flows through the conductors up to approximately
conductors through openings in the end winding and flows the pole center, where it passes into a collection compartment
through these conductors to the center of the rotor body. The and is then discharged into the air gap via slots in the end of the
hot gas is then discharged into the air gap between the rotor rotor body.
1 1 2 3
All Rights Reserved
e Siemens AG 2008 --
1 Rotor body
1 Gas inlet (slot portion) 2 Gas outlet in rotor wedge (cooling gas flow from left)
2 Gas inlet (end winding) 3 Gas outlet in rotor wedge (cooling gas flow from right)
Copyright
Fig. 1 End Winding Gas Inlets Fig. 2: Gas Outlets at Rotor Center
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKA40 &MDB 2.1--3100--0020
Energy Sector 1008E
0114E
Turbogeneratoren D-Khlsystem fr Lufer
Turbogenerators D-Cooling System for Rotor
All Rights Reserved
e Siemens AG 2008 --
Gasaustritt
gas outlet
Copyright
Distribution: UNRESTRICTED
Handhabung: OFFEN
Siemens
BHEL,Haridwar AG MKA40 &MDC 2.1--3101--0034
Energy Sector 1008DE
0114E
Turbogenerators Rotor
Description Rotor Winding
1.3 Insulation
All Rights Reserved
the frame, thick top strips of glass fiber laminate are inserted
below the slot wedges.
6
2.1 Rotor Slot Wedges 6 6
To protect the winding against the effects of the centrifugal
force, the winding is secured in the slots with wedges. The slot
wedges are made from a copper-nickel-silicon alloy featuring 1 2 3 4 5
high strength and good electrical conductivity, and are used as
damper winding bars. The slot wedges extend below the shrink
1 Rotor body 4 Filler
seats of the retaining rings. The rings act as short-circuit rings 2 Slot wedge 5 Gas outlet, transverse conductor
to induced currents in the damper windings. In addition, slots 3 Gas inlets, longitudinal conductor
are milled in the pole area to receive the damper wedges. Fig. 1 Rotor End Winding
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKA41 &MDB 2.1--3300--0015
Energy Sector 1008E
0114E
Turbogenerators
Rotor Slot
Description
1 2 3 4
6
All Rights Reserved
7
e Siemens AG 2010 --
8
Copyright
Note: The number of conductors shown does not necessarily correspond to the number of conductors of
the generator described.
BHEL,Haridwar
Siemens AG MKA41 &MDB 2.1--3301--0037
Energy Sector 0210E
0114E
Distribution: UNRESTRICTED Copyright e Siemens AG 2001 -- All Rights Reserved
BHEL,Haridwar
Energy Sector
1 2 3 4 5 6 7 8
Description
Turbogenerators
Siemens AG
MKA41
&MDB
Rotor
Rotor End Winding
0114E
0901E
2.1--3310--0075
Note: The number of conductors shown does not necessarily correspond to the number of conductors of the generator described.
Turbogenerators Arrangement of Damper Bars in Rotor Body
Description SGen5--3000W Series
All Rights Reserved
e Siemens AG 2010 --
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKA40 &MDB 2.1--3333--0013
Energy Sector 0114E
0210E
Turbogenerators
Rotor Retaining Ring
Description
Siemens
BHEL,Haridwar AG MKA &MDB 2.1--3350--0003
Energy Sector 1008E
0114E
Turbogenerators Rotor
Description Field Connections
The field current connection comprises several fluorocarbon-elastomer O-rings placed next to each other
components, which are detailed below, and provides the along the axis of the radial bolt. The sealing effect is achieved
electrical connection between the rotor winding and the by the clamping action of a threaded ring and fiberboard. The
exciter. seal can be checked via two holes machined radially into the
shaft end near the O-rings.
1 J-strap Lead
The J-strap lead consists of a copper conductor. One end
of the J-strap lead is brazed to the rotor winding, while the other
end is screwed to the radial bolt. 3 Field Current Lead in Shaft Bore
The leads are run in the axial direction from the radial bolt
2 Radial Bolt to the EE coupling. They consist of two semi-circular
The radial bolts are screwed into the semicircular field conductors insulated from each other through a plate and from
current leads, and are connected to the rotor coils by means the shaft by a tube. The field current leads in the generator
of J-strap leads. The radial bolts are subjected to extreme shaft are connected to the field current leads in the exciter
centrifugal forces, and are made from hight-strenght copper. shaft/slipring shaft at the coupling with Multi-Contakt plug-in
The seal between the air and hydrogen spaces is located contacts which allow for unobstructed thermal expansion of
at the exciter end of the shaft, and comprises two the field current leads.
All Rights Reserved
2
e Siemens AG 2010 --
3
Copyright
4
1
3
Distribution: UNRESTRICTED
Fig. 1 Radial Bolt (Similar Design) Fig. 2 J-strap Lead (Similar Design)
Siemens AG
BHEL,Haridwar MKA &MDC 2.1--3370--0016
Energy Sector 1010E
0114E
Turbogenerators Rotor
Description Mechanical and Electrical Connection of EE Coupling
1 2 3
4
All Rights Reserved
5
6
e Siemens AG 2010 --
7
8
Copyright
11 2 10
Note: The sketch must not in agreement with all design details of the actual generator.
Siemens AG
BHEL,Haridwar MKA &MDB 2.1--3373--0021
Energy Sector 0114E
0210E
Turbogenerators
Rotor Fan
Description
The generator cooling gas is circulated by one axial-flow The moving blades of the fan are inserted into T-shaped
fan located on the turbine-end shaft journal. To augment the grooves in the fan hubs. The fan hubs are shrink-fitted to the
cooling of the rotor winding, the pressure established by the shaft journal spider.
fan works in conjunction with the gas expelled from the
discharge ports along the rotor.
1 2 3 4 5 6
All Rights Reserved
e Siemens AG 2010 --
Copyright
Note: Depending on the relevant generator size, the rotor fan has 3 to 6 stages.
Siemens AG
BHEL,Haridwar MKA &MDB 2.1--3600--0001
Energy Sector 0210E
0114E
Turbogenerators
Rotor Fan and Fan Baffle Ring
Description
1 2
All Rights Reserved
e Siemens AG 2010 --
Copyright
6 6 5 4 3
1 5 3 2
6 4
Distribution: UNRESTRICTED
Note: Depending on generator size the rotor fan is of the three-to-six-stage type.
Siemens AG
BHEL,Haridwar MKA40 &MDB 2.1--3603--0021
Energy Sector 0210E
0114E
Turbogenerators
H2 Cooler
Description
The hydrogen cooler is a surface-type heat exchanger. The cooling water flow through the cooler elements and thus proper
heat removed from the hydrogen is dissipated through the cooler performance.
cooling water. The water flows through the finned tubes while
the hydrogen flows around them.
The vertical arrangement enables the heat exchanger to be
installed without having to increase the overall axial length of
the generator or the cross-sectional area of the stator frame.
The cooler comprises a pair of separate cooling elements
each of which consists of two tube bundles, the two
tubesheets, two return water channels as well as the inlet and
outlet water channels. The water inlet and outlet lines which
route the cooling water to and from the cooler are connected
to inlet and outlet channels which are situated above the cooler
elements. The tube bundles are interconnected by the shared
upper tubesheet. The end compartment is located below the
cooling elements. The gaps between the stator frame and the
end compartment as well as between the stator frame and the
upper tubesheet are sealed with O-rings.
The side walls of the cooling elements are made of
structural steel and serve to brace the cooler and direct the
hydrogen flow. Close the rubber profiles attached to the cooler
All Rights Reserved
BHEL,Haridwar
Siemens AG MKA70 &MDB 2.1--4000--0033
Energy Sector 1008E
0114E
Turbogeneratoren
Generator Bearings
Description
1 2 3 4 5 6
All Rights Reserved
e Siemens AG 2008 --
Copyright
The rotor shaft is supported in sleeve bearings having of 0.2 mm between the bearing sleeve and the insulation of the
forced-oil lubrication. The bearings are located in the stator radial locator.
end shields The oil required for bearing lubrication and cooling A stop is provided at the bearing sleeve joint to prevent the
is obtained from the turbine oil supply system and supplied to bearing from turning in the saddle.
the lubricating gap via pipes permanently installed inside the The inner surface of the cast bearing sleeve body is
lower half of the stator end shield and via grooves in the provided with spiral dovetail grooves which firmly hold the
bearing saddle and lower bearing sleeve. babbitt liner to the bearing sleeve body. The lower bearing
The lower bearing sleeve with its self-aligning outer portion sleeve has a groove to admit the bearing oil to the bearing
Distribution: UNRESTRICTED
rests on the bearing saddle. The bearing saddle is insulated surface. The upper sleeve consists of an overflow groove
from the stator end shield to prevent the flow of shaft currents through which the oil flows over the shaft journals and is fed to
and provide for insulation of the generator bearing from the lubricating gap. The oil is drained laterally from the
ground. The radial locator serves to locate the bearing in the lubricating gap, caught by wipers, collected in the bearing
vertical direction and is bolted to the upper half of the stator end compartment and returned to the turbine oil tank via pipes.
shield. The Iocator should be adjusted to maintain a clearance All generator bearings are provided with a hydraulic shaft lift
Siemens AG
BHEL,Haridwar MKD &MDB 2.1--5000--0024 / 1
Energy Sector 0114E
1008E
oil system to reduce bearing friction during startup of the 1 2 3
turbine--generator. High pressure oil is forced between the
bearing surface and the shaft journal, lifting the rotor shaft to
allow the formation of a lubricating oil film.
The bearing temperature is monitored with thermocouples
located approximately in the plane of maximum oil film
pressure. The thermocouples are screwed in position on both
sides of the lower bearing sleeve from outside with the
detectors extending to the babbitt liner.
1 Overflow groove
2 Babbitt
3 Stop
Siemens AG
BHEL,Haridwar 2.1--5000--0024 / 2
Energy Sector 1008E
0114E
Distribution: UNRESTRICTED Copyright e Siemens AG 2008 -- All Rights Reserved
A--A A
Air side H2 --side
Energy Sector
Description
BHEL,Haridwar
Turbogenerators
Siemens AG
2
4 16
MKD
5
&MDB
6
7
15
8
14
Generator Bearing -- Drawing
10 13
11 12
1 Endshield bearing 5 Support for vibration pick--up 10 Connection for seal oil inlet, air side 15 Fast H2 exhaust
2 Oil vapor and H2 exhaust 6 Drain for H2 side seal oil 11 Connection for ring relief 1 16 Connection for ring relief 2
3 Connection for Munters drier 7 Hydraulic shaft lifting 12 Connection for seal oil inlet, H2 side * Joint
(at standstill and unpressurized air filling) 8 Bearing oil inlet 13 Connection for seal oil inlet, air side
0114E
2.1--5001--0036
1008E
4 Connection for seal oil, H2 side 9 Bearing oil outlet 14 Connection for seal oil outlet, H2 side
Turbogenerators
Measuring of Bearing Temperature
Description
6
All Rights Reserved
3
4
e Siemens AG 2008 --
3
Copyright
1 End shield
2 Thermocouple lead
Distribution: UNRESTRICTED
3 Insulation
4 Spacer ring
5 Bearing shell support
6 Bearing sleeve
7 Thermocouple
8 Babbitt
Siemens AG
BHEL,Haridwar MKD10 &MDB 2.1--5003--0013
Energy Sector 1008E
0114E
Turbogenerators
Generator Bearing Insulation
Description
All Rights Reserved
e Siemens AG 2008 --
Copyright
1 2 3 4 5 6 7
1 End shield
2 Bearing saddle
3 Bearing oil inlet
4 Spacer ring
5 Plug screw
6 Insulation
7 Mounting screw
Distribution: UNRESTRICTED
BHEL,Haridwar
Siemens AG MKD &MDB 2.1--5005--0018
Energy Sector 1008E
0114E
Distribution: UNRESTRICTED Copyright e Siemens AG 2008 -- All Rights Reserved
B--B A--A
Energy Sector
Description
BHEL,Haridwar
A B
Turbogenerators
Siemens AG
1
MKD
5
&MDB
7
Oil System
8
Generator Bearing
10 A 9 B
0114E
1008E
2.1--5007--0012
7XUERJHQHUDWRU
'HVFULSWLRQ /,672)9$/9(6)256($/2,/6<67(0
Due to load variations during operation and the resulting After startup and runup to rated speed, the cooling water
thermal expansions and contractions, the generator is sub- supply to the hydrogen coolers should be opened only when
jected to stresses. the temperature of the hydrogen gas has reached the preset
In order to reduce these stresses, the hydrogen cooling cold gas reference. The temperature difference between cold
circuit and the primary water cooling circuit are each provided gas and hot gas is determined by the no-load losses.
with a temperature control system to control the cooling gas The cooling water supply to the primary water coolers
and primary water temperatures so that the active generator should be opened only when the generator is carrying load,
components are maintained at the proper temperature Ievel. since only then current-dependent heat losses will have to be
The requirements for the temperature control system are dissipated.
described below: The temperature control systems are cold coolant tempera-
ture control schemes with variable set point as a function of the
cold = Cold gas temperature or cold primary water stator current. Set point adjustment is selectable between I and
temperature I2 or with an exponent between one and two. With rising stator
hot = Hot gas temperature or hot primary water current, the set point is reduced, so that the mean value (mean)
temperature of hot and cold coolant temperatures assumes a nearly
mean = Mean temperature of hot and cold gas or of hot and constant value, as shown in Fig. 1.
cold primary water temperature The difference between the setting values of the two set
' = hot -- cold with generator carrying full load points corresponds to half the temperature rise of the hydrogen
cooling gas at no-load, with 5 -- 10 K (9 -- 18 qF) to be taken as
a guiding value.
The temperature rise ' at full load is the temperature In order to maintain a low temperature level in the generator,
All Rights Reserved
difference between the hot and cold hydrogen gas as given in the reference should be set at the lowest possible value, ensur-
the hydrogen cooler design data or between the hot and cold ing that the cold coolant temperature will not drop below the
primary water as given in the design data of the primary water minimum level of 10 qC (50 qF) even when the generator is
cooler. carrying full load.
e Siemens AG 2008 --
Copyright
Class.: UNRESTRICTED
BHEL,Haridwar
Siemens AG MKY MDB 2.1--8010--0002 / 1
Energy Sector 1008E
0114E
Parallel shifting of the curves shown in Fig. 1 is possible by The control valve must be absolutely tight when in the
adjustment of the cold coolant references. The temperature of closed position to ensure that the coolant temperature will not
the cold primary water must, however, always be higher than drop while the generator is being shut down.
the temperature of the cold hydrogen cooling gas over the For details on the operation and technical features of this
entire load range of the generator in order to avoid any equipment, see equipment suppliers operating instructions.
condensation of moisture contained in the gas on the The required temperatures for setting the coolant tempera-
generator components carrying primary water. ture control systems must be observed.
Siemens AG
BHEL,Haridwar 2.1--8010--0002 / 2
Energy Sector 1008E
0114E
Turbogenerators
Mechanical Equipment Protection
Description
2 Protection Circuits
Copyright
bushings and phase connectors. Secondary cooling water protection are designed a 2-out-of-3 configuration with
flows through the hydrogen coolers located in the cooling facilities for functional testing, analog Signal comparison and
header. Generator operation will only be endangered by these backup energizing. Both channels must respond to activate a
coolants in the event of large leakages. As a result of the high trip.
hydrogen pressure, only little water will emerge from a small This redundant system prevents erroneous tripping due to
leak. Hydrogen will, however, enter into the water system. The an active fault.
Siemens AG
BHEL,Haridwar MKY &MDB 2.1--8320--0029
Energy Sector 1298E
0114E
Turbogeneratoren
Electrical Generator Protection
Description
Relay time: %60 ms a warning will be given when the steady-state stability limit is
reached. The generator will be shut down after a few seconds
In certain cases, the generator may also be included in the only.
differential protection for the main transformer and station The protection must operate instantaneously if a loss of field
service feeder. Generator faults are then detected by two occurs when the steady-state stability limit is reached.
differential protection devices. lf the loss of field cannot be detected directly (e.g. exciters
with rotating diodes), it is recommended to introduce a second
2 Stator Ground Fault Protection stator criterion covering the range of the permeance values
Breakdown of insulation between the stator winding and 1/xd and 1/xd and to provide for instantaneous tripping when
frame results in a stator ground fault. If possible, the stator this criterion is exceeded.
ground fault protection should cover the complete winding,
including the neutral point of the generator. The protection is to 5 Overcurrent Protection
initiate immediate isolation and de-excitation of the generator. System faults may result in in admissible thermal stressing
of the generator. For this reason, an overcurrent protection
should be provided which operates on failure of the system
Relay time: %1s
protection.
A definite-time delay overcurrent relay may be used for this
The load resistance of a grounding transformer and any purpose, however, its relay time should be longer than that of
required boost to raise the neutral point potential should be the system protection.
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKY &MDB 2.1--8330--0008 / 1
Energy Sector 0114E
1008E
relay is energized by overcurrent and operates with long or Since the frequency deviation due to a system disturbance
short-time setting, dependent on the location of the is normally accompanied by a voltage deviation, the protection
short-circuit. should be designed on the basis of the permissible load
lf connected to the generator neutral point, the overcurrent characteristic of the generator on frequency and voltage
protection serves as back-up protection for the differential deviations.
protection.
9 Reverse Power Protection
A rise in system frequency for any reason whatsoever
6 Load Unbalance Protection
Generators operating in an interconnected system are results in closing of the control valves, and the turbine is driven
by the motoring generator. Since the turbine is then no longer
normally subjected to small load unbalances only. However, all
one- and two-line-to-ground faults occurring in the system, supplied with cooling steam, the unit must be disconnected
phase breakages or circuit breaker failures are in fact load from the system. The relay must be provided with a time delay
unbalances which may result in unduly high thermal stressing of approximately 20s to prevent undesired response to system
of the rotor. swings (long time setting).
Specific faults in the turbine-generator interior initiate
lt is recommended to provide a two-stage load unbalance
protection. When the continuously permissible load unbalance emergency tripping. The steam supply to the turbine is
interrupted. A reliable criterion of perfectly tight closure of the
is reached, an alarm is given, whereas a time-dependent
isolation from the system occurs when this value is exceeded. emergency stop valves is the flow of power from the system
In case of large units, it is recommended to provide a back into the generator.
protection with unbalanced load/time characteristic. Operating Disconnection of the unit from the system by the generator
value and relay time should be matched to the load circuit breaker with a time delay of 4 s is only permissible after
unbalance/time characteristic applicable to the particular the reverse power has been drawn by the generator
generator. (short-time setting).
Siemens AG
BHEL,Haridwar 2.1--8330--0008 / 2
Energy Sector 1008E
0114E
Turbogenerators Arrangement of Brush Holders
Description for Rotor Grounding System
Grounding brushes are fitted to the outer turbine end The brush holders are arranged with 90_ displacement,
labyrinth ring to remove the static recharges of the shafts. which ensures that at least one brush will be in contact with the
rotating shafts.
View Z
1 4
A Two-layer
contact brush
Two-layer (Design B)
contact brush
(Design A)
A 6
Direction
of Rotation
All Rights Reserved
A--A
5
EG5U
AG20
3
Copyright
6
3
Z Z
BHEL,Haridwar
Siemens AG MKY &MDB 2.1--8351--0011
Energy Sector 0103E
0114E
Measuring Devices and
Turbogenerators
Supervisory Equipment
Description
Introduction
The equipment consists of alarms and measuring de- Closely associated with the supervisory equipment are
vices. The measuring devices give a visual indication of the regulating systems, automatic controls and protective
system parameters, the alarm devices initiate visual or audi- devices which provide for a reduction of the manual
ble signals in the event of a controlled quantity falling below supervisory work.
or exeeding the predetermined limit values. In many cases,
the measuring and alarm devices are combined to form one
supervisory unit.
All Rights Reserved
e Siemens AG 2010 --
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKY &MDB 2.1--8400--0002
Energy Sector 1010E
0114E
Temperature Detectors
Turbogeneratoren
Resistance Temperature Detectors and
Description
Thermocouples
RL2
R = Ro u (1 + B u T)
where
Ro = reference resistance at 0 _C
B = temperature coefficient and
T = temperature in _C. Fig. 2 Wire-Wire Connection
The standard reference resistance of the platinum Due to the mostly very high input resistance of amplifier V, the
All Rights Reserved
resistance element is 100 ohms. The temperature coefficient resistance of lead wires RL3 and RL4 from the RTD to the amplifier
is B = 3.85 u10-3 degC-1, this being the mean value for the is negligible, even if it would be substantially increased by the
range 0--100 _C. provision of a safety barrier (explosion protection).
To obtain optimum results, the four-wire connection is
180 generally used.
e Siemens AG 2010 --
ohm
160 2 Thermocouples
Siemens AG
BHEL,Haridwar MKY &MDB 2.1--8410--0004 / 1
Energy Sector 1010E
0114E
2 3 5 6
Thermoelectric U therm in mV
10
NiCr-CuN
1 4 Fe-CuNi
7
6 Cu-CuNi
NiCr-Ni
1 Hot junction 5 Connecting cables
2 Thermocouple 6 Millivoltmeter
3 Compensating lead 7 Compensating resistor 4
4 Cold junction erection
Fig. 3 Thermocouple 2
The sheath enclosing and protecting the compensating 20 40 60 80 100 120 140
lead wires has also been colour-marked for the various Temperatur in _C
thermocouples. Fig. 4 Voltages as a Function of Temperature for
Standardized Thermocouples acc. to DIN IEC 584, sect. 1
2.3 Cold Junction temperature to the measured thermoelectric emf and read
For measuring a temperature by means of a thermocouple, measuring point temperature to obtain the total thermoelectric
the cold junction temperature must be known. A cold junction emf.
at a temperature of 0 _C can be easily produced by melting ice. The cold junction can, however, also be implemented by
The use of thermostats with reference junction temperatures using a Pt100 RTD for determination of the actual temperature.
of 20 _C and 50 _C is also possible. Note that in these cases The temperature is referred to the calibration figure for 0_C by
certain corrections must be added to the calibration figures of electronic means. The electronic cold junction also avoids the
the particular thermocouple which are referred to 0 _C. To do temperature error due to the junction between the compensating
this, add the thermoelectric emf due to the cold junction leads and the copper leads.
Siemens AG
BHEL,Haridwar 2.1--8410--0004 / 2
Energy Sector 1010E
0114E
Turbogenerators
Description Supervision of Generator
The arrangement of the measuring points and supervisory connected gastight to pipes from the low-level points of the
equipment at the generator is illustrated in the attached generator. See Fig. 2 and 3.
diagram.
J Temperature monitoring 1 2 3
J Stator liquid detection im Inneren des Generators
1 Temperature Monitoring
1 2
1 2 3 4 5 6 7 8
3
e Siemens AG 2011 --
4
5
3 Separator
Fig. 1 Stator Slot Resistance Temperature Detector
10
1.2 Cold and Hot Gas Temperatures
The temperatures of the hot and cold gases are measured 11
by RTDs upstream and downstream of the hydrogen coolers.
The temperatures measured are provided to be used with the
hydrogen temperature control system and the generator
electronical equipment protection. 1 Liquid from stator frame, center
Temperature detectors located in the generator interior are 2 Liquid from terminal box, top
3 Liquid from cooling header, coolers C/D
mounted in gastight protective tubes welded to the stator 4 Liquid from cooling header, coolers A/B
frame. 5 Liquid from cooling header, center
6 Liquid from EE end winding, above hard-paper cover, top
7 Liquid from terminal box, bottom
1.3 Primary Water Temperatures 8 Liquid from EE end winding, above hard-paper cover, bottom
9 Shutoff valve upstream level detector
The temperature of the hot primary water in the drain water 10 Level detector
manifold of the stator winding is measured with resistance 11 Drain valve downstream level detector
temperature detectors. The temperature detectors are welded Fig. 3 Level Detector Rack
to the drain water manifold in protective tubes exposed to the Below the cooling header from where three pipes are
primary water temperature. routed to a shared level detector (see Items 3, 4 and 5 in
Fig. 3), sight glasses are installed in the pipes to enable the
identification and location of liquid in the cooling header.
Handhabung: OFFEN
One of the two pipes (Items 6 and 8 in Fig. 3), which are
2 Stator Liquid Detection used for detecting liquid above the hard-paper cover, is con-
nected a few centimeters above the other. The objective of this
Liquid (cooling water from hydrogen cooler or seal oil) approach is to ensure that liquid can only flow to the level de-
entering the generator housing is sensed by level detectors tector rack once it has reached a certain level. This pipe
Siemens AG
BHEL,Haridwar MKA &MDB 2.1--8420--0034 / 1
Energy Sector 0711E
0114E
(Item 6 in Fig. 3) is routed via three level detectors which are generator protection system is activated.
connected in parallel. If two of the three detectors signal the in- The other level detectors only trigger alarms.
gress of liquid, the mechanical generator protection system is
activated.
One of the two pipes (Items 2 and 7 in Fig. 3), which are con- 3 Dew Point Temperatures Measuring Unit
nected to the terminal box, does not end flush with the inside
surface of the box but slightly protrudes into the interior. The A possible risk to the generator cannot be excluded when
objective of this approach is to ensure that liquid can only flow the temperature of the generator components reaches or
to the level detector rack through this pipe once it has reached even falls below the drew point temperature of the cooling air.
a certain level. This pipe (Item 2 in Fig. 3) is routed via three This condition can occur after a drop of the component
level detectors which are connected in parallel. If two of the temperature or a rise of the dew point temperature in response
three detectors signal the ingress of liquid, the mechanical to an increase un the relative humidity.
Siemens AG
BHEL,Haridwar 2.1--8420--0034 / 2
Energy Sector 0711E
0114E
Turbogenerators
Supervision of Bearing Temperatures
Description
1 Rotor Shaft
2 Babbitt
3 Thermocouple
All Rights Reserved
Siemens AG
BHEL,Haridwar MKD &MDB 2.1--8440--0001
Energy Sector MKY 1008E
0114E
Turbogenerators
Supervision of Seal Oil System
Description
The location of the transmitters of the measuring and Pressure Downstream of Standby Seal Oil Pump
supervisory equipment in the seal oil system is shown in the A pressure transmitter signals the takeover of the seal oil
Seal Oil Diagram(see 2.1--7111). supply by the standby seal oil pump.
The most essential measuring and supervisory devices in Local indication is provided for setting the pressure
the seal oil system are: regulator and for observation.
increase in the amount of seal oil on the hydrogen side of the This local indicator displays the degree of filter
shaft seal, results in an alarm. The alarm is initiated when the contamination on a dial (red/white) and activates an alarm at
probe is immersed in oil. a preset pressure differential.
A low oil level in the intermediate oil tank and in the seal oil
e Siemens AG 2009 --
storage tank is monitored such that an alarm is activated when 3 Temperature Measuring Devices
the probe is no longer immersed in oil. The following temperatures are measured locally:
At high oil level in the seal oil tank, the vacuum pump is
stopped to prevent it from drawing seal oil. The alarm is J Seal oil temperature upstream and downstream of seal oil
activated when the probe is immersed in oil. coolers
Copyright
Siemens AG
BHEL,Haridwar MKY &MDB 2.1--8450--0016
Energy Sector 0309E
0114E
Turbogenerators
Supervision of Gas System
Description
The location of the transmitters of the measuring and 3 Pressure Measuring Points
supervisory equipment in the gas system is shown in the Gas
Diagram (see 24--2604--...). The following measuring points are provided:
The essential measuring and supervisory devices in the
gas system are: CO2 bottle pressure
The bottle pressure during CO2 filling can be observed at a
J Purity meter systems local pressure gauge.
J Volume flowmeter
H2 bottle pressure
J Pressure measuring points The bottle pressure can be read at the pressure gauge. The
J Temperature measuring points electrical signal of the pressure transmitter is used for
activating an alarm.
removing the hydrogen from the generator, where the The high pressure is monitored with a pressure transmitter
hydrogen is replaced with carbon dioxide and the carbon initiating a signal. In addition, a local indicator is used to monitor
dioxide in turn with air. The gas required for the measurement the H2 high pressure.
is taken from the generator or from the filling Iines, respectively,
Pressure in gas dryer chamber
and, on completion of the measurement, is discharged to the
e Siemens AG 2006 --
MKY
Siemens AG
BHEL,Haridwar MKG &MDC 2.1--8460--0028
Energy Sector 0106E
0114E
Turbogenerators Gas Analyzer for the Detection
Description of Hydrogen Leakages
If an undue loss of hydrogen occurs on the generator or in For this reason, the second principle of measurement is
the gas system, the location of the leak must be determined by used in the lower concentration range.
means of a suitable gas analyzer. To do this, we recommend
the Type 634P Exotector gas analyzer and gas alarm unit
Catalytic Combustion Method
(product of Gesellschaft fr Gertebau mbH, Dortmund).
The combustible constituents of a gas-air mixture are
The Type G634P Exotector gas analyzer and gas alarm unit
ignited at a heated detector, the active catalyst. The resulting
is calibrated for hydrogen and has three ranges, i.e.:
temperature rise leads to a change in resistance. Together with
a reference catalyst, the active catalyst forms the arm of a
Range I: 0 -- 100 vol % H2
Wheatstone bridge circuit. The current flowing through the
Range II: 0 -- 4 vol % H2
bridge circuit is proportional to the gas concentration, with the
Range III: leak detection, approx. 0 -- 15 vol of
various gases and vapors exhibiting different characteristic
lower explosion limit of H2
curves. The signals measured are transmitted to the display
unit and to the alarm section via an amplifier.
The Exotector instrument has been tested for explosion
protection by the BVS-Institut fr Explosionsschutz und
Sprengtechnik (Institute for Explosion Protection and Blasting
1
Technology). The following type of protection has been
approved: 10
2
Siemens AG
BHEL,Haridwar MKY &MDB 2.1--8469--0001
Energy Sector 1008E
0114E
Turbogenerators Primary Water System
Description Supervision
The Primary Water Diagram shows the location of the trans- 4 Pressure Gauges
mitters of the measuring and supervisory equipment for the Pressure levels and differential pressure levels in the
primary water system. primary water system are measured at the following locations:
The main measuring and supervisory systems and instru-
ments in the primary water system are as follows: J Downstream of primary water pump 1
J Downstream of primary water pump 2.
J Conductivity meter system
J Level monitoring system The two pressure measuring points are equipped with
J Volume flowmeter system pressure switches, and are required for the automatic control
J Pressure gauges of the primary water pumps.
J Temperature detectors. In addition, a pressure gauge is provided downstream of
each pump to allow the pressure to be monitored locally.
MKY
Siemens
BHEL,Haridwar AG MKF &MDB 2.1--8470--0008
Energy Sector 0708E
0114E
Turbogenerators Preparations for Startup
Operation Introduction
lf auxiliaries were taken out of operation, the operating 1.3 Primary Water Supply
fluids required to fill the auxiliary systems should be made The water quantitiy to be provided for filling the entire
available. primary water system shall amount to approximately two times
the primary water filling quantity. This allows for the water
quantity required for flushing the primary water system.
1 Operating Fluids
1.4 Cooling Water Supply
The operating fluids used, i.e. The coolers to be placed in operation shall be filled with
All Rights Reserved
1.1 Seal Oil System Prior to startup, all connections shall be rechecked. This
The seal oil systems is filled with turbine oil. The quantity of applies to piping as weIl as to cabling. When checking the
turbine oil required to fill the seal oil systems all be taken into cabling, special attention shall be paid to testing the instrument
consideration when filling the turbine oil tank. and signal cables. All alarm systems shall be checked.
All temperature measuring points shall also be checked.
1.2 Gas System This applies to temperature detectors with local and remote
1.2.1 Carbon Dioxide (CO2) indication. Unless temperature rises were brought about by
The carbon dioxide quantity to be provided shall be other preparatory work at the measuring points, temperatures
sufficient for two complete generator fillings (see also of approximately ambient or room temperature should be
2.1--1625, Gas Quantities), i e. for displacement of the air prior indicated. Where doubts exist regarding the electrical
to hydrogen filling and for immediate removal of the hydrogen temperature measurement, calibration and line
from the generator. compensation shall be repeated.
Distribution: UNRESTRICTED
MKA
Siemens AG
BHEL,Haridwar MKF &MDC 2.3--5000--0002
Energy Sector 0806E
0114E
MKG
MKW
Turbogenerators
Hints for Cooler Operation
Operation
J The growth of micro-organisms and, in case of seawater Deposits in the cooler tubes are best prevented by
installations, the growth of mussels must be prevented. supplying the normal-service coolers with the full cooling water
volume flow.
Cooling water obtained from a closed secondary cooling lf the temperature of the medium to be cooled is controlled
water circuit mostly meets these requirements provided that by varying the cooling water volume flow, it is recommended
the necessary care is exercised during initial operation, for to supply the normal-service cooler with the full cooling water
Siemens AG
BHEL,Haridwar MK &MDC 2.3--5003--0006 / 1
Energy Sector 0210E
0114E
volume for a brief period twice every week in order to flush 8 Cooler Changeover
away any deposits formed on the tubes due to insufficient Make sure to fill and vent standby coolers on their water
cooling water velocity. sides prior to changing over the coolers. Fully open shutoff
During occasional outages of sufficient duration or during valves. After cooler changeover, which must be performed by
an overhaul it should then be checked whether in-service experienced personnel, perform all measures required for
flushing is sufficient or whether manual clearing is required. If preservation of the cooler removed from normal service and
frequent manual cleaning is necessary on account of poor now on standby.
cooling water conditions, the installation of a high-velocity To do this, close shutoff valves upstream and downstream
water cleaning system or of a cleaning system using sponge of the standby cooler, since the cooling water system is mostly
rubber balls should be considered. designed only for supply of the cooling water flow through the
normal-service cooler(s). Then open the shutoff valve on the
7 Special Measures for Wet Preservation
outlet side by a small amount to avoid the effects of a water
lf a cooler has to be maintained ready for service in filled
expansion due to water heating.
condition, the water volume in the cooler must not be
A cooler changeover is necessary when, with the valves in
hermetically sealed from the cooling water system or from the
the cooling water circuit fully open, the temperature of the
surrounding atmosphere, respectively. Improper cooler
medium to be cooled is rising above the normal level or when
changeover would then result in heating and excessive
required on account of abnormal events (e.g. leakage).
expansion of the cooling water volume, leading to damage to
the cooler, gaskets or piping due to excessive pressure.
For wet preservation, always open a cooler vent on the
water side or a shutoff valve by a small amount, making sure
to avoid a low-velocity water flow that would promote the entry
of suspended material.
NOTE:
Standby coolers should be maintained ready
for operation in dry condition in preference to
wet preservation.
Siemens AG
BHEL,Haridwar 2.3--5003--0006 / 2
Energy Sector 0210E
0114E
Turbogenerators Turning Gear Operation and
Description Runup of Generator
control system should be changed over from the Automatic to no restriction regarding the rate of runup need be observed
the Manual mode. Use manual mode to adjust a cooling water other than those required for the turbine.
volume flow through the hydrogen coolers of approximately 5
to 10 % of the nominal flow rate. 5 Generator Air Operation
This causes the moisture contained in the gas to be Besides the above operating conditions, it may be
removed by condensation on the cooler tubes and fins. necessary in certain cases to operate the generator without
Copyright
The cooling water volume flow through the hydrogen hydrogen, i.e. during initial runup of the unit to check the
coolers should not be increased as long as the H2 cold gas bearings and vibrations and for clean-up. In view of the high
temperature ist not at rated value. windage losses and the resulting high temperature rise of the
During runup, the cooling water volume flow through the air such air operation is only permissible for brief periods and
hydrogen coolers should be increased by manual adjustment only with generator non-excited.
to maintain the cold gas temperature at lest 5 K below the The cold air temperature downstream of the coolers should
primary water inlet temperature. Changing over the H2 coolant not exceed 40 qC. At higher cold air temperatures, the
temperature control system from the Manual to the Automatic hydrogen coolers should be placed into service.
mode is permissible as soon as the primary water temperature During generator air operation, the supply of seal oil to the
control system, set for the automatic mode, opens the final shaft seals must be ensured as well.
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MK &MDC 2.3--8010--0012
Energy Sector 0210E
0114E
Turbogenerators
Simplified Generator Startup Procedure
Operation
Speed
Command: Generator startup Condition
in %
Vapor exhausters in operation
Primary water supply in operation
Primary water flow rates set (see also 2.1--1634, Operating and Setting Values)
Primary water cooler, cooling-water side in operation and vented
Primary water temperature control in operation
Seal oil system in operation
Seal oil inlet temperature 38 to 42 _C (100 to 108 _F)
Gas system in operation
0
Generator hydrogen pressure p = 0.3 bar below rated gas pressure
Hydrogen purity 95 %
Gas dryer ready for operation
Measuring and supervisory equipment apply power
Hydrogen coolers activate on, cooling-water side
H2 temperature control set to Manaul
Cooling water flow rate 5...10% at rated flow (manual control)
Automatic voltage regulator ready for operation
All Rights Reserved
Speed
Command: Generator runup Condition
in %
e Siemens AG 2010 --
Speed
Synchronizing, paralleling and loading Condition
in %
Synchronizing and paralleling see MKC/MKY manual
100 to required load, but within the limits of the capability
Loading
curve
Distribution: UNRESTRICTED
NOTE:
The above tables list the main startup criteria for the turbogenerator.
Siemens AG
BHEL,Haridwar MK &MDC 2.3--8011--0027
Energy Sector 0210E
0114E
Startup
Turbogenerators
Voltage Regulation With Automatic Control
Operation
Static Excitation System
2
Preparatory work
2.1
Set voltage regulator on Auto If the voltage regulator is on Manual, press the Auto
pushbutton; observe the signal lamps for Manual and Auto.
All Rights Reserved
2.2
Raise speed to 90 % of rated value Follow turbine operating instructions.
e Siemens AG 2006 --
3
Excite generator Excite the generator using the Excitation On pushbutton.
Observe the corresponding signal lamps and the instrument
for the generator voltage. This signal is interlocked via a speed
limit value and blocked by faults of the Excitation equipment.
Copyright
NOTE:
Excitation On command is blocked if the exci-
tation equipment is impaired by a fault.
4
Raise speed to rated value
5
Synchronize Observe the operating instructions for automatic
synchronization.
Switch on synchronizer by synchro selector at
approximately rated voltage and rated speed.
After pressing the synchronizer startbuttons, the voltage
and frequency balancing device matches the generator
voltage and frequency, and the synchronizer gives a closing
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKC &MDC 2.3--8030--0021
Energy Sector 0806E
0114E
On-Load Running
Turbogenerators
Voltage Regulation With Automatic Control
Operation
Static Excitation System
2
Loading Follow turbine operating instructions.
2.1
Set active power The active power is changed by adjustment of the turbine
controller.
2.2
Set reactive power The reactive power controller can be activated externally,
but only if automatic mode is selected, meaning that the
generator voltage controller is active, and the generator is
All Rights Reserved
Siemens AG
BHEL,Haridwar MKC &MDC 2.3--8130--0026
Energy Sector 0209E
0114E
On-Load Running
Turbogenerators Changeover of Automatic Voltage Regulator
Operation from Automatic to Manual
Static Excitation System
2
Changeover to Manual Because of the Automatic follow-up control a balancing
instrument is not provided.
Press the Manual pushbutton. Monitor Manual/Auto
signal lamps and generator voltage and/or reactive power.
3
Continue on-load running
All Rights Reserved
e Siemens AG 2009 --
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKB &MDC 2.3--8150--0021
Energy Sector 0709E
0114E
On-Load Running
Turbogenerators Changeover of Automatic Voltage Regulator
Operation from Manual to Automatic
Static Excitation System
Changeover from A follow-up control tracks the Auto setpoint adjuster so that
1 a changeover does not vary the excitation substantially.
Manual to Auto
2
Changeover to Auto If the voltage regulator is on Manual, press the Auto push-
button and monitor the signal lamps for Manual and Auto.
3
Continue on-load running
-- All Rights Reserved
e Siemens AG 2009
Copyright
Class.: UNRESTRICTED
BHEL,Haridwar
Siemens AG MKC &MDC 2.3--8160--0019
Energy Sector 0709E
0114E
Turbogenerators
Generator Load Limits
Operation
limits of the reactive capability curve. The permissible rate of 4.2 Deviation from Rated Hydrogen Pressure
loading depends on the condition of the winding insulation. lf the hydrogen pressure cannot be maintained at the spe-
Generators with a Micalastic stator winding insulation and a cified level due to e.g. gas loss or insufficient gas supply (see
rotor winding of silver-alloyed copper with glass laminate Section 2.1--1607) and has dropped 0.3 bar (30 kPa) below the
specified operating pressure, the generator load must be re-
Copyright
Siemens
BHEL,Haridwar AG MK &MDC 2.3--8170--0050
Energy Sector 0210E
0114E
Turbogenerators
Shutdown of Generator
Operation
1 General without interruption until the rotor has cooled down to nearly
During shutdown of the generator, the shaft lift oil pump room temperature.
must be started as soon as the unit reaches the speed
specified in the Turbine Instruction Manual. 3 Coolers
When the generator is on the turning gear, the hydrogen
coolers remain active for 15 hours. The purpose of this
approach is to ensure that the moisture contained in the gas
2 Turning Gear Operation condenses on the cooler tubes and fins.
To prevent any difficulties during a subsequent runup due
to thermal unbalances and resulting rotor distortion, the 4 Gas Dryer Circulating Fan
turning gear must be started as soon as the turbine-generator Below the turning gear operation automatically the
coasts down to the speed (turning gear speed) specified for circulating fan downstream the gas dryer is connected.
the turbine (normally automatic) and maintained in operation Thereby the gas dryer remains further in operation.
All Rights Reserved
e Siemens AG 2010 --
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MK &MDC 2.3--8310--0012
Energy Sector 0114E
0610E
Turbogenerators
Generator Shutdown Diagram
Operation
Actual Condition
1 Command: Unload generator
D
Generator main circuit breaker automatic trip through reverse-power protection
D
Speed approximately 90 %
D
Excitation field circuit breaker tripped
D
Turning gear operation see Turbine Instruction Manual
D
Hydrogen coolers in service with reduced flow (approx.10% of nominal flow)
All Rights Reserved
D
Seal oil system in operation
D
e Siemens AG 2009 --
Siemens
BHEL,Haridwar AG MK &MDC 2.3--8311--0025
Energy Sector 0709E
0114E
Unloading and Shutdown
Turbogenerators
Voltage Regulation With Automatic Control
Operation
Static Excitation System
2
Unloading Follow turbine operating instructions.
2.1
Remove active power The active power is changed by adjustment of the turbine
controller.
2.2
All Rights Reserved
Remove reactive power Reduce reactive power uniformly together with active
power:
3
Main circuit breaker off
4
Shutdown The Excitation Off command is automatically given after
the main circuit breaker is open.
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKC &MDC 2.3--8330--0024
Energy Sector 0806E
0114E
Turbogenerators Supervision of Generator During Standstill
Operation General
1 Generator at Standstill with Seal Oil, Gas 2 Generator at Standstill with Seal Oil, Gas
and Primary Water Systems in Operation and Primary Water Systems Out of Operation
Due to operational conditions, it may become necessary to Preservation measures will have to be taken when the
shut down the generator for a short period. When the unit is at generator is to be shut down for a period exceeding two
standstill, the bearing oil system can be taken out of service. months with the seal oil, gas and primary water systems to be
In the absence of any operational needs, e.g. inspection or taken out of operation. The scope of the preservation work
faults on generator, the primary water and hydrogen should required depends on the duration of the shutdown, on the
remain in the generator in order to retain the most favorable overall conditions in the vicinity of the unit and the extent to
prerequisites for a dry condition. All observations required for which checks an inspections are possible during such period.
a generator partly taken into service should be performed, After the hydrogen has been removed from the generator
such observations being essentially limited to the seal oil, gas by purging with Inert gas (CO2 or Argon), and the generator is
and primary water systems. depressized and filled with air, it is recommended that the
Normally it can be assumed that the generator was generator be opend by removing two manhole covers and to
operated with the gas dryer during the preceding service connect a dryer or hot air blower for continuous drying or
period. The generator interior will thus be in a dry condition circulation of the air in the generator. Care should be taken to
provided that the cooling gas was not replaced. ensure that this equipment is connected in such a way that a
Special measures should be taken to prevent corrosion circulation through the entire generator interior will be
damage to the tubes of the coolers during idle periods. During accomplished.
a brief outage, the coolers should be supplied with a small The hydrogen, primary water and seal oil coolers should be
cooling water flow. In addition, the coolers should be flushed drained on their cooling water sides and dried by suitable
All Rights Reserved
with the full cooling water flow at least twice weekly. measures.
In the case of prolonged outages, the coolers should be These measures are intended to prevent any condensation
drained on their cooling water sides and dried. in the generator interior even under varying environmental
conditions.
The sliprings should be cleaned at shutdowns, if required,
e Siemens AG 2009 --
Siemens
BHEL,Haridwar AG MK &MDC 2.3--8400--0030
Energy Sector 0709E
0114E
Turbogenerators Supervision of Generator During Standstill
Operation Slipring Assembly
1 Carbon Brushes
Hose
Removing the plug-in brush holders during a brief outage
(< 2 days) is not required. In the case of a prolonged outage
(> 2 days), it is, however, recommended to remove the plug-in
brush holders to prevent the formation of rust between the
slipring and the carbon brushes. After removal of the plug-in
brush holders, check the carbon brushes for breakage and for
reduction in brush length due to wear (see also 2.1--1609,
Mechanical Data).
2 Hose
For brief outages it is also recommended that the hose
between the fan casing and the labyrinth ring of the slipring
bearing compartment be disconnected, cleaned with com-
pressed air and then be reconnected.
The purpose of this measure is to remove any dirt which
could act as electrical conductor between the insulated
bearing compartment and the fan casing.
Siemens AG
BHEL,Haridwar MKC &MDC 2.3--8900--0020
Energy Sector 0901E
0114E
Turbogenerators Fault Tracing
Trouble-Shooting General
The details given herein on faults, their possible causes and can be taken in accordance with the following instructions, the
the corrective measures cannot be considered complete in turbine-generator should be shut down and the hydrogen
every respect, since all possible troubles cannot be covered in should be replaced with inertgas. If required, the services of the
advance. In most cases, the operator will have to decide on the manufacturer should be requested. In most cases, however,
measures to be taken. The individual measures required sufficient details will be found in the Turbogenerator Manual.
depend on the mode of operation. Unless corrective measures
All Rights Reserved
e Siemens AG 2008 --
Copyright
Distribution: UNRESTRICTED
BHEL,Haridwar
Siemens AG MK &MDB 2.3--9000--0001
Energy Sector 0808E
0114E
Turbogenerators Fault Tracing
Trouble-Shooting Stator and Generator Supervisory Equipment
Fault/Cause Remedy
J Faulty hydrogen temperature control. Insufficient cooling Verify cause of fault by checking analog indicators (uniform
water flow volume through hydrogen coolers. rise of temperatures in all coolers). See 2.3--9280 for remedial
action.
Copyright
J Insufficient cooling water volume flow through a single Verify cause of fault by checking analog indicators (uniform
hydrogen cooler. rise of temperatures at one coolers).
Check positions of cooling water valves at the
corresponding cooler. Check to ensure that the cooling water
inlet valve is fully open. Lower cold gas temperature of
defective cooler by adjusting the cooling water volume flow
with the cooling water outlet valve. Ensure that cold gas
temperatures downstream all hydrogen coolers are equal.
Siemens AG
BHEL,Haridwar MKA &MDC 2.3--9200--0031 / 1
Energy Sector 0114E
0710E
Fault/Cause Remedy
Liquid in generator
NOTE:
If two of the three parallel-connected liquid de-
tectors (see Fig. 1, Item 1) signal the ingress of
liquid, the mechanical equipment protection is tripped.
DANGER
Fire and explosion hazard due to escaping hydrogen gas.
The pipes of the liquid detector rack are H2-filled and
under pressure.
To prevent H2 leaks, close the shutoff valves before the
level detectors before draining the liquid.
To do this
J Close shutoff valve(s) upstream of level detector which
activated the alarm.
J Remove drain plug from drain valve downstream of the
corresponding level detector.
J Drain the liquid via the drain valve and inspect liquid.
J Then close drain valve and reopen shutoff valve upstream
of level detector.
J Repeat this procedure until no liquid is discharged from the
drain valve.
J Close drain valve downstream of the level detector and
open shutoff valve upstream of level detector. Insert and
tighten drain plug to seal the system (gastight).
1 2 3 4 5 6 7 8
10
11
Siemens AG
BHEL,Haridwar 2.3--9200--0031 / 2
Energy Sector 0710E
0114E
Fault/Cause Remedy
J Cooling water from a defective hydrogen cooler Lager amounts of water point to a leaking cooler section.
Identify defective cooler section. Reduce generator load
(see also 2.3--8170) and take cooler section out of service by
closing the shutoff valves. Than take measures outlined in the
corresponding instructions (see also 2.3--9440).
J Primary water Since the primary water pressure is lower than the H2
casing pressure during generator operation at rated hydrogen
pressure, liquid accumulation in the generator can only occur
in case of a major leak (tube failure, burst Teflon hose). The
leakage water quantities require, however, a shutdown of the
turbine-generator.
As soon as the generator has been disconnected from the
system and is de-excited, take primary water pumps out of
service and close control valve upstream of the stator winding
and bushings. Remove hydrogen from the generator
immediately and fill with inert gas. Fault tracing and corrective
action may be started as soon as the generator is filled with air
at atmospheric pressure.
Siemens AG
BHEL,Haridwar 2.3--9200--0031 / 3
Energy Sector 0710E
0114E
Turbogenerators Fault Tracing
Operation Rotor
Fault/Cause Remedy
Siemens
BHEL,Haridwar AG MKA40 &MDC 2.3--9310--0001
Energy Sector 1208E
0114E
Turbogenerators Fault Tracing
Operation Cooler
Fault/Cause Remedy
DANGER
J Leak or tube rupture in H2 cooler tube bundle Risk of explosion and fire due to leaking hydro-
gen. The generator is filled with hydrogen. Do
not unfasten any screws or bolts at the coolers
while the generator is filled with pressurized
hydrogen. Do not start any work on the cooler until the
hydrogen has been completely removed from the genera-
tor and the generator is filled with air at atmospheric
pressure.
Shut down the generator and seal off the cooling water
supply to the H2 cooler section.
NOTE
The hydrogen must be removed from the generator by
e Siemens AG 2011
Siemens
BHEL,Haridwar AG MKA70 &MDC 2.3--9440--0030 / 1
Energy Sector 0511E
0114E
Fault/Cause Remedy
J Tube side fouling Tube side fouling is caused by improper chemistry control
or excessive silting in open loop systems. Biological corro-
sion (MIC) is also due to improper chemistry control. Tubes
may be cleaned by a number of methods. See tube cleaning
equipment manufacturers and water chemistry vendors for
recommendations. Contact Siemens Generator Engineering
for further information.
J Tube side plugging Tube side plugging may occur because of biological
growth or silting. See tube cleaning equipment manufacturers
and water chemistry vendors for recommendations. Contact
Siemens Generator Engineering for further information.
J Gas purity levels Low gas purity levels decrease the performance of the
MKG31 CQ001, MKG32 CQ001 coolers below 98% Hydrogen purity. See recommendations
in Gas System Troubleshooting to increase Hydrogen purity.
J Gas side fouling Gas side fouling occurs when either oil or other fluids enter
the gas stream and collect on the surfaces of the fins. This
leads to an increase in thermal resistance as with tube side
fouling.
Coolers should be removed. Contact Siemens Generator
Engineering for further information.
J Decrease in water flow A decrease in cooling water flow is evident when the gas
side temperature drop remains nearly constant and the water
side temperature rise increases. Check to see if flows measu-
red to the coolers are near design requirements.
Siemens
BHEL,Haridwar AG 2.3--9440--0030 / 2
Energy Sector 0114E
0511E
Turbogenerators Fault Tracing
Operation Bearings
Fault/Cause Remedy
WARNING
WARNUNG
Risk of personal injury. Faulty oil cooling can lead to unallo-
wably high or low lube oil temperatures. This can cause
damage to the rotor bearings and bearing oil can leak at high
pressure and flow rate. Damaged shaft bearings can also lead
to damage of the shaft journals and can cause severe personal
injury due to ejected parts. Check the oil quality and oil filters
as per the corresponding maintenance schedule. Ensure com-
pliance with the instructions for changing the bearing oil and
All Rights Reserved
flushing the oil system. Check the cooler data as per the corre-
sponding maintenance schedule and ensure compliance with
the information about and instructions for the oil system in the
turbine maintenance manual.
e Siemens AG 2010 --
down.
Siemens
BHEL,Haridwar AG MKD &MDC 2.3--9450--0001
Energy Sector 0710E
0114E
Turbogenerators Fault Tracing
Trouble-Shooting General
The details given herein on faults, their possible causes and can be taken in accordance with the following instructions, the
the corrective measures cannot be considered complete in turbine-generator should be shut down and the hydrogen
every respect, since all possible troubles cannot be covered in should be replaced with inertgas. If required, the services of the
advance. In most cases, the operator will have to decide on the manufacturer should be requested. In most cases, however,
measures to be taken. The individual measures required sufficient details will be found in the Turbogenerator Manual.
depend on the mode of operation. Unless corrective measures
All Rights Reserved
e Siemens AG 2008 --
Copyright
Distribution: UNRESTRICTED
BHEL,Haridwar
Siemens AG MK &MDB 2.3--9000--0001
Energy Sector 0114E
0808E
Turbogenerators Fault Tracing
Trouble-Shooting Stator and Generator Supervisory Equipment
Fault/Cause Remedy
J Faulty hydrogen temperature control. Insufficient cooling Verify cause of fault by checking analog indicators (uniform
water flow volume through hydrogen coolers. rise of temperatures in all coolers). See 2.3--9280 for remedial
action.
Copyright
J Insufficient cooling water volume flow through a single Verify cause of fault by checking analog indicators (uniform
hydrogen cooler. rise of temperatures at one coolers).
Check positions of cooling water valves at the
corresponding cooler. Check to ensure that the cooling water
inlet valve is fully open. Lower cold gas temperature of
defective cooler by adjusting the cooling water volume flow
with the cooling water outlet valve. Ensure that cold gas
temperatures downstream all hydrogen coolers are equal.
Siemens
BHEL,Haridwar AG MKA &MDC 2.3--9200--0031 / 1
Energy Sector 0710E
0114E
Fault/Cause Remedy
Liquid in generator
NOTE:
If two of the three parallel-connected liquid de-
tectors (see Fig. 1, Item 1) signal the ingress of
liquid, the mechanical equipment protection is tripped.
DANGER
Fire and explosion hazard due to escaping hydrogen gas.
The pipes of the liquid detector rack are H2-filled and
under pressure.
To prevent H2 leaks, close the shutoff valves before the
level detectors before draining the liquid.
To do this
J Close shutoff valve(s) upstream of level detector which
activated the alarm.
J Remove drain plug from drain valve downstream of the
corresponding level detector.
J Drain the liquid via the drain valve and inspect liquid.
J Then close drain valve and reopen shutoff valve upstream
of level detector.
J Repeat this procedure until no liquid is discharged from the
drain valve.
J Close drain valve downstream of the level detector and
open shutoff valve upstream of level detector. Insert and
tighten drain plug to seal the system (gastight).
1 2 3 4 5 6 7 8
10
11
BHEL,Haridwar
Siemens AG 2.3--9200--0031 / 2
Energy Sector 0710E
0114E
Fault/Cause Remedy
J Cooling water from a defective hydrogen cooler Lager amounts of water point to a leaking cooler section.
Identify defective cooler section. Reduce generator load
(see also 2.3--8170) and take cooler section out of service by
closing the shutoff valves. Than take measures outlined in the
corresponding instructions (see also 2.3--9440).
J Primary water Since the primary water pressure is lower than the H2
casing pressure during generator operation at rated hydrogen
pressure, liquid accumulation in the generator can only occur
in case of a major leak (tube failure, burst Teflon hose). The
leakage water quantities require, however, a shutdown of the
turbine-generator.
As soon as the generator has been disconnected from the
system and is de-excited, take primary water pumps out of
service and close control valve upstream of the stator winding
and bushings. Remove hydrogen from the generator
immediately and fill with inert gas. Fault tracing and corrective
action may be started as soon as the generator is filled with air
at atmospheric pressure.
Siemens AG
BHEL,Haridwar 2.3--9200--0031 / 3
Energy Sector 0710E
0114E
Turbogenerators Fault Tracing
Operation Rotor
Fault/Cause Remedy
Siemens
BHEL,Haridwar AG MKA40 &MDC 2.3--9310--0001
Energy Sector 1208E
0114E
Turbogenerators Fault Tracing
Operation Cooler
Fault/Cause Remedy
DANGER
J Leak or tube rupture in H2 cooler tube bundle Risk of explosion and fire due to leaking hydro-
gen. The generator is filled with hydrogen. Do
not unfasten any screws or bolts at the coolers
while the generator is filled with pressurized
hydrogen. Do not start any work on the cooler until the
hydrogen has been completely removed from the genera-
tor and the generator is filled with air at atmospheric
pressure.
Shut down the generator and seal off the cooling water
supply to the H2 cooler section.
NOTE
The hydrogen must be removed from the generator by
e Siemens AG 2011
Siemens
BHEL,Haridwar AG MKA70 &MDC 2.3--9440--0030 / 1
Energy Sector 0511E
0114E
Fault/Cause Remedy
J Tube side fouling Tube side fouling is caused by improper chemistry control
or excessive silting in open loop systems. Biological corro-
sion (MIC) is also due to improper chemistry control. Tubes
may be cleaned by a number of methods. See tube cleaning
equipment manufacturers and water chemistry vendors for
recommendations. Contact Siemens Generator Engineering
for further information.
J Tube side plugging Tube side plugging may occur because of biological
growth or silting. See tube cleaning equipment manufacturers
and water chemistry vendors for recommendations. Contact
Siemens Generator Engineering for further information.
J Gas purity levels Low gas purity levels decrease the performance of the
MKG31 CQ001, MKG32 CQ001 coolers below 98% Hydrogen purity. See recommendations
in Gas System Troubleshooting to increase Hydrogen purity.
J Gas side fouling Gas side fouling occurs when either oil or other fluids enter
the gas stream and collect on the surfaces of the fins. This
leads to an increase in thermal resistance as with tube side
fouling.
Coolers should be removed. Contact Siemens Generator
Engineering for further information.
J Decrease in water flow A decrease in cooling water flow is evident when the gas
side temperature drop remains nearly constant and the water
side temperature rise increases. Check to see if flows measu-
red to the coolers are near design requirements.
Siemens AG
BHEL,Haridwar 2.3--9440--0030 / 2
Energy Sector 0511E
0114E
Turbogenerators Fault Tracing
Operation Bearings
Fault/Cause Remedy
WARNING
WARNUNG
Risk of personal injury. Faulty oil cooling can lead to unallo-
wably high or low lube oil temperatures. This can cause
damage to the rotor bearings and bearing oil can leak at high
pressure and flow rate. Damaged shaft bearings can also lead
to damage of the shaft journals and can cause severe personal
injury due to ejected parts. Check the oil quality and oil filters
as per the corresponding maintenance schedule. Ensure com-
pliance with the instructions for changing the bearing oil and
All Rights Reserved
flushing the oil system. Check the cooler data as per the corre-
sponding maintenance schedule and ensure compliance with
the information about and instructions for the oil system in the
turbine maintenance manual.
e Siemens AG 2010 --
down.
Siemens
BHEL,Haridwar AG MKD &MDC 2.3--9450--0001
Energy Sector 0710E
0114E
Turbogenerators Maintenance and Supervision
Maintenance Introduction
CAUTION
Risk of personal injury. Increased risk of personal injury due
to maintenance work. Always ensure sufficient support and
wear suitable protective clothing.
e Siemens AG 2010 --
Copyright
Distribution: UNRESTRICTED
BHEL,Haridwar
Siemens AG MK &MDC 2.4--4200--0001
Energy Sector 0710E
0114E
Turbogenerators
Survey on Maintenance and Supervision
Maintenance
Maintenance intervals
Every 3 months
Every 6 months
see
Work required
Instruction
Annually
Monthly
Weekly
Daily
Check sight class after level detectors for liquid level x 2.4--4210--....
Check shaft grounding brushes x 2.4--4210--....
Check hydrogen cooler vents x 2.4--4240--....
Check EE generator bearing insulation x 2.4--4250--....
Check shaft seal insulation, EE x 2.4--4250--....
Measure insulation resistance of rotor winding x 2.4--4310--....
All Rights Reserved
e Siemens AG 2012 --
Copyright
Handhabung: OFFEN
Siemens AG
BHEL,Haridwar MK &MDC 2.4--4205--12580
Energy Sector 0212E
0114E
Turbogenerators
Maintenance and Supervision of Stator
Inspection
Maintenance intervals
Every 3 mounths
Every 6 mounths
Work required
Mounthly
Annually
Weekly
Daily
Check grounding brushes x
Check sight glasses after level transmitters for liquid level x
1 Monitoring the Temperature of Components upstream and downstream of each cooler section. The tempe-
lt is important that all temperatures remain within the rature transmitters, installed downstream of the coolers, mea-
specified upper and lower limits. If a temperature deviation is sure the temperature of the gas used for cooling the generator.
observed the cause must be determined immediately and the The cooling water supply to the cooler section must be con-
original temperature restored. trolled in such a manner that the temperature of the gas exiting
lf there exists the danger of overheating, a corresponding the cooler sections is approximately identical. The volumetric
load reduction should be made. flow rate of the cooling water must be adjusted by means of the
The temperatures between the top and bottom bars of the control valves in the cooling water outlets. The shutoff valves
stator winding are measured with resistance temperature at the cooling water inlets must be fully opened.
All Rights Reserved
currents in all three phases. If different temperatures are indi- perature is also measured. The cooling water inlet tempera-
cated with identical currents in the three phases, a check tures of all cooler sections should be measured in the cooling
should be performed to determine if the slot RTDs are correctly water inlet pipes, while the cooling water outlet temperature
calibrated and/or compensated. Differences in the tempera- should be measured separately for each cooler section in the
ture indication up to 5 K may be due to tolerances in the slot cooling water outlet pipe after each cooler section.
RTDs, compensating resistors and tolerances caused by dif-
Copyright
BHEL,Haridwar
Siemens AG MKA &MDC 2.4--4210--0061 / 1
Energy Sector 0210E
0114E
The carbon brushes should be replaced with new ones
having contact faces which match the rotor shaft contour.
DANGER
The temperature of the cold primary water should be NOTE:
higher than the H2 cold gas temperature by not less than When inserting new brushes, make sure that
5 K under all conditions of operation in order to avoid the carbon layer comes before silver layer in direc-
formation of condensate on the components carring tion of rotation.
primary water.
6
6 Primary Water Pressure
Upstream of Stator Winding
In combination with the pressure differential across the
stator winding, the pressure of the primary water upstream the
stator winding can be taken as a reliable criterion for a safe
cooling water supply to the various branches.
A small change in pressure up to a maximum of 10 % has
no influence on cooling of the stator winding. Major changes
with rising tendency may be indicative of a disturbance in uni-
form cooling in individual branches. To avoid any risk in cooling
of the stator winding, it is recommended to contact Direction of Rotation
manufacturers service department and to ask for removal of
the cause. 1 2 4 3 5
Siemens AG
BHEL,Haridwar 2.4--4210--0061 / 2
Energy Sector 0210E
0114E
Turbogenerators
Maintenance and Supervision of Rotor
Maintenance
Maintenance Intervals
Every 6 months
Every 3 months
Work required
Annually
Monthly
Weekly
Daily
Measure insulation resistance u
1 Monitoring Rotor Vibrations may lead to overspeed of the turbine. This could cause fire or
The vibrations of the generator rotor should be monitored personal injury by ejected parts. Shut down generator when
and any change should be carefully observed. Should a the speed control system is faulted
change in vibration characteristics be noted, it is recom-
mended to have the manufacturers product service personnel
determine the cause and assist in correcting any problems.
2 Measuring Insulation Resistance
The insulation resistance of the rotor winding toward
CAUTION ground should be measured once a year provided this is
possible during a short outage.(see 2.5--3300).
Risk of fire and personal injury. Failure of the speed control
All Rights Reserved
e Siemens AG 2010 --
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKA40 &MDC 2.4--4310--0003
Energy Sector 0114E
0710E
Turbogenerators Maintenance and Supervision
Maintenance of Generator Coolers
Maintenance Intervals
Every 3 months
Every 6 months
Work required
Annually
Monthly
Weekly
Daily
Check cooler vents u
1 General 2 Coolers
Special measures should be taken to prevent corrosion During normal operation, the cooling water flows through all
damage to the cooler (see also 2.3--5003). Cooler sections cooler sections. Since the coolers are designed for 100 %
having no cooling water flows for some time may be subject to capacity at maximum cooling water temperature, the condition
standstill corrosion. ln addition to many other corrosive may arise that the coolers are supplied with smaller cooling
influences, such as the different elements of the cooling water, water flows for long periods. Depending on the purity of the
locally differing deposits, raw materials, etc., there exists the cooling water, this may result in deposits due to the lower water
danger that micro-organisms on the tube walls may die and velocity in the cooler. To prevent cooler damage, it is therefore
decay due to a loss of fresh water supply (lack of oxygen). recommended to rinse the coolers with the full water flow
Ammonia is formed from such decay which may lead to stress during short outages. ln addition, the coolers should be
All Rights Reserved
corrosion cracking. Corrosion damage can only be properly frequently cleaned with brushes. For heavy cooler
prevented if the cooler is drained on the water side, cleaned, contamination and if operational restrictions and shutdowns
completely dried and maintained in a dry condition. With the are undesirable, it is recommended to install a continuous
generator in commercial operation, such measures are often cooler water purification system.
unfeasible, particularly in cases of short outages. In such Remove cooler elements for cleaning.
e Siemens AG 2006 --
DANGER
Fire and expolsion hazard due to escaping hydrogen gas.
Copyright
Siemens AG
BHEL,Haridwar MKA70 &MDC 2.4--4240--0007
Energy Sector 0806E
0114E
Turbogenerators Maintenance and Supervision
Maintenance of Bearings
Maintenance Intervals
Every 3 months
Every 6 months
Work required
Annually
Monthly
Weekly
Daily
Check EE generator bearing insulation u
Check EE shaft seal insulation u
operating values prevailing after a restart exceed the permis- Checking the shaft seal and bearing insulation during
sible limit values, the unit should be shut down immediately. operation (see Section 2.5--0300, Checking the Bearing and
The lift oil pressure for the shaft journals should be adjusted Seal Insulation) may be done by way of the shaft voltage pre-
so that the shaft is lifted by not more than 50 % of the bearing vailing with the generator running in an excited condition. For
this purpose, the potential of the insulated shaft seals and
e Siemens AG 2009 --
served, the respective bearings should be checked. Such seals and bearing sleeves which is dictated by the magnitude
pressure reduction may be indicative of damage in the area of of the resistances of the oil film and insulating parts.
Distribution: UNRESTRICTED
BHEL,Haridwar
Siemens AG MKD &MDC 2.4--4250--0004
Energy Sector 0109E
0114E
Turbogenerators
Introduction
Maintenance
Reliable operation of the turbine generator will be ensured The assignment and number of Siemens product service
only if inspections and overhauls are carried out at regular personnel required for an inspection should be planned well
intervals so that any faults can be detected and corrected in advance to enable Siemens to make the necessary
before they result in costly failures. Following each inspection, arrangements. In addition, the period available for execution
the next inspection should be scheduled. of the inspection should be indicated.
Provided that commercial tools can be used and that no The spare parts stored for repairs and overhauls should be
special skills are required for the dismantling and erection checked at regular intervals. Components packed in plastic
work, the inspections can be performed by skilled power sheeting mostly contain a desiccant which must be replaced
station personnel. In all other cases, however, such as for the of reactivated from time to time.
inspection of the shaft seals and their auxiliaries, the services
of experienced Siemens product service personnel will be
required. WARNING
The shutdown of a turbine generator for inspection should Rotating components. These may cause injury to per-
be made in exactly the reverse order of startup. It should be sons. When working on generator or auxiliary equipment
noted in particular that the hydrogen must be removed from ensure that this is electrically isolated and cannot acci-
the generator housing with argon only. Should opening of the dentally be reconnected.
gas system or of the generator proper be required during an In single shaft configurations, do not open the generator
inspection, it is necessary to replace the argon with air. frame and do not start any work on the rotor or the bear-
Following an inspection, the generator should be restarted ings until the gas turbine and the steam turbine as well as
in the same way as during initial startup. the generator have come to a complete standstill.
All Rights Reserved
e Siemens AG 2010 --
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MK &MDC 2.5--0010--0008
Energy Sector 0210E
0114E
Turbogenerators
Determination of Dewpoint Temperature
Maintenance
500
Absolute and relative humidity at different temperatures
Absolute humidity in g/m 3
80
DT in O C
60
100
90
50
80
70
60
40
50
40
All Rights Reserved
30 30
e Siemens AG 2009 --
20
20
Copyright
10 10
9 +9
8
7
6
5 0
4 --2
--4
3 --6
--8
--10
2
Distribution: UNRESTRICTED
1
1 2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90 100
Relative humidity in %
Example: Relative humidity of ambient air = 50 % and room temperature = + 20 _C result in a
dewpoint temperature (DT) of + 9 _C, corresponding to an absolute humidity of 8.6 g/m3.
Siemens
BHEL,Haridwar AG MK &MDC 2.5--0019--0001
Energy Sector 0109E
0114E
Turbogenerators Preservation, Packaging, Shipment and
Maintenance Storage of Generator Components
J
J wrapping in polyethylene sheeting Differentiation is made between two types of airtight pack-
J sealing of openings to render components airtight, e.g., for aging:
casings (rigid barrier) J Packages sealed with metal plates and closures and
J sealing in foil or film, e.g. rotors and shafts (flexible barrier). Denso sealing tape (rigid barrier)
Any component that is suitable for rigid-barrier packaging
The preservation methods are based on the following peri-
should be sealed with metal plates and Denso tape
ods of time:
because of their robustness and reliable airtight enclosure.
J up to 6 months (shipping and storage It is important in this respect to avoid the use of seals and
J up to 12 months (storage) gaskets made of substances that are hygroscopic or per-
J up to 24 months (long-term storage) or longer, assuming meable to air, e.g. foam rubber or felt in combination with
regular in-storage inspections. metal plates and covers.
An inspection window sealed with Denso tape should be
provided in an appropriate position. A moisture indicator
1.1 Volatile Corrosion Inhibitor (VCI)
shall be positioned in a visible location behind the inspec-
Impregnated Paper U5
tion window.
When VCI-impregnated paper is used, the wrapped
components, including the paper, should be given an outer J Packages sealed with foil or film (flexible barrier)
wrapping of polyethylene sheeting to create an airtight space In cases where a rigid barrier is not feasible or economical,
in which the corrosion-inhibiting substances can develop their laminated aluminum foil must be used to achieve airtight
Distribution: UNRESTRICTED
full protective effects through evaporation and chemical packaging. To prevent damage to the laminated aluminum
conversion processes. foil, the sharp edges of components must be protected with
Approximately 7 m2 VCI-impregnated paper is required per suitable padding material prior to wrapping. The airtight
cubic meter of enclosed space with this method of packaging. package must not contain any hygroscopic materials such
The effectiveness of the paper is limited to a distance of as excelsior, corrugated cardboard or felt. Care must be
approximately 300 mm under loose cover. taken to ensure that the aluminum foil is nor damaged in the
Siemens
BHEL,Haridwar AG MK &MDC 2.5--0030--0003 / 1
Energy Sector 0710E
0114E
course of the packaging process because even the slight- tion 4), the adsorptive capacity of the desiccant in the airtight
est damage, e.g., a hairline crack in the foil, would render package must be checked. This can be performed by means
the airtight package ineffective. The seams of airtight of indicators located inside the package. The minimum clear-
packages must be heat-sealed with great care at corners, ance between the indicators and the foil is 5 cm. The indicators
and intersecting seams must be executed in criss-cross are marked with a unique position code and show the relative
fashion. humidity inside the package for three ranges ( 30 %, 40 %
Airtight packages of aluminum foil must be subjected to a and 50 %). If the package is dry, all circles are blue. When
leaktest. To this end a vacuum cleaner must be used to the color changes to pink, the relative humidity is shown in the
remove the air from the package, which can be deemed air- corresponding circle (cf. Fig. 1). When the 40 % indicator
tight if it retains its full vacuum condition for at least one changes to pink, the desiccant must be removed and replaced
hour (pinch test). or reactivated by drying.
For components destined for long-term storage or sea This period should not exceed 20 hours and the opening
freight, laminated aluminum foil is, as a rule, the preferred through which the desiccant was removed should be pro-
material for airtight packaging. visionally sealed during this period. Before removing the
desiccant, be sure to check that either replacement desiccant
1.3 Desiccant or the necessary reactivation equipment is available.
1.3.1 Type and Position
The desiccant is supplied in dustfree and moisture-perme-
able linen bags. The bags of desiccant should be strung
together and should, at the time of insertion in the package, be
in an active condition, i.e. they must be absolutely dry. The
desiccant should be located to ensure easy accessibility to
facilitate replacement and must not make any direct contact
with parts made of steel or nonferrous metals (danger of corro-
sion).
The bags of desiccant should be placed near to and on both
ends of the rotor retaining rings and rectifier wheels.
2 Packaging
When pink: replace desiccant
2.1 Wooden and Steel Crates or Containers
All packing crates must have stable bases with skids
capable of supporting the weight of the components to be
packed. Components packed in crates must be securely and
When pink: caution
adequately bolted down or otherwise held in position to
prevent any shifting during shipment. The measures taken
must account for the fact that crates may be tilted up to 30_.
Fig. 1 Humidity Indicator Crates for sea freight (with the exception of plywood boxes
(exact location to be indicated) or crates with airtight wrappings) must be lined with poly-
Siemens
BHEL,Haridwar AG 2.5--0030--0003 / 2
Energy Sector 0710E
0114E
Fig. 3 Rotor in Tightpack on Skid
ethylene sheeting. Only the bottom of the crate must remain secured to pallets for dustfree transportation. Be sure to pro-
unlined. Instead the bottom of the packing crate must be vide adequate cushioning on all sharp edges and corners of
provided with holes of sufficient size and number to ensure the items in question.
good drainage of any water and to ventilate the interior of the
case.
Crates with interior airtight wrappings of polyethylene 2.4 Cushioning Material
sheeting must have inspection openings with covers at those Suitable cushioning materials include high-air-content
locations where the inspection windows and the humidity indi- expanded plastic, expanded rubber, expanded-plastic strip-
cators are situated in the wrapping. If long-term storage is ping, sheet rubber and styrofoam. The cargo, its cushioning
planned, additional openings must be provided to enable and the packaging materials should form a strong, stable unit
replacement of desiccant. with the capacity to effectively absorb mechanical impact and
Crate covers must be reinforced with a sufficient number of vibrations.
square-timber braces to withstand the lateral compressive Consequently, and due to the fact that they tend to plug up
forces resulting from hook and rope attachments. cooling ducts and ports, styrofoam chips are unsuitable for
Packages in which the center of gravity is off-center or use as cushioning material. If at all, they should only be used
situated in the upper half of the package must be marked with for very light items with large surface areas.
a center of gravity symbol.
Crates with maximum dimensions of
5000 x 2500 x 3500 mm (L x W x H ) and a weight of 15000 kg or 2.5 Marking
less must have a base structure designed to permit handling To ensure correct and careful handling of goods during
by means of a forklift truck. shipment, each package should be marked appropriately on
at least two diagonally opposite sides.
The packages should also be marked to indicate the sensi-
tivity of the cargo. The symbols indicating Keep dry and This
CAUTION side up must be applied to every package. Any package in
Do NOT use forklift trucks for handling cases containing which the center of gravity is off-center must also be marked
stator winding bars. with the Center of gravity symbol in such a manner that the
actual location of the packages center of gravity can be clearly
2.2 Skids identified. Cases containing airtight-wrapped items must also
Heavy components should be transported on skids, the carry on orange Roof symbol. All packages weighing more
dimensions of which depend on the size and weight of the than 1000 kg must be marked with the symbol Attach lifting
component and on the planned mode of transport (railway car, gear here to identify the rope attachment points. The symbol
truck or ship). denoting Do not use forklift trucks must be stamped on
In case of extreme shipment conditions, very heavy crates that are unsuitable for forklift handling.
weights, or at the Customers request, skids for rotor and
stator can be made of steel. Example:
2.3 Tightpacks
Tightpacks, i.e., packages employing a shrink film system,
should be used whenever small, light items are to be efficiency
Siemens
BHEL,Haridwar AG 2.5--0030--0003 / 3
Energy Sector 0710E
0114E
3 Shipping corresponding notice must be displayed both on the transport
vehicle and in the shipping documents.
Upon arrival at their place of destination, the components
WARNING
WARNUNG and their protective packaging must be examined for damage.
Any damage discovered must be recorded, and the necessary
Risk of personal injury. Lifting trunnions can shear off during
repairs initiated without delay.
transport. The generator can fall down and cause personal in-
jury. Ensure compliance with the handling procedures for the
lifting beam. Do not stand, walk or work under suspended
loads and wear suitable personal protective equipment and WARNING
WARNUNG
clothes. Risk of personal injury. Any rotor shipping braces acci-
dentally left on the rotor can cause damage to the generator.
The mode of transportation (truck, railway car, ship, air- Risk of personal injury due to ejected parts. When assembling
craft) should be selected according to the nature, size and the generator, check and ensure that all rotor shipping braces
weight of the cargo, the traffic conditions anticipated for the have been removed.
chosen route, and the urgency of the shipment.
It should be ensured that only vehicles are selected which
feature the necessary structures and equipment for safety 4 Storage and Long-Term Storage
withstanding the loads generated by the cargo.
The cargo should be loaded and secured such that it will Any period of storage exceeding 12 months is referred to
not, under normal conditions of transportation, move, roll, tip as long-term storage. Storage must not impair the function or
over, fall down or cause the vehicle to overturn. Tie-down the quality of the goods.
chains and straps, and anti-skid plates are the preferred types In cases where open-air storage is unavoidable, the stored
of constraint and should be used in accordance with the goods must be protected by either a durable outer packing or
manufacturers instructions. an equivalent form of surface protection.
All components on skids should be slid into position on the The outdoor storage area must offer adequate protection
transport vehicle with the aid of guide timbers. A slipway length for the stored goods against precipitation, standing water,
of at least 1.5 m must be provided for this purpose. If several ground moisture, dirt, vermin and unauthorized access. The
units are to be formed, they must be spaced at least 50 cm goods must be covered with waterproof tarpaulins or located
apart. If this method of loading is used, the weight of the load under protective roofing, and must be adequately ventilated.
must not exceed 75 % of the relevant load limit of the vehicle Components in storage, including long-term storage, must
in question. be inspected at monthly intervals with regard to surface
Tarpaulins should be used to protect packing crates, protection, nitrogen pressure and humidity indicator colors.
unpackaged and/or sensitive components against moisture Any damage to the surface protection, loss of nitrogen
and soiling. pressure or changes in the color of humidity indicators of air-
Large, heavy and sensitive components and items packed tight packages during these inspections must be recorded by
in crates for rail transport must not be loaded via humps. A the responsible personnel.
Siemens
BHEL,Haridwar AG 2.5--0030--0003 / 4
Energy Sector 0710E
0114E
Turbogenerators
Checking Desiccant in Packing of Components
Maintenance
Desiccant Checking Requirements should be recorded in the table below. The desiccant must be
The absorbent capacity of the desiccant must be checked removed and replaced or reactived by drying when a change
after shipment has been completed and at intervals of one in the color of the 40 % moisture indicator is observed.
month during any subsequent storage period. The results
Condition of
component
or identification in packing or
Company
Prior to TE
shipment
TE
TE
EE
EE
EE
All Rights Reserved
TE
TE
TE
e Siemens AG 2009 --
EE
EE
EE
TE
Copyright
TE
TE
EE
EE
EE
TE
TE
TE
EE
EE
EE
TE
TE
TE
Distribution: UNRESTRICTED
EE
EE
EE
Siemens AG
BHEL,Haridwar MKA40 &MDC 2.5--0032--0001
Energy Sector 0109E
0114E
Insulation Resistance Measurements
Turbogenerators
on Rotor Windings
Maintenance
Test Report
indicator in 30
packing
blue or 50
pink? EE1 40
30
Pressure of nitrogen
blanket in bar
Applied voltage in V
15 s
30 s
Copyright
45 s
Insulation resistance in M 8
01 min
02 min
03 min
04 min
05 min
06 min
07 min
08 min
09 min
10 min
insulation measuring device (% 500 V). 5. After each measurement, any static charges should be
2. Prior to each measurement, any static charges should be removed by short-circuiting the winding through the rotor
removed by grounding the windings as a precautionary body (not less than 20 minutes)
measure (10 minutes).
Siemens AG
BHEL,Haridwar MKA41 &MDC 2.5--0033--0002
Energy Sector MKC36 0909E
0114E
Turbogenerators
Preparation of Machinery Parts
Maintenance
Siemens AG
BHEL,Haridwar MK &MDC 2.5--0200--0001
Energy Sector 0210E
0114E
Turbogeneratoren Checking the Insulation for
Maintenance Protection From Shaft Currents
With satisfactory insulation, a value in excess of check should be performed. The total insulation resistance
10 megohms is to be expected. If an insulation resistance must not be less than 0.1 megohm. Due to contact with the
value below 0.3 megohms is measured, the insulating parts shaft, the measuring curcuit covers in parallel:
should be checked for moisture, contamination or metallic
contacts. If required, the insulation should be dried at 80 _C TE/EE bearings
e Siemens AG 2010 --
With this measurement and the following oil, bearing lube oil and seal oil).
checks both rotor bearings must be insulated,
and the generator rotor must not come into contact with
the turbine shaft through measuring devices or similar 3 Checking the Shaft Seal and Bearing
parts, to prevent the generator rotor from being grounded. Insulation of the Assembled Unit
Since, with the rotor inserted, all individual resistances
measured previously are now in parallel in the measuring Checking the shaft seal and bearing insulation during
circuit, the total resistance will be slightly lower than the operation may be done by way of the shaft voltage prevailing
lowest individual resistance value measured before. with the generator running in an excited condition. For this
purpose, the potential of the insulated shaft seals and bearings
2.2 Inner and Outer Labyrinth Rings is accessible external to the generator. With the generator
Inner and outer labyrinth rings are insulated from other running, the components coming into contact with the shaft are
components. The insulation resistance of each individual separated from the shaft by an oil film, which has insulating
labyrinth ring should be measured after installation in order to properties. Consequently, a non-defined resistance value is
preclude any lengthly search for faulty mounting on set up at the potential measuring points of the shaft seals and
measurement of a poor insulation resistance. Proceed with bearing sleeves which is dictated by the magnitude of the
mounting of the next component only after having indentified resistances of the oil film and insulating parts. The following
and removed the cause of a poor insulation resistance. After method permits the insulation to be checked without
installation of all insulated components the total resistance will disassembly of components being required.
Distribution: UNRESTRICTED
be slightly lower than the lowest individual resistance valvue Useful results are, however, to be excepted only if the
measured before. turbine end of the generator rotor and the turbine shaft are
grounded properly during the measurements. Grounding must
2.3 Shaft Seals be maintained to discharge to ground any static charges
Both shaft seals are mounted such that they are insulated. occurring continuously during operation due to steam and oil
To check the insulation resistance, follow the same procedure film friction.
Siemens AG
BHEL,Haridwar MKD &MDC 2.5--0300--0002 / 1
Energy Sector 0210E
0114E
3.1 Checking the Insulation With the Generator satisfactory insulation, the instrument will continue to indicate
in an Excited Condition a shaft voltage of the original magnitude. In the event of
Due to the rotor grounding arrangement at the turbine end, insufficient insulation resistance, a current will flow through the
the shaft voltage should be measured at the exciter end. Since insulation, which may be read at the ammeter into the circuit.
the result depends, however, on the function of the rotor Bridging of the oil film results in a reduction of the original shaft
grounding system (carbon brush sliding on shaft), the shaft voltage or in its complete collapse.
voltage should first be measured according to Fig. 1 with the
generator running and excited. Normally, this will be an
ac voltage of a few volts on which a small dc component is
superimposed. Measurement should be performed by means Roil
of a voltmeter in the ac range. The voltage should be picked off
the shaft through a sliding contact with an insulated handle,
which is connected to the meter by a cable.
TE EE
A
Roil Roil
Rins Rins 2 1 V
Rins
1
V
1 Voltmeter (ac range)
2 Ammeter
1 Voltmeter (ac range)
Fig. 3 Measurement of Shaft Current With the Generator
Fig. 1 Measurement of Shaft Voltage With the Generator in Excited Condition
in Excited Condition
The resulting current can be measured for a brief moment
The shaft voltage measured in this way should then be by means of an ammeter connected into the circuit between
compared with the voltage measured according to Fig. 2. If the the measuring brush and the potential measuring terminal.
two readings are not identical, the rotor grounding system
should be rectified first before taking any further readings to
check the insulation for shaft currents. Roil
EE
Roil
1
Rins
V 1
Rins
1 Bridge instrument
1 Voltmeter (ac range) Fig. 4 Measurement of Insulation Resistance With the Generator
in Non-Excited Condition
Fig. 2 Measurement of Shaft Voltage at Exciter End With the
Generator in Excited Condition
If the shaft voltage can be accurately measured according 3.2 Checking the Insulation With the Generator
to Fig. 2, the measuring brush on the shaft should first be in Non-Excited Condition
connected to the potential measuring terminal on the insulated If the previous tests are inconclusive, additional tests may
component (bearing sleeve of shaft seal) at the exciter end by be performed in consultation with the manufacturer to locate
means of a cable. The oil film of the component is thus bridged, insulation defects with the generator running and in
with the component assuming the shaft potential. With non-excited condition. A bridge instrument must be used. To
Siemens AG
BHEL,Haridwar 2.5--0300--0002 / 2
Energy Sector 0114E
0210E
measure the resistance of the insulated component with standstill, since a stable oil film providing for full insulation can
respect to the shaft and ground, the bridge instrument should only be formed above a speed of approximately 3.33 to
be connected between this component and ground. 6,66 s-1.
The resistances (Roil and Rins in series) of the parts in In case of a low insulation resistance, it must be assumed
contact with the shaft are then connected in parallel with the that the insulation is defective, requiring detailed checking of
measuring voltage. the insulating parts (Contact the manufactorer).
This measurement is not practicable with the generator at
Siemens AG
BHEL,Haridwar 2.5--0300--0002 / 3
Energy Sector 0210E
0114E
Turbogenerators
Flushing the Oil Piping
Maintenance
MKD
Siemens AG
BHEL,Haridwar MKW &MDC 2.5--0320--0001 / 1
Energy Sector 0310E
0114E
During flushing, the oil lines should be hammered regularly shaft lift oil system should be connected to the bearings and
to remove dirt particles from the walls. During the last third of checked for tightness.
the entire flushing period, the screens should be temporarily
installed in the throttle valves upstream of the bearings for
checking the dirt accumulation. 6 Supervision of Oil Circuits
After draining of the flushing oil, remove any dirt deposits After recommissioning, all screens and filters should be
from the bearing compartments. Remove and clean all filters replaced and/or cleaned as frequently as possible. During
and screens. Remove all bypasses, orifice plates or blank commissioning, the oil should be checked for contamination,
flanges as weIl as the additionally installed filters. Refit the e.g. via vent ports. In case of an extremely high dirt content due
valve cones in the throttle valves before the bearings. to carbon dust, construction work, etc., special precautionary
Assemble the bearings ready for operation. The hoses of the measures should be taken.
Siemens AG
BHEL,Haridwar 2.5--0320--0001 / 2
Energy Sector 0310E
0114E
Turbogenerators Measures to Prevent Corrosion
Maintenance During Inspections
During an inspection, the individual components of the ally the retaining ring area can be kept dry and above ambient
generator are exposed to the ambient conditions which may temperature level. The air dryer or fan-forced heater should be
result in hazards to these components. It is therefore strongly arranged so that the air will circulate in a closed circuit.
recommended to take suitable measures for preventing any If possible, the primary cooling water should be circulated
exposure to moisture, especially rain, snow, liquids of any kind through the system during the inspection. The heat dissipated
and condensation. Covering the components will not afford by the pump is sufficient to maintain the temperature of the pri-
sufficient protection. mary water and the stator winding above ambient tempera-
To avoid the above-mentioned hazards, the assembly work ture.
during an inspection should be accomplished under protection The cooling water should be drained from the hydrogen
from weather conditions. The generator should only be and the seal oil coolers, and the secondary cooling water
opened if an uninterrupted execution of the work will be should be drained from the primary water coolers. The coolers
ensured and provided that the necessary protective measures should cleaned, dried and then be kept dry by means of suit-
can be taken. After opening of the unit and withdrawal of the able measures.
rotor, the stator openings should be promptly reclosed. The Normally, a condensation hazard can be recognized with
stator should be dried by means of a portable air dryer or the help of a dewpoint measuring device. In case of doubt,
fan-forced heater and kept above ambient temperature level. however, it is recommended to dry the components on a
The air dryer or fan-forced heater should be arranged so that continuous basis in order to achieve a markedly low dew-point
the air will circulate through the stator interior in a closed circuit temperature on these components, i.e. to maintain their
for ventilation of the entire internal space. temperature above ambient temperature level.
The rotor should be protected in such a manner that especi-
All Rights Reserved
e Siemens AG 2004 --
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MK &MDC 2.5--1003--0021
Energy Sector 0504E
0114E
Preventive Measures
Turbogenerators
to Avoid Moisture Condensation
Maintenance
Survey
Open generator, 10 With danger of condensation (outdoor installations and open power house), blow
rotor installed dry air from portable air dryers into rotor end windings and slipring assembly.
Ready for 11 H2 cooled generators:
operation Pass small cooling water flow through H2 cooler to ensure that cooler is coldest
Generator closed,
(standstill component in the generator (condensation hazard!).
filled with
or turning
e Siemens AG 2009 --
H2 gas:
gear
operation)
Scheduled Outdoor 12 Generator closed: Measures as under Ready for operation.
mainten. installation:
without
13 Generator open: Shelters must prevent precipitation from entering the generator;
Copyright
rotor
removal the retaining rings areas must be covered and kept dry by supplying dry air.
Scheduled Indoor 14 If rotor is set down in dry power house with even temperature, it is sufficient if the
mainten. installation: entire rotor is covered against dirt and wetness. If danger of condensation, the
with rotor rotor area between the bearing journals must be provided with dry packing.
removal
Outdoor 15 Set down rotor under shelter and provide rotor areas between bearing journals
installation: with dry packing.
Distribution: UNRESTRICTED
BHEL,Haridwar
Siemens AG MK &MDC 2.5--1005--0003
Energy Sector 0109E
0114E
Turbogeneratoren Inspection
Maintenance Foreword
Preventive maintenance of generators serves to avoid equivalent operation time under consideration of the machine
major problems or damage while the unit is in service. output in four performance groups.
Apart from its scope, the timing of an inspection is
Tequiv = K1 T1 + K2 T2 + n T3
important. To account for the deterioration and stresses due to
different modes of operation, the number of operating hours, Tequiv t, Tequiv r = Equivalent operating hours Subscript t
the number of starts and the turning times are used as criteria K1 = Weighting factor for stress refers to total
in determinating the intervals between the inspections. impact during normal operat. hours
The intervals recommended in the following are the same operation since initial
as those indicated in the VDEW Recommendations for T1t ,T1r = Operating time in hours commissioning
Intervals Between Generator lnspections [1] which are based K2 = Weighting factor for turning
on the accumulated experience of the German public utilities, gear operation
machine insurance companies and manufacturers. This T2t ,T2r = Turning gear operation time Subscript r
Foreword contains a large number of extracts from the VDE in hours refers to
Recommendations. n t ,n r = Number of starts operat. hours
The guiding values given in the VDEW Recommendations T3 = Weighted time equivalent between two
are to assist the power plant owners/operators in scheduling in hours per start main inspect.
inspections, taking into account also own experience on the
performance of their generators and that of sister machines. Table 2: Weighting Factors for the Different Power
Output Ranges
Types of lnspection Power
Depending on the scope, date and duration of the Rating K1 K2 T3
Output Range
All Rights Reserved
J Main lnspection (Ml) (or Major lnspection) 4 SN < 50 MVA 0.7 0.1 05
Table 1: Types of Inspection, Features and Duration The recommendations given in the following apply to
normal operation without major disturbances. Abnormal
Type Features Duration disturbances, such as close-in system faults, faulty
Copyright
Siemens AG
BHEL,Haridwar MK &MDC 2.5--1010--0005 / 1
Energy Sector 1110E
0114E
The Main Inspection (MI) after an equivalent operating time (power output range 2) at peak load (operating mode D) will
40 000 h Tequiv r 60 000 h result in an interval of 6 to 10 years.
Siemens AG
BHEL,Haridwar 2.5--1010--0005 / 2
Energy Sector 1110E
0114E
Turbogenerators Inspection Schedule
Maintenance Stator
Major Inspection
Minor Inspection
Initial Inspection
Work required
Remove TE and EE end shields. Replace seals and gaskets prior to re-assembly u u
Replace all seals and gaskets for generator connection flanges and terminal bushings u
All Rights Reserved
Replace seals and gaskets for PTFE hoses connected to stator winding u
1) Dissipation factor measurement charging and leakage current measurement, and, in particular cases, high-potential test.
Siemens AG
BHEL,Haridwar MKA &MDC 2.5--1020--0022
Energy Sector 0302E
0114E
Turbogenerators Inspection Schedule
Maintenance Rotor
Major Inspection
Minor Inspection
Initial Inspection
Work required
Remove radial bolts, check and replace if necessary. Replace multicontact band u
e Siemens AG 2008 --
Siemens AG
BHEL,Haridwar MKA40 &MDC 2.5--1030--0025
Energy Sector 0408E
0114E
Turbogenerators Inspection Schedule
Maintenance Cooler
Minor Inspection
Major Inspection
Initial Inspection
Work required
General
Check cooling water inlet and outlet pipes, vent pipes, drain pipes and valves on all coolers u u u
Check condition and function of temperature and pressure measuring instruments at all coolers u u u
Replace all ball valves (including the O-rings in the AVIT joints) u
H2 -Cooler
Dismantle H2 cooler, check on water and gas sides; clean and perform leakage tests u
Remove seal oil cooler, check for fouling and clean if necessary
e Siemens AG 2009 --
u u u
Replace any gaskets if damaged, and perform pressure test following re-assembly
Remove primary water cooler, check for fouling and clean if necessary
u u u
Copyright
Replace any gaskets if damaged, and perform pressure test following re-assembly
Distribution: UNRESTRICTED
MKA
Siemens AG
BHEL,Haridwar MKF &MDC 2.5--1040--0016
Energy Sector MKW 0109E
0114E
Turbogenerators Inspection Schedule
Maintenance Bearings
Major inspection
Minor inspection
Initial inspection
Work required
Check bearing surfaces and babbitt bonding (dye penetrant and US*-test) u u
* US = ultrasonic test
MKC
Siemens AG
BHEL,Haridwar MKD &MDC 2.5--1050--0005
Energy Sector 0109E
0114E
Turbogenerators Inspection Schedule
Maintenance Shaft Seals
Major inspection
Minor inspection
Initial inspection
Work required
Check sliding contact faces of seal rings and seal ring carriers u u
MKA06
Siemens AG
BHEL,Haridwar
MKA07 &MDC 2.5--1060--0002
Energy Sector 0109E
0114E
Turbogenerators Inspection Schedule
Maintenance Generator Supervisory Equipment
Major inspection
Minor inspection
Initial inspection
Work required
Check condition and performance of level meter system (liquid level alarm switches) u u u
BHEL,Haridwar
Siemens AG MKY &MDC 2.5--1080--0005
Energy Sector 0114E
0109E
Turbogenerators
Measures for Preservation of Generator
Maintenance
During Standstill
Preservation measures will have to be taken when a The supply of water to the bearing oil and seal oil coolers
water-cooled generator is to be shut down. is not required during this period.
The scope of the preservation work required depends on
the duration of the shutdown, on the overall conditions in the 3 Coolers
vicinity of the unit and on the extent to which checks and All coolers should be drained on their cooling water sides
maintenance are possible during such period. and dried in a suitable measures. During the outage, the drains
The preservation measures recommended in the following and vents should be kept open.
are sufficient under normal conditions. High relative humidity Caution: Never leave water-filled coolers standing idle for
in combination with severe temperature changes involves the several weeks.
risk that the temperature of certain surfaces in the generator For cooler drying, hot air or dry ambient air may be used
may drop below the dew point, resulting in the possible which should be admitted by means of blowers via the cooling
formation of a moisture film due to condensation on these water inlet/outlet flanges. A fan-forced heater with a rating of
generator components. In such a case, special measures may 1 to 2 kW has proved satisfactory for this purpose.
be required for preservation of the rotor retaining rings (see
also 2.5--0030, Packing, Transport and Storage of Generator
4 Slipring Assembly
Rotors). The slipring assembly should be protected against
moisture by maintaining the space below the enclosure at a
1 Generator Interior
moderate temperature by suitable means. This may be
The hydrogen gas should be removed from the generator.
achieved with a hot air blower installed inside the enclosure.
The stator and rotor windings should then be protected against
The carbon brushes should be removed and the sliprings
All Rights Reserved
Siemens AG
BHEL,Haridwar MK &MDC 2.5--1100--0025
Energy Sector 0114E
0109E
Turbogenerators
Shaft Seal
Maintenance
The inspection of shaft seal rings and seal ring carriers is wear shall be replaced or reworked.
performed as follows: In addition, the contact surfaces shall be examined for
fractures and scoring marks. This is particularly required if
J If the components are not dismantled for the inspection, the parameters such as seal oil pressure, seal oil volume, H2
insulating effect of the shaft seal with regard to the side seal oil temperature, etc. displayed fluctuations in the
generator casing can only be measured via the shaft operating period prior to the inspection. Liquid penetrant
current. testing may be performed to obtain more accurate results.
J If the seal ring is removed, the clearances between seal
strips of the labyrinth rings and the shaft must be recorded Reassembly of the shaft seals should be performed with
prior to removing the seal ring. During the removal, the utmost care.
condition of all shaft seal components and particularly that During each inspection, a check should be made to ensure
of insulating elements such as flange insulation and that the seal rings are still sufficiently insulated from the stator
insulation barriers shall be checked. frame.
Following removal of the shaft seal, all components shall be
cleaned thoroughly. Any components displaying signs of
All Rights Reserved
e Siemens AG 2009 --
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKA06/07 &MDC 2.5--6000--0005
Energy Sector 0109E
0114E
Turbogenerators
Maintenance Insulation and Sealing of Shaft Seals
2 Seal Rubber
In terms of its shape and quality, the rubber material used
for the seals is a special design which is characterized by its Fig. 2 Cut in Insulating Rings
resistance to gas and oil, and its high insulation resistance.
Each ring is cut radially to enable the rings to be installed
The rubber material is produced and supplied by Siemens,
on the shaft. Following installation, the cuts must be offset by
and it must be ensured that no other material is used for this
90q.
purpose. Any additional rubber must be ordered from Sie-
mens.
6 Check and Installation of Insulation
3 Cutting the Rubber to Length Before installing the labyrinth ring and the seal ring carrier,
Prior to installing the labyrinth rings and seal ring carriers in the insulating rings must be checked thoroughly, and be
All Rights Reserved
the generator, these must be assembled provisionally, and the replaced if necessary. When preparing new insulating rings,
required length of rubber must be determined by inserting this care must be taken to ensure that one cut is at the 12 oclock
in the groove. The position of the rubber (round side facing out- position and the other offset by 90_ (i.e. at the 3 oclock or
ward) and the chamfered joint must be taken into account. 9 oclock position), and that the holes for the bolts are smaller
e Siemens AG 2010 --
The rubber should be cut so that the ring only has one joint. than the holes in the end-shield bearing and the seal ring
carrier.
With regard to the insulating rings for the seal ring carrier,
particular attention must also be paid to the holes for the
J
J Seal ring oil supply.
These holes must exactly match the bores in the seal ring
carrier.
The outside diameter of the insulating rings must exactly
match the outside diameter of the flange face of the end-shield
bearings. This ensures that the seals are centered around the
center of the shaft and cannot move when the seal ring carrier
* Apply pressure in direction of arrow
is installed.
Fig. 1 Joining the Seal Rubber The inside diameter of the insulating ring is shown in the
corresponding drawing. Strict compliance must be ensured
4 Inserting the Seal Rubber with the specified dimensions because an insufficient inside
After cutting the rubber to length, and after both ends have diameter would prevent the rubber from fitting snug to the seal
been prepared for application of the adhesive, the rubber must face of the end-shield bearing.
be placed round the shaft and joined together (cf. 2.5--2120) The closed insulating rings must be cut fully at the prepared
before placing it in the groove. It must be ensured that the positions and placed round the shaft. Thinly apply Ramsey
round side of the rubber faces toward the end-shield bearing, grease to the side of the insulating rings facing toward the end-
and that the joint is arranged as shown in Fig. 1 above so that shield bearing, and press the insulating rings against the con-
the chamfered joint is firmly pressed together when the compo- tact surface of the end-shield bearing. Close the cut rings by
nent is bolted to the end-shield bearing. pressing the two ends together. The Ramsey grease prevents
Handhabung: OFFEN
Siemens AG
BHEL,Haridwar MKA &MDC 2.5--6110--0002 / 1
Energy Sector 0114E
1010E
NOTE:
Do not use electrically conductive vaseline.
Siemens AG
BHEL,Haridwar 2.5--6110--0002 / 2
Energy Sector 1010E
0114E
Turbogenerators
Stator
Maintenance
logged.
6 Flanged Joints and Metering Connections 07 All winding areas on which work is to be
All stator flanges should be checked for proper alignment performed must be covered off carefully before
and seating. The stator should be checked for tight anchoring work is started.
to the foundation.
08 All parts to be installed or removed should be
All metering connections should be checked for proper
listed, with details of their exact whereabouts.
mounting and condition as far as practicable. This should
include both the electrical metering connections and the pipe 09 Should a part be dropped despite all the above
connections to the measuring instruments. precautionary measures, it is imperative that it be
Prior to recommissioning, the insulation resistance of the located and removed. Site management should
stator winding should be measured and, if necessary, be informed in the case of any problems in this
improved. context.
Siemens AG
BHEL,Haridwar MKA &MDC 2.5--2000--0016
Energy Sector 0409E
0114E
Turbogenerators Check List for Works on Generator
Maintenance
BHEL,Haridwar
Siemens AG 2.5--2001--0001
MKA &MDC
Energy Sector 0109E
0114E
Turbogenerators
Cementing the Joints of Profiled Gaskets
Maintenance
1 Sicomet 50 Adhesive take care that the profile does not suffer any visible distortion
and that the pressure applied after pulling together the parts to
Profiled gaskets should preferably be cemented together be mounted is exerted on the area of cut (see arrow in Fig. 1).
by means of Sicomet one-component adhesive. This adhesive The faces to be cemented together should be well roughened.
meets all requirements, its only disadvantage being the
difficulties encountered in storage. 2.2 Cementing the Joint
Sicomet should be protected from moisture, heat and sun- The adhesive should be applied in drops on the joint areas
light and should therefore be stored in a dry, cool and dark to be cemented together, using a plastic or metal spreader for
place. To prevent an increase in viscosity and discoloring of the obtaining a thin film. Immediately afterwards the joint faces
adhesive Sicomet is best stored at a temperature of -10 _C should be assembled and located in position. Because of the
(14 _F). If stored under these conditions, Sicomet has an unlim- short curing time of 10 to 30 s any readjustment will be almost
ited working life. Defrost Sicomet prior to use and bring to room impossible. After curing, any cement residue should be
temperature. removed from the outer surface of the bonded joint by means
Repeated freezing and defrosting does not affect the bond- of emery paper.
ing properties. The maximum storage time at room tempera-
ture is six months. The adhesive not used up must be stored WARNING:
at a temperature of -10 _C immediately. Sicomet should only be used in well ventilated work areas.
Care must be taken to avoid body contact. In the event of
contact with the eye, rinse immediately with ample
2 Preparatory Work and Application of Adhesive amounts of distilled or drinking water to dilute the adhe-
sive. The eye should then be treated to soothe any in-
All Rights Reserved
joint faces could be cut so that the overlapping portion to be in a bath of either dimethyl-formamide for a brief period or of
cemented is approximately 30 to 40 mm long. When cutting ethylacetate for a longer time, resulting in swelling.
Copyright
30 to 40 mm
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MK &MDC 2.5--2120--0001
Energy Sector 0109E
0114E
Turbogenerators
Generator Drying System
Maintenance
1 2 3 4 5
e Siemens AG 2009 --
5 4 7 6
Siemens AG
BHEL,Haridwar MKA05 &MDC 2.5--2155--0002
Energy Sector 0109E
0114E
Turbogenerators
Mounting of Inner Labyrinth Rings
Maintenance
bearing, the inner labyrinth ring should be bolted in position. means of the two bolts at joint level so that the fitting device can
At this stage, the generator rotor must not be coupled to the be detached afterwards.
turbine rotor. When placing the upper half labyrinth ring in position, make
Mounting of the inner labyrinth rings is facilitated if the rings sure that the joints are aligned and that the taper pins can be
are already assembled on the rotor prior to rotor installation easily inserted.
Copyright
and the joint bolts tightened from outside. The labyrinth rings The joint bolts, nuts and lockplates should then be inserted
are then installed in the stator together with the rotor. and uniformly tightened.
To avoid contact with the shaft and the resulting flow of shaft Remove the two bolts provisionally inserted at the labyrinth
currents the labyrinth rings must be insulated from the end ring-to-end-shield bearing joint and move labyrinth ring in axial
shields at the flanged points. Attention should be given to direction away from the flange up to the shaft collar. With the
careful fitting of the insulation. After completion of the labyrinth ring in this position, insert the gasket and the
assembly work, the insulation of the labyrinth rings should be insulation.
checked (see also 2.5--0300, Checking the Bearing and Seal
Insulation).
4 Installation of Gaskets and lnsulation
Prior to connecting the labyrinth ring to the end-shield
2 Preparatory Work bearing, the insulation and gasket should be checked,
The labyrinth rings should be cleaned with a suitable replaced (if necessary), and placed in the proper position.
solvent. Clean the groove for the gasket and all fixing holes
and oil drain holes in the lower half labyrinth rings with
compressed air. Check flange surfaces facing the end-shield 5 Assembling Labyrinth Rings
bearings and perform a bluing check. Correct any unevenness Shift Iabyrinth rings up to the flange of the end shield
by local rescraping. bearing. Provide mounting bolts with insulating sleeves,
The mating upper and lower half labyrinth rings are marked insulating washers, washers and lockplates. Insert bolts from
Distribution: UNRESTRICTED
TE or EE close to the joints and should be mounted the bearing compartment side via the through holes of the end-
accordingly. shield bearing and screw them into the tapped holes of the
The labyrinth rings should be provisionally assembled and labyrinth ring.
the length of the gasket (seal rubber) determined and Measure the insulation resistance and compare with the
prepared. value measured previously (see also 2.5--0300, Checking the
Following this, the insulating rings should be matched. Bearing and Seal Insulation).
BHEL,Haridwar
Siemens AG MKA &MDC 2.5--2162--0004 / 1
Energy Sector 0109E
0114E
6 Checking Labyrinth Ring Clearances Labyrinth Rings). New seal strips are available from Siemens
The labyrinth rings are adjusted. Mlheim Manufacturing Plant.
To check the radial clearances, measure the gap between
the caulked seal strips and the shaft at two opposite points 10 Final Assembly of Labyrinth Rings
each of the horizontal and vertical centerlines. After assembly of the labyrinth rings with the specified
Use air gap gauges or feeler gauges (0.02 mm clearances, check the insulation and compare the results with
increments) for making the measurements. The clearances those of previous measurements. lf the results correspond to
measured should be plotted in a coordinate system and the specified minimum values, place the upper half end-shield
compared with the reference dimensions. bearing in position.
The clearances are specified in the shop records, and are Bolt the labyrinth ring to the upper half end shield bearing
typically determined as follows: only after the upper half end-shield bearing has been
completely attached to the stator frame and bolted to the lower
Top clearance half at the joint. When bolting the labyrinth ring, check that the
insulating sleeves, insulating washers, washers and
lockplates are positioned correctly.
Finally, check all flange bolts again for uniform tightening.
1/2 lateral clearance 1/2 lateral clearance Then check again the insulation resistance of the labyrinth
ring insulation.
With satisfactory insulation, secure all bolts on the
circumference as weIl as the joint bolts and nuts. Check the
insulation resistance again.
1
0.05 mm
(0.1 mm for shafts measuring 500 mm in diameter)
new seal strips (see also 2.5--2163, Fitting New Seal Strips to
Siemens AG
BHEL,Haridwar 2.5--2162--0004 / 2
Energy Sector 0109E
0114E
Turbogenerators
Fitting New Seal Strips to Labyrinth Rings
Maintenance
1 General labyrinth ring groove. Apply auxiliary tool to the seal strip at the
During initial installation or inspection of the unit the radial labyrinth ring joint and drive out seal strip by light hammer
clearances between the caulked-in seal strips of the labyrinth blows until the turn-out tool can be applied. The machined slot
rings and the shaft should be measured. For required labyrinth in the turn-out tool should be pushed over the caulked seal strip
ring clearances, see the binding drawing Rotor Clearances. and the seal strip pulled out by turning the turn-out tool.
If the actual clearances are excessive, new seal strips should
be fitted to the labyrinth rings. To do this, the old seal strips
should be removed and replaced by new ones. New seal strips
are available from stock at KWU Mlheim Works.
WARNUNG
WARNING
Risk of fire and personal injury. Excessive clearance at the
oil wiper rings and bearing can cause oil to escape. Risk of per-
sonal injury due to fire or slipping. Replace the seal strips of the
oil wiper rings as per the corresponding maintenance sched-
ule. Check the oil wiper rings and bearings for signs of oil leaks
and clearances as per the maintenance schedule. Record the
parameters in the assembly record.
2010 -- All Rights Reserved
2 Tools
The tools shown below are required for removal and fitting
of seal strips.
1 2 3 4 5 6 7 8
Fig. 3 Pulling Out Seal Strip
1 Scraper
2 Sharpening tool 4 Cutting New Seal Strips to Length
3 Smooth file The new seal strips to be fitted are delivered in the form of
4 Caulking tool
5 Pincers a coil approximately 300 mm (11.8 in.) in diameter. From this
6 Turn-out tool coil the required length including a sufficient allowance for one
7 Drift key
8 Hammer groove of the half labyrinth ring should be cut by means of pin-
Distribution: UNRESTRICTED
Fig. 1 Tools Required for Fitting New Seal Strips to cers. Bend seal strip by hand so that its diameter matches the
Labyrinth Rings diameter of the labyrinth ring. Cut seal strip to required length
with an allowance of 2 to 3 cm (0.8 - 1.2 in.). Using this strip as
3 Removing Seal Strips a sample, the half rings required for the remaining number of
For removal of the old seal strips, a chisel, screwdriver or grooves should be cut from the coil and bent as described
similar device should be sharpened so that it fits into the above.
Siemens AG
BHEL,Haridwar
MKA &MDC 2.5--2163--0001 / 1
Energy Sector 0710E
0114E
Fig. 4 Seal Strip, Pulled Out
Fig. 6 Cutting Projecting Seal Strip Ends
5 Caulking New Seal Strips
Insert seal strip into groove at bottom center of labyrinth ring
and gradually drive seal strip into the groove over its full length
by applying light hammer blows to the caulking tool.
BHEL,Haridwar
Siemens AG 2.5--2163--0001 / 2
Energy Sector 0710E
0114E
7 Turning lnside Diameter of Labyrinth Ring
After color print control, the half labyrinth rings should be
assembled according to the marks and then turned on a lathe
to suit the shaft dimensions and clearances specified on the
drawing Rotor Clearances.
CAUTION
Fig. 9 Rescraping Joint Surfaces Risk of personal injury due to sharp edges. Be sure to wear
suitable protective gloves when sharpening the seal strips.
Siemens AG
BHEL,Haridwar 2.5--2163--0001 / 3
Energy Sector 0710E
0114E
Turbogenerators Insulation Resistance Measurements
Inspection on Stator Winding
During manufacture and transport, the insulation of the lf the insulation resistance measured is lower than the
stator winding may have been exposed to moisture which specified minimum value, the neutral connections must be
would reduce the insulation resistance of the windings. The separated and the insulation resistances of the individual
insulation resistance should therefore be measured prior to winding phases measured. During the test, the other two
initial startup, after prolonged shutdowns and after work on the phases which are not involved should be grounded. lf the
windings. lf required, the generator should be dried until a insulation resistances of the individual phases are likewise
sufficient insulation resistance is obtained. Iower than the required limit value, drying of the windings will
be indispensable. Great differences in the insulation
resistance values are indicative of local contaminations, e.g.
1 Required Insulation Resistance of Stator Winding insulators at bus duct or terminal bushings. lf practicable,
The insulation resistance measured is dependent on the additional connections should be separated.
temperature. To permit a proper assessment, a correction to an If this measure does not result in an improvement, it is
agreed reference temperature (formerly 75 _C) must be made. recommended to obtain the services of a specialist from the
An insulation resistance of 1 megohm per each kilovolt of manufacturers works.
rated voltage at 75 _C is normally attainable without any
difficulties. 2 Measurement of Insulation Resistance
New international standards specify an insulation Prior to each measurement, the generator must be
resistance of not less than 1 megohm per each kilovolt of rated deexcited and any static charges removed by grounding the
generator voltage at 40 _C. windings. The windings should also be grounded after each
A correction of the insulation resistance measured at the measurement for the duration of the recharging period.
All Rights Reserved
winding temperature prevailing during the measurement to the The insulation resistance of the stator is measured between
above reference temperature can be made using the diagram the winding copper and the stator core.
in Fig. 1. Prior to primary water filling, the insulation resistances of the
individual stator winding phases with respect to the steel part
should be measured by means of a 2.5 to 5 kV megger.
e Siemens AG 1994 --
10000
During normal operation, the winding bars are electrically
connected to the grounded cooling water manifolds through
Insulation resistance R in megohm
5000
the water in the water inlet and outlet hoses.
3000 Because of the considerably Iower resistance in the hoses,
2000 a determination of the insulation resistance according to the
Copyright
0 20 40 60 80 100 120 140 160 low leakage current, the power source is now also required to
supply the possibly very high partial currents via the cooling
Temperature t in _C
water connections, batteries are not suitable for this purpose.
Fig. 1 Diagram for Correction of Insulation Resistance The dc voltage should therefore be obtained from a stabilized
Measured to a Temperature of 40 _C power supply.
Siemens AG
BHEL,Haridwar 2.5--2300--0004 / 1
Energy Sector 1194E
The measuring circuit is shown in Fig. 2. U(kV)
R10 = = 103 M8
To determine the insulation resistance of water-cooled I (mA)
windings, the currents due to any cells resulting from the
cooling water in the hoses between the winding copper and the Note: When the generator is filled with hydrogen, make
water manifolds of steel must be taken into consideration. For sure that the rotor shaft ends are properly grounded
this reason, the insulation resistance of the complete winding during measurement and discharging.
should first be measured by applying a positive voltage. After During measurement the movement of ammeter AN is
discharging, the measurement should be repeated with a connected to the positive pole of the stabilized power
negative voltage. supply (approximately 1000 V to ground).
Note: Current may pass through zero. In such a case, the Temperature detectors may be installed in the
ammeter should be changed over and the current read and ring-shaped water manifold. To protect the connected
recorded, observing the negative sign. The recharging metering leads and measuring instruments, the metering
current is the mean value of the tests performed with leads should be disconnected at the generator terminal
positive and negative voltage. strip (at stator frame) during the above test.
lndividual phases can be tested by a similar procedure. After completion of the measurements the measuring circuit
The insulation resistance (R10) is calculated from the should be removed.
applied voltage and the 10-minute recharging current.
1 = Stator
Stator winding connection and terminal arrangement 2 = Rotor
2 3 = Terminal bushing
as shown in this diagram were arbitrarily selected; not 4 = Water manifold ground contact
identical with machine described herein. 5 = Generator ground connection
6 = Hose with contact sleeve
7 = Ground connection for manifolds
G1 = Grounding of generator frame
G2 = Grounding of TE shaft end
G3 = Grounding of EE shaft end
G2 G3 B = Stabilized power supply
UB = Voltmeter
Z Y X W V U AN = Ammeter
IUVW = Current to winding
S = Switch
3 4 5
7 G1 7 4
-- Note:
B V UB J The primary water must flow through
IUVW the winding during the measurement.
S AN J After measurement, the water manifolds
A
should be grounded again via the
ground contacts.
BHEL,Haridwar
Siemens AG 2.5--2300--0004 / 2
Energy Sector 1194E
0114E
Turbogenerators
Drying the Windings
Maintenance
The epoxy resin mica insulation applied to the stator Run up the turbine-generator to rated speed and excite
winding by mean of the VPI process absorbs practically no generator. As a result of this, a current in accordance with the
moisture. Any reduction of the insulation resistance during short-circuit characteristic will flow in the stator winding. The
transport, erection or a prolonged shutdown is mostly caused currents in the three phases should be of identical magnitude.
by a moisture film on the surface of the insulation. To prevent Should this not be the case, the generator will have to be de-
damage to the insulation, it will be necessary to check the in- excited and the cause of the non-uniformity (e.g. poor contact
sulation resistance of the stator and rotor windings prior to of buses) removed.
running up the unit to full voltage. Please refer to Section The stator winding temperature and the hot and cold gas
2.5--2300 for details on performing insulation resistance temperatures should be brought to the maximum operating
measurements on the stator winding particularly for level by slowly raising the field current.
applications with direct water cooling. In case of an insufficient During drying, the absorbent material in the gas dryer
insulation resistance being detected, the winding must be should be carefully observed. When the gas dryer filling is no
dried first. longer active, reactivation should be carried out.
The drying process for hydrogen-cooled generators should During drying, the generator must be occasionally de-
preferably be carried out with the generator filled with excited and run down, and the insualtion resistances must be
hydrogen, making sure that the gas dryer is in operation and measured. In the event of sufficient insulation resistances
that the absorbent material is sufficiently active. being obtained, short-circuit drying may be stopped.
The stator winding should be short-circuited at the Remove the short-circuit at the bushings.
bushings by means of buses. The buses should be fitted so as Following this, the generator may be run up to full voltage.
to permit a measurement of the short-circuit current by means In the event of a prolonged shutdown of the generator, it is
All Rights Reserved
of current transformers. The primary water system for the preferred that the hydrogen filling be retained in the generator,
stator winding must be activated and the conductivity of the thereby eliminating surface moisture on the windings.
water must be reduced to the normal operating level.
e Siemens AG 2006 --
Copyright
Distribution: UNRESTRICTED
Siemens AG
BHEL,Haridwar MKA20 &MDC 2.5--2310--0014
Energy Sector 0806E
0114E
Electrical Tests on Stator Winding
Turbogenerators With Vacuum Impregnated
Maintenance Micalastic High-Voltage Insulation
1 The Insulation System of the Stator Winding reasons to be explained in the following sections, not all of
these tests are suitable for checking the insulation of large
The insulation system serves to insulate the generator turbogenerators, especially those with water-cooled windings.
stator bars, which are subjected to a high-voltage potential of
up to 30 kV, from each other and from the grounded stator iron J Insulation resistance measurement (megger)
parts for reliable protection against the additional thermal and J Recharging and leakage current measurement for exact
mechanical stresses arising during operation. determination of insulation resistance
For decades, insulation systems with a high mica content J Dissipation factor measurement
of up to 65 % have been and are still being used most J Partial discharge measurements
successfully. J High-potential proof tests
Since 1960, all generators built by KWU and its parent AC voltage
companies. Siemens Power Generation, respectively, have DC voltage
been equipped with synthetic-resin insulation systems. This
system uses epoxy resin featuring a high resistance to
3 Insulation Resistance Measurement
mechanical, thermal and electric stresses.
The Micalastic insulation consists of mica tapes applied Insulation resistance measurement is by far the simplest
continuously from end to end on the bars, including the involute and easiest of the available tests to perform to determine the
section. Vacuum pressure impregnation with epoxy resin integrity of the insulation. lt is made with an instrument
provides an insulation system which is highly resistant to commonly known as megger and supplying a variable DC
mechanical, thermal and electric stresses and also impervious voltage between 100 V and 5000 V. The instrument is
All Rights Reserved
to moisture. Drying the insulation prior to startup of the calibrated for direct reading of the insulation resistance in
generator will thus only be required to remove any moisture film megohms. The DC voltage for measurement is generated by
on the surface. a hand-operated or motor-operated generator or by electronic
means. This voltage should be applied for not less than one
minute prior to reading the insulation resistance value to allow
2 Purpose and Kind of Electrical Tests
e Siemens AG 2009 --
generator provided with the high-grade Micalasticinsulation only the presence or absence of a winding short to ground and
system in 1958 has meanwhile completed 200 000 operating that the insulation resistance is at a level above the accepted
hours without any failure. minimum limit. This test is performed prior to each startup of the
During the manufacturing process until delivery of the unit and prior to each high-potential test on a winding.
generator, a comprehensive quality verification program is On water-cooled generators with water-filled winding, the
performed by subjecting the insulation to electrical tests. relatively low resistance of the water in the hoses between the
Unless the insulated parts in the generator are stressed due to winding and ground potential is connected in parallel to the true
abnormal conditions during transport or during the installation insulation resistance. A megger reading would indicate the
and assembly at the power plant, no electrical testing would be resistance value of the water in the hoses. Depending on the
required prior to placing a new generator into operation. For conductivity of the water and the number of parallel-connected
safety considerations, the insulation resistance should, hoses, this value may be far below 1 megohm and does not
however, be checked by means of a megger prior to each provide any information on the magnitude of the insulation
startup. resistance of the winding. It merely serves to determine that
lt is a known fact that even the best insulation system is there exists no direct short to ground.
subject to aging during service, especially as a result of To determine the insulation resistance of water-filled
operational disturbances, such as voltage surges due to windings by means of megger readings in the usual way, the
sudden short-circuits. etc. water must be drained from the windings, and the surface of the
During overhauls, the degradation of the insulation and any supply hoses requires thorough drying.
Distribution: UNRESTRICTED
BHEL,Haridwar
Siemens AG MK &MDB 2.5--2320--0001 / 1
Energy Sector 0409E
0114E
permitting also a determination of the polarization index. For Prolonged exposure to thermal and mechanical stresses
this test, a stabilized DC power source and a micro ammeter and last but not least the effect of partial discharges may result
are required, enabling the current to be measured as a function in new separations and thus in additional discharges.
of the test period under otherwise constant conditions and Measurement of the dissipation factor as a function of the test
allowing the influence of temperature, moisture and dirt to be voltage can therefore provide information on the aging of an
determined and considered. insulation by a relatively simple method.
In hydrogen-cooled generators, the ambient is quite clean, Measuring the dissipation factor on individual winding
and the winding is protected against moisture absorption, components, such as bars, is mostly performed by means of
because, in contrast to air-cooled units, these machines have a guarded electrode to eliminate the effect of leakage currents
a closed cooling circuit. across the coil end. Such a guarded electrode system cannot
In addition, the insulation of Micalastic-insulated be provided for complete windings which are mostly equipped
generators is not subject to moisture absorption. Recharging with an end corona protection. This effect must therefore be
and leakage current behavior and the insulation resistance, taken into consideration when evaluating the variation of the
respectively, may merely be affected by dirt or moisture on the dissipation factor with voltage.
surface of the end windings. The dielectric constant and the dissipation factor are
On windings without water conductor cooling, this test is just measured with a Schering bridge.
as easy to perform as the megger reading. However, to permit
the use of this test also on water-cooled windings with water
circulating in the windings without affecting the recharging
current or the insulation resistance through the water in the
Cxx
C
multiple parallel hoses from the winding to the ground, CN
Siemens Power Generation generators are equipped with Screen
special devices in the water circuit, enabling the water
manifolds to be disconnected from the ground in a simple way.
The bushing hoses are equipped with contact sleeves to
R3 VG
compensate for the leakage current through the water in the R4
hoses.
Since, in addition to the leakage current, the stabilized DC
power source is also required to supply the partial currents via C4
the water in the hoses, i.e. up to 40 mA dependent on the
conductivity of the water, the micro ammeter is inserted in the
circuit through which only the recharging current and the
leakage current of the winding insulation are flowing.
Fig. 1 Schering Bridge
5 Dissipation Factor Measurement At balance, zero current flows through the bridge branch.
The capacitance of the winding is then:
The winding insulation system is primarily a capacitive
setup, with the winding copper constituting one electrode and R4 CN
Cx =
the grounded frame the other electrode. Such circuits are R3
accessible for bridge methods of resistance measurement to
determine the dielectric constant and the dielectric loss factor. and the dissipation factor:
Dielectric loss is defined as the ratio of active power to reactive tan G = R4 Z C4
power. In connection with insulation testing, the dielectric loss
indicates the amount of electrical energy converted into heat To perform dissipation factor measurements on generator
in the insulation. windings, disturbing error capacitances can be eliminated with
The dissipation factor and capacitance of a solid insulating a universal capacitance/dissipation factor bridge using
material are not dependent on the test voltage applied as long ancillary equipment for the initial balancing adjustment. This
as there is no change in the conduction mechanism. A change scheme offers an effective method for measurements on
in the conduction mechanism of insulating materials occurs windings in a directly grounded stator.
due to loss of bond between layers of insulation, with voids
being formed in minute cracks. As the voltage is increased
6 Partial Discharge Measurements
above a certain level (partial discharge start voltage) during the
dissipation factor measurement, partial discharges will occur The dissipation factor measurement described in the
which increase with rising voltage and result in a dissipation preceding section covers the sum of the losses occurring in the
factor tip-up. insulation voids due to partial discharges. Since partial
Micalastic insulation is impregnated with epoxy resin discharge is a radio-frequency phenomenon, this opens up the
under vacuum to be essentially void-free. In new condition, this possibility of using radio-frequency methods for detection.
insulation thus exhibits a dissipation factor tip-up of less than Partial discharge measurements provide useful information
0.001 for each measuring interval of 20 % of rated voltage. for the detection of localized defects in winding components,
Siemens AG
BHEL,Haridwar 2.5--2320--0001 / 2
Energy Sector 0114E
0409E
such as the phase connector insulation system. This method reliability. The application of a high test voltage is especially
is also used for quality assurance during manufacturing.
BHEL,Haridwar recommended in all cases where it is to be expected that the
HV reactor U V W insulation may have suffered localized damage as a result of
extremely high mechanical stresses due to a sudden
Regulating short-circuit or extremely high electric stresses due to
transformer CK Cx transients. A high-potential proof test is also applied in the case
RT of serious aging as identified by a dissipation factor
measurement and if localized weak points in the insulation
cannot be ruled out.
Any breakdown occurring during a proof test indicates that
AKV the winding is approaching the end of its serviceability. After
removal of bars on which a breakdown has occurred, the areas
of the insulation most severely affected by degradation can be
assessed, permitting scheduling of a suitable date for
HV
rewinding. lf no breakdown occurs during the proof test or
transformer
following the removal of already failed bars, this means that
after completion of the test even the weakest area of the
insulation still has a certain life expectancy which will be
PD Plotter
detector XY longer at the field intensity arising during normal operation than
at the test stress level. This enhances the probability of
troublefree operation at least for a certain service period
In the case of generator windings, the partial discharge following the test and avoids the risk of a breakdown occurring
method has so far been applied to detect high-energy during operation together with the consequential damage
discharges, as caused, for instance, by a break in the internal resulting from the high currents arising.
corona shielding system. The measurement is performed in a
manner similar to the dissipation factor measurement by 7.1 AC Voltage Test
recording the maximum apparent discharge magnitude as a This test is normally performed with a power-frequency
function of the voltage for each phase up to 120 % of rated AC voltage of 1.5 times rated voltage. The use of a 50-Hz or
voltage. To do this, a coupling capacitor CK is connected in 60-Hz AC voltage offers the advantage that the field
parallel to the phase capacitance CX. The partial discharge is distribution will be the same as during normal operation,
then detected in the ground connection of the coupling especially at the transition between the straight slot section
capacitor with a suitable partial discharge detector via a four and the end winding, resulting in a proportional stressing of the
terminal coupling network AKV. winding components. As generator sizes increase, the
As with the dissipation factor measurement, the test voltage capacitance of the winding to ground increases accordingly
is applied via a regulating transformer, a high-voltage and thus also the transformer rating required for the test. To test
transformer and a reactor to compensate for the winding and one phase of a large turbogenerator, a test set of 400 kVA or
coupling capacitances. more will fairly often be required. For this reason, resonance
Such a test setup is sensitive to external noise which cannot test circuits are frequently used, permitting a compensation of
be avoided at the power station or in the test field. lf no the high leading reactive power. An exact control of the preset
additional measures for rejection of the external noise are test voltage is accomplished through a high-voltage instrument
taken, background noise levels from 100 pC to more than transformer.
1000 pC are to be expected.
7.2 DC Voltage Test
When utilizing a high DC voltage for proof testing, the field
7 High-Potential Proof Tests
distribution will differ from that described in the preceding
All tests described in the preceding sections are performed section especially at the end windings. As a result of this, DC
with relatively low voltages. Using suitable standards for testing subjects the end turn insulation to considerably higher
comparison, they provide information on the contamination, stresses than AC testing.
surface moisture condition and also on the aging of the The equipment involved in performing a DC high-potential
insulation. They are indicative of the dielectric strength of the test is considerably smaller and easier to transport than the
insulation with a certain probability only. AC test equipment. lf DC testing is used for this reason, it is
A high-voltage test is an indispensable last criterion for necessary to use a multiplication factor to obtain nearly
determining with assurance whether or not the insulation on a equivalent searching ability as an AC test. lt is recommended
winding is suitable for continued operation with sufficient that 1.7 times the AC RMS test voltage be used.
Siemens AG
BHEL,Haridwar 2.5--2320--0001 / 3
Energy Sector 0409E
0114E
Turbogenerators
Treatment of Bolted Contact Surfaces
Maintenance
1 Leakage Test of Field Current Lead recommended to make use of the services of our experienced
Before starting overhaul work and H2 purging, check H2 product service personnel who will carefully remove any dirt
seals at the field current lead for leakage. To do this, use a leak accumulations below the retaining rings and within the range
detector and check coupling flange generator rotor/ slip ring of the end windings by means of a special vacuum cleaner.
for gas leakage.
lf no H2 gas leak is detected, the exciter should be
dismantled. The slip ring shaft should be uncoupled from the
generator and a new leakage test of the central field CAUTION
connection performed.
Any inexpert use of compressed air involves the risk of
lf a leak is detected during this leakage test, the
cooling duct clogging and of damage to insulated parts.
manufacturer must be notified. The hydrogen should be
purged from the generator only after completion of the leakage
test.
5 Contact Pins and Plug-in Socket Strips
2 Rotor Wedges and Retaining Rings The contact pins and plug-in socket strips should be
lf the rotor is removed, examine it carefully. The wedges checked for arc erosion and proper contact resistances.
and retaining rings should be inspected for proper condition. Proper seating of the contact pins on the plug-in socket strips
can be verified by visual examination.
3 Shaft Journals and Shaft Seal Contact Faces
The shaft journals and shaft seal contact faces should be 6 Coupling
checked for grooves. lf any irregularities are detected, The coupling flange at the rotor should be checked both at
All Rights Reserved
reconditioning should be carried out according to instructions the guide flanges and at the fitting bolt holes. The coupling
from our service personnel. bolts should be inspected for proper condition.
After each withdrawal, the rotor should be cleaned Prior to recommissioning, the insulation resistance of the
thoroughly, even if the visual inspection did not reveal any rotor winding should be measured and, if necessary,
contamination. Careful cleaning is important so as not to improved. Details are given elsewhere in this manual (see
damage any of the numerous insulated parts. lt is, therefore, 2.5--3300 and 2.5--2310).
Copyright
Distribution: UNRESTRICTED
BHEL,Haridwar
Siemens AG MKA40 &MDC 2.5--3000--0016
Energy Sector 0114E
0310E
Turbogenerators Insulation Resistance Measurements
Maintenance on Rotor Winding
0.2
0.1
0 10 20 30 40 50 60 70 80 90
Slot temperature in_C
Fig. 1 Correction Curve for Insulation Resistance
Measured (Rmeas) to a Temperature of 40 _C
Distribution: UNRESTRICTED
BHEL,Haridwar
Siemens AG MK &MDC 2.5--3300--0004
Energy Sector 0310E
0114E
Turbogenerators
Hydrogen Cooler
Maintenance
1 General This does not require the removal of the cooler. Chemical
The intervals at which the coolers should be cleaned cleaning should be applied if scale has formed on the inside
essentially depend on the condition of the cooling water (rf. of the tubes which cannot be removed by brushing.
2.5--5003). If the cooling water is severely contaminated it may Chemical cleaning requires the following equipment:
be necessary to clean the coolers every two months. If, how- -- Pumps
ever, the condition of the cooling water is good (closed cooling -- Vessels
system and use of demineralized water) it may not be neces- -- Piping
sary to clean the coolers for a number of years. Note that the -- Shutoff valves
coolers must be cleaned if the cooler performance deterio- -- Cleaning agents.
rates.
The first inspection of the hydrogen coolers should be The following commercially available cleaning agents are
performed three months after their commissioning. To be able recommended:
to check the level of contamination of the tubes and inlet and
outlet water channels, the top sections of the inlet and outlet Water Side
lines, and the inlet and outlet water channels must be Cleaning Agent Supplier
removed. Depending on the findings, the subsequent
inspections can be performed at intervals of up to 12 months. P3-T288 Henkel KG, Dsseldorf,
Germany
The definitive cleaning intervals can,however, only be reliably
determined after a number of years of operation. SAF-ACID Drew Ameroid GmbH, Hamburg,
Germany
All Rights Reserved
generator has been shut down and is filled with air at at- Germany
mospheric pressure.
Ameroid ACC9 Drew Ameroid GmbH, Hamburg,
The hydrogen coolers should be cleaned on the water side Germany
if the inspection reveals increasing cold gas temperatures or Vecom B-85 Vecom GmbH, Hamburg, Ger-
the formation of deposits on the inside surfaces of the tubes. many
Copyright
2 Cleaning on the Water Side Connect a circulating pump to the cleaning system via the
It is recommended that the cooler sections be removed for water supply and return lines. Fill the system, close vent valves
this purpose, rf. 2.5--4100. and pump cleaning agent through system. After cleaning,
One of the following procedures can be applied for water- thoroughly flush the system with water.
side cleaning: In the event that the requisite expertise for performing a
J Cleaning the Brushes chemical cleaning procedure is not available, it is recom-
Slightly lower the water level in the cooler and then remove mended that this work be performed by specialist contractors.
the inlet and outlet water channels. Clean the tubes by mov-
NOTE:
ing specially-designed brushes up and down the individual
When performing chemical cleaning work be
tubes. Be sure to avoid any damage to the coating when in-
sure to comply with the instructions for safe
serting the brush in the lower return water channel. The de-
handling of chemicals.
bris removed from the tube surfaces must the be flushed
from the tubes, and the contaminated water completely re-
3 Cleaning on the Gas Side
moved from the cooling system. For this purpose, the cooler sections must be removed, rf.
J Cleaning with High-Pressure Water System 2.5--4100. Following their removal, the cooler sections must
Remove inlet and outlet water channels, connect high- be thoroughly checked on their gas side. To remove minor
Distribution: UNRESTRICTED
pressure water cleaning system and insert nozzle into each contamination, clean the fins and tubes with dry compressed
individual tube. air. If the inspection reveals more severe fouling, clean the
tubes with a high--pressure water system. Recommended
J Chemical Cleaning
pressure: 120 bar with 3 mm spray nozzle. The distance
between the nozzle and the tube bundle should be approx-
imately 2 meters.
Siemens AG
BHEL,Haridwar MKA70 &MDC 2.5--4000-0020
Energy Sector 0909E
0114E
Turbogenerators
Bearings
Maintenance
The insulation resistance of insulated bearings should be damage by cathodic action. Clean the insulation at the bearing
measured prior to each inspection. The bearings should then saddle, as otherwise the insulation properties are affected.
be dismantled and cleaned thoroughly. Bearing sleeves and The inspection procedure described above should be
shaft journals should be checked for proper condition. If performed at all sleeve bearings of the turbine generator.
grooves are detected the manufacturer should be asked for It is also recommended that the hose between the fan
advice whether the bearing may be used further. If a low casing and the labyrinth ring of the insulated slipring bearing
insulation resistance has been previously measured, the compartment be disconnected, cleaned with compressed air
respective bearing should be inspected thoroughly for any and then be reconnected.
All Rights Reserved
e Siemens AG 2009 --
Copyright
Distribution: UNRESTRICTED
MKC
BHEL,Haridwar
Siemens AG MKD &MDC 2.5--5000--0009
Energy Sector 0109E
0114E
Exciter
Components Manual
1 General
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
Siemens
BHEL,Haridwar AG
(QHUJ\6HFWRU
Preface
([FLWHU
*HQHUDO
7KLV PDQXDOPXVWEHUHDGWKURXJKFDUHIXOO\DQGWKRURXJKO\$Q RPLVVLRQ FDQ OHDG WR SHUVRQDO
LQMXULHVDQGPDWHULDOGDPDJH
,WFRQWDLQVLQIRUPDWLRQZKLFKLVDQLPSRUWDQWSUHUHTXLVLWHIRUIDXOWOHVV RSHUDWLRQDQGPDLQWHQDQFH
RI WKH H[FLWHU ,W KDVEHHQZULWWHQRQWKHDVVXPSWLRQWKDWWKHRSHUDWLQJDQGPDLQWHQDQFHSHUVRQQHO
KDYH GHWDLOHGNQRZOHGJHRISRZHUVWDWLRQ WHFKQRORJ\ DQGRSHUDWLRQDQGKDYH DOUHDG\ EHHQ
LQVWUXFWHGLQWKHRSHUDWLRQDQGPDLQWHQDQFHRIWKHV\VWHPE\WUDLQHGSHUVRQQHO
7KLV PDQXDOLVQRWDFRPSOHWHUHIHUHQFHZRUN$PDQXDO RI WKLV W\SH FDQQRW FRQWDLQ FRPSOHWH
LQIRUPDWLRQ DERXWDOODVSHFWVRIWKHH[FLWHUDQGLWVDSSOLFDWLRQ)XUWKHUPRUHLWGRHV QRW SURYLGH
LQVWUXFWLRQV RULQIRUPDWLRQDERXWHYHU\HYHQWXDOLW\WKDWFDQDULVH GXULQJ WKH DVVHPEO\ RSHUDWLRQ RU
PDLQWHQDQFHRIWKHH[FLWHU$OOTXHVWLRQVWKDWFDQQRWEHFOHDUO\DQVZHUHGZLWKWKHDLGRIWKLVPDQXDO
PXVWEHUHIHUUHGWR6LHPHQV$*
$OOWKHLQIRUPDWLRQFRQWDLQHGLQWKLVPDQXDOLVLQWHQGHGVROHO\IRUWKHXVH RIWKHEX\HUDQGIRUWKH
VSHFLILF SXUSRVHVWDWHGE\WKHEX\HU WR 6LHPHQV $* IRUWKHSXUFKDVHRIWKHH[FLWHU8VHE\RWKHU
SHUVRQVRUIRURWKHUSXUSRVHVLVQRWDXWKRUL]HGDQG6LHPHQV$*GRHVQRWDFFHSWDQ\OLDELOLW\IRUDQ\
W\SHRIVXFKXQDXWKRUL]HGXVH
7KLV PDQXDO LV QRWDJXDUDQWHHRUFRQWUDFWXDOGRFXPHQW7KHREOLJDWLRQVRI6LHPHQV$*DUH
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
Siemens AG
BHEL,Haridwar ELR-1.1-0001-0001
(QHUJ\6HFWRU H
0114E
([FLWHU Addresses
*HQHUDO
1 Manual service )RUH[SUHVVSDUFHOV
7KH H[FLWHUPDQXDOLVSXEOLVKHGE\ WKH VSHFLDOL]HG
Siemens AG
Electrical Machines Engineering GHSDUWPHQW 7KLV
Energy Sector
GHSDUWPHQW DOVRFDUULHVRXWDPHQGPHQWVDQG NHHSV
Fossil Power Generation
WKHPDQXDOXSWRGDWH
Erfurt Generator Works
&RPSODLQWV DERXW WKLVPDQXDOSURSRVDOVIRU
Bereich Technik
LPSURYHPHQWUHTXHVWVIRUVXSSOHPHQWDU\LQIRUPDWLRQ
P.O. Box 80 03 61
HFWVKRXOGEHGLUHFWHGWRWKHIROORZLQJDGGUHVV
99029 Erfurt
RU
Siemens AG
Werner-von-Siemens-Strae 1
Energy Sector
99086 Erfurt
Fossil Power Generation
RU
Erfurt Generator Works
Bestimmungsbahnhof / Gterbahnhof
Bereich Technik
99085 Erfurt
P.O. Box 80 03 61
99029 Erfurt
RU
)RUZDJRQORDGV
Werner-von-Siemens-Strae 1
99086 Erfurt
Siemens AG
Energy Sector
Fossil Power Generation
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
2 Product service
Erfurt Generator Works
7KH6LHPHQV$*RSHUDWHVDJHQFLHVLQDOOODUJHUFLWLHV Bahnhof Erfurt - Nord
DW KRPHDQGLQPRVWFRXQWUL HV RI WKHZRUOG3OHDVH Richteinheit 770 - 31
FRQWDFW WKHDJHQF\DSSOLFDEOHWR\RX ZLWK UHJDUG WR Bahnhof Nr. 164 269
UHSODFHPHQW SDUW RUGHUVUHTXLUHPHQWVRISHUVRQQHO
DVZHOODVUHTXHVWVIRUWHFKQLFDOLQIRUPDWLRQ
,Q WKHHYHQWRITXHVWLRQVFRQFHUQLQJWKH SURSHU
DGGUHVV DQG IRUZDUGLQJ PRGHSOHDVHFRQWDFWWKH
3 Returns (UIXUWZRUNVIRUGHWDLOHGLQIRUPDWLRQ
(YHU\ FRPSRQHQWZKLFKLVUHWXUQHGVKRXOGEH
:KHQ UHWXUQLQJSDUWVWRWKH VXSSOLHU
V ZRUNV LW LV
DFFRPSDQLHGE\WKHIROORZLQJLQIRUPDWLRQ
HVVHQWLDO WRXVHWKHSURSHUDGGUHVVDQGIRUZDUGLQJ
PRGH DQG WRLQFOXGHWKHQHFHVVDU\VXSSOHPHQWDU\
1DPHRIVHQGHU
LQIRUPDWLRQLQWKHFRQVLJQPHQWWRHQVXUHWKHVPRRWK
&RPSDQ\GHSDUWPHQWDQGQDPHRISHUVRQ
LQLWLDWLRQRISURFHVVLQJ
ZKRPDGHWKHDUUDQJHPHQWVIRUWKHUHWXUQ
5HWXUQV WR WKH (UIXUW ZRUNVVKRXOGEHDGGUHVVHGDV
IROORZV
,QDGGLWLRQWKHFRQVLJQPHQWVKRXOGEHDFFRPSDQLHG
E\WKHIROORZLQJLQIRUPDWLRQ
)RUSDUFHOV
5HDVRQIRUUHWXUQ
Siemens AG
2IILFHRI6LHPHQV$*ZKLFKLVDOUHDG\GHDOLQJ
Energy Sector
ZLWKWKHPDWWHU
Fossil Power Generation
0DFKLQHQRWRZKLFKWKHUHWXUQHGFRPSRQHQW
Erfurt Generator Works
EHORQJV
Bereich Technik
P.O. Box 80 03 61
99029 Erfurt
RU
Werner-von-Siemens-Strae 1
99086 Erfurt
RU
Bestimmungsbahnhof / Gterbahnhof
99085 Erfurt
BHEL,Haridwar
Siemens AG ELR-1.2-0001-0001
(QHUJ\6HFWRU 0114E
H
([FLWHU General safety precautions
*HQHUDOLQIRUPDWLRQ
1 General information 7KLV VLJQLVIROORZHGE\LQIRUPDWLRQ DQG
LQVWUXFWLRQVDLPHGDWSUHYHQWLQJGDPDJHWR
7KLV SXEOLFDWLRQ LVLQWHQGHGIRUFRPSDQLHVDQG
SURSHUW\
SHUVRQQHORSHUDWLQJH[FLWHUPDFKLQHV,WFRQWDLQV WKH
UHOHYDQW LQIRUPDWLRQQHFHVVD U\ IRUVDIHRSHUDWLRQRI
DQH[FLWHU 7KLV VLJQLVIROORZHGE\LQVWUXFWLRQV WR HQ
7KHH[FLWDWLRQPDFKLQHKDVEHHQFRQVWUXFWHGDF VXUH HIILFLHQW DQGHFRQRPLFRSHUDWLRQRI
WKHH[FLWHU
FRUGLQJWRWKHVWDWHRIWKHDUWDQGLQFRPSOLDQFH ZLWK
WKH UHFRJQL]HG VDIHW\UXOHV+RZHYHUGHVSLWHWKHLU
7KH RSHUDWLQJLQVWUXFWLRQVDOVRLQFOXGH RWKHU
DSSOLFDWLRQGDQJHUWRWKHOLIHDQGOLPERIWKHXVHU RU
VLJQV ,IWKHSLFWRJUDPLVQRWVHOIH[SODQDWRU\LWLV
WKLUGSDUWLHVDVZHOODVGDPDJHWRWKHH[FLWDWLRQPD
H[SODLQHGWR\RXE\DVKRUWGHVFULSWLRQRIWKHGDQJHU
FKLQHDQGRWKHUWDQJLEOHDVVHWVFDQRFFXU
DWWKHEHJLQQLQJRIWKHVDIHW\LQVWUXFWLRQ
3OHDVH UHDG WKLV VHFWLRQFDUHIXOO\DQGPDNHVXUH
WKDW\RXFRPSO\ZLWKWKHLQVWUXFWLRQVLQRUGHUWRVDIH
JXDUG DJDLQVWSHUVRQDOLQMXU\DQG GDPDJH WR WKH 3 Intended Usage of the Exciter
H[FLWHU 7KH IXQFWLRQRIDQH[FLWHULVWRFRQYHUWURWDWLQJ
3OHDVHQRWHWKDWWKHVDIHW\LQIRUPDWLRQLQWKLVVHFW PHFKDQLFDO HQHUJ\WRHOHFWULFDOHQHUJ\WKXV H[FLWLQJ
WLRQLVJHQHUDODQGDSSOLHV WRGLIIHUHQWW\SHVRIH[FLW WKHJHQHUDWRU
HUV 6SHFLILFVDIHW\LQVW UXFWLRQV DUHLQFOXGHG LQ WKH 7RHQVXUHQRUPDODQGWURXEOHIUHHRSHUDWLRQRIWKH
RSHUDWLQJLQVWUXFWLRQVSURYLGHGIRUWKHLQGLYLGXDOFRP H[FLWHU LWLVQHFHVVDU\ WR FRPSO\ZLWKWKHRSHUDWLQJ
SRQHQWVRULQWKHYDULRXVDSSHQGLFHV LQVWUXFWLRQV DVZHOODVWKHLQVSHFWLRQDQG PDLQWH
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
QDQFHLQWHUYDOV
2 Warning notes $Q\ RWKHU XVDJH LV GHHPHGWREHQRWLQDFFRU
GDQFH ZLWK WKH VSHFLILFDWLRQV$Q\GDPDJHUHVXOWLQJ
7KH RSHUDWLQJ LQVWUXFWLRQVXVHDUDQJHRINH\
IURPWKLVLVWKHVROHUHVSRQVLELOLW\RIWKH6LHPHQV$*
ZRUGVDQGV\PEROVWRLGHQWLI\ LQIRUPDWLRQZKLFKLVRI
SDUWLFXODULPSRUWDQFH$OOVDIHW\LQVWUXFWLRQVDUHLQWUR
GXFHGE\DNH\ZRUG7KHNH\ZRUGV DangerWarn- 4 General Organization
ingCautionDQGNoteJLYH\RXDEHWWHULGHDRI WKH 7KHIROORZLQJLQVWUXFWLRQVPXVWEH IROORZHGWRHQ
VLJQLILFDQFHRIWKHZDUQLQJQRWLFHV VXUHVDIHDQGUHOLDEOHRSHUDWLRQ
- Danger - 7KH RSHUDWLQJLQVWUXFWLRQVPXVWDOZD\VEH NHSW
7KH 'DQJHU FDWHJRU\ LVXVHGWRZDUQDJDLQVW RQKDQGDWWKHSODFHRILQVWDOODWLRQ
SRWHQWLDOOHWKDOKD]DUGVRUVHULRXV LQMXU\WRKHDOWK
LIWKHZDUQLQJLVLJQRUHGRUQRWSURSHUO\KHHGHG - ,Q DGGLWLRQWRWKHRSHUDWLQJLQVWUXFWLRQV WKHJHQ
HUDOOHJDOSURYLVLRQVDQGRWKHUUHJXODWLRQVIRUWKH
- Warning SUHYHQWLRQ RIDFFLGHQWVDQG WKH SURWHFWLRQRIWKH
7KH:DUQLQJFDWHJRU\LVXVHGZKHQWKHUHLVULVN HQYLURQPHQW PXVWEH REVHUYHG
WR KHDOWKRUSRWHQWLDOGDPDJH WR SURSHUW\ LI WKH 1RWH VDIHW\ GDWDVKHHWZKHQXVLQJKD]DUGRXV
ZDUQLQJQRWLFHLVLJQRUHGRUQRWSURSHUO\KHHGHG PDWHULDO
- Caution - 3UHSDUHVKLIWSURFHGXUHV7KHRSHUDWLQJLQVWUXF
7KH&DXWLRQFDWHJRU\LVXVHGZKHQWKHUH LVQR WLRQV PD\EHXVHGDVDEDVLVWR DGG UHJXODWLRQV
ULVN WRKHDOWKEXWSRWHQWLDO GDPDJH WR SURSHUW\ LI ZKLFK WDNH LQWRDFFRXQWVSHFLILFFRQGLWLRQVVXFK
WKHQRWLFHLVLJQRUHGRUQRWSURSHUO\KHHGHG DVZRUNRUJDQL]DWLRQDQGZRUNVHTXHQFHV
- Note - 3ODFH VLJQV LQWKHEXLOGLQJVDWH[LWVDQGHQ
7KLV FDWHJRU\LVXVHGWR LGHQWLI\ DQ\ LQIRUPDWLRQ WUDQFHV DQG QHDU WKHH[FLWHU&RPSOLDQFHZLWK
UHOHYDQWWRHQVXUHPD[LPXPH[FLWHUHIILFLHQF\ WKHVHVLJQVPXVWEHHQVXUHG
,Q RUGHUWRKLJKOLJKWWKHDERYHZDUQLQJV DQG QR - $Q\SHUVRQQHOZRUNLQJRQWKHH[FLWHUDQGLWVDX[
WLFHV LQ WKH WH[WWKH\DUHXVHGLQFRQMXQFWLRQZLWK LOLDU\V\VWHPVPXVWEHIDPLOLDUL]HGZLWKWKHRSHU
VSHFLDO VLJQVXWLOL]LQJSLFWRULDOV\PEROVSLFWRJUDSKV DWLQJLQVWUXFWLRQVDQGVKLIWSURFHGXUHVDQGLQSDU
VXFKDVWKHIROORZLQJ WLFXODUZLWKWKHVDIHW\LQVWUXFWLRQV DQGUHJXODWLRQV
7KLV VLJQLVIROORZHGE\LQIRUPDWLRQ DQG EHIRUH VWDUWLQJZRUN7KLVSDUWLFXODUO\DSSOLHV WR
LQVWUXFWLRQV DLPHGDW SUHYHQWLQJ LQMXU\WR SHUVRQQHO VXFK DV PDLQWHQDQFHSHUVRQQHOZKR
SHUVRQV GRQRWZRUNRQWKHH[FLWHURQDUHJXODUEDVLV
Siemens AG
BHEL,Haridwar ELR-1.3-0001-0001 / 1
(QHUJ\6HFWRU 0114E
H
([FLWHU General safety precautions
*HQHUDOLQIRUPDWLRQ
- 3URWHFWLYH DSSDUHO DQGHTXLSPHQWPXVWEHXVHG Notice:
ZKHUHVWLSXODWHGRUUHTXLUHG Support and lift machine parts only at
- &RPSOLDQFHZLWKDOOVDIHW\LQVWUXFWLRQVDQGZDUQ specified points.
LQJVPXVWEHHQVXUHG
- $Q\LUUHJXODUHYHQWVZKLFKRFFXU GXULQJRSHUDWLRQ - 3OHDVH UHIHUWRWKHVKLSSLQJGRFXPHQWVIRU LQIRU
PXVWEHUHSRUWHGGLUHFWO\ PDWLRQ DERXWWKHGLPHQVLRQVDQGZHLJKWVRIH[
FLWHUFRPSRQHQWV
5 Personnel - 'R QRW UHPRYHSDFNDJLQJRUSURWHFWLYHFRYHUV
GXULQJVKLSPHQW
([FLWHU
- 2QO\ XVHVSHFLILHGORDG DWWDFKPHQW SRLQWV2QO\
- 3HUVRQQHOPXVWEHUHOLDEOH
XVH VXLWDEOHRUVSHFLILHGOLIWLQJHTXLSPHQW 7KH
- 3HUVRQQHOPXVWEHDSSURSULDWHO\WUDLQHGDQG TXD OLIWLQJ HTXLSPHQWPXVWEHLQJRRG FRQGLWLRQ DQG
OLILHG KDYHDVXIILFLHQWORDGFDUU\LQJFDSDFLW\
- $FWLYLWLHV DQG DVVRFLDWHGUHVSRQVLELOLWLHVDUH - 3URWHFW WKHH[FLWHUURWRUDJDLQVW GDPDJHV 6XLW
FOHDUO\GHILQHGIRUWKHSHUVRQQHO DEOH XQGHUOD\VPXVWEHLQVHUWHGEHWZHHQURSH
- :RUN RQWKHH[FLWHUDQG LWV DX[LOLDU\V\VWHPVLV DQGDWWDFKPHQWSRLQW
SHUIRUPHGE\DXWKRUL]HGSHUVRQQHORQO\ - 2QO\ XVHTXDOLILHGDQGH[SHULHQFHGVWDIIIRUDW
- 3HUVRQQHO UHTXLULQJ RU XQGHUJRLQJWUDLQLQJPXVW WDFKLQJ ORDGVRULQVWUXFWLQJ FUDQH RSHUDWRUV 7KH
RQO\EHDOORZHGWRSHUIRUPZRUNRQ WKHH[FLWHURU SHUVRQ LVVXLQJLQVWUXFWLRQVPXVW UHPDLQ ZLWKLQ
RSHUDWRUVVLJKWRULQYRLFHFRQWDFWZLWKKLP
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
8.1 Transport
7KH IROORZLQJ JHQHUDO LQVWUXFWLRQVDSSO\GXULQJ
VKLSPHQW
Danger:
Suspended load. Falling loads may cau-
se injury to persons. Do not stand or
walk under suspended loads.
Siemens AG
BHEL,Haridwar ELR-1.3-0001-0001 / 2
(QHUJ\6HFWRU 0114E
H
([FLWHU General safety precautions
*HQHUDOLQIRUPDWLRQ
Notice: - %HIRUHH[FLWDWLRQUHPRYHDQ\PRLVWXUHFDXVHG E\
Do not step on machine parts, such as WHPSHUDWXUHGURSVEHORZWKHGHZSRLQWXVLQJ VXLW
oil inlet and oil outlet armatures, flan- DEOHPHWKRGVHJGU\LQJ
ges, measuring devices, thermometers
- 5HFRUGDOORSHUDWLQJGDWDDIWHUDOORZLQJ VXIILFLHQW
and so on.
WLPHIRUVWHDG\VWDWHFRQGLWLRQVWREHHVWDEOLVKHG
If massive pressure oil pipes are con-
- 3UHSDUHVWDUWXSUHFRUG
nected to the hydrostatic connectors of
the bearing, then they must be ade- 8.4 Operation
quately supported, and their natural
frequency is to be measured in the area 7KH IROORZLQJVDIHW\LQVWUXFWLRQVDSSO\GXULQJRS
of the connection if possible. The pipes HUDWLRQ
must be adapted and aligned during Danger:
assembly. The strain on the connection Electromagnetic fields in the machines
point must be relieved by a suitable vicinity. The power house may not be
device. All pipe screw connections must entered by people with heart pacemak-
be checked for tightness and tightened ers.
according to the manufacturer's instruc-
tions.
Danger:
- %HIRUHHUHFWLRQXVHWKHOD\RXWSODQVIRUWKHEXLOG
Hot surface. Exciter parts can be hot
LQJVWRGHWHUPLQHVHWGRZQDUHDVDQG LQVWDOODWLRQ
and cause burns. Do not touch.
ORFDWLRQVIRUKHDY\ORDGV
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
BHEL,Haridwar
Siemens AG ELR-1.3-0001-0001 / 3
(QHUJ\6HFWRU 0114E
H
([FLWHU General safety precautions
*HQHUDOLQIRUPDWLRQ
Danger: 9 Waste Disposal
Machine parts start-up. These may cau-
,I \RXKDYHWRGLVSRVHRIZDVWHRIDQ\NLQG HJ
se injury to persons. When working on
OXEULFDQWVIROORZWKHFXUUHQWO\YDOLGOHJDOZDVWHUHJX
exciter or auxiliary equipment ensure
ODWLRQVIRUWKHPHWKRGDQGURXWHRIGLVSRVDO
that this is electrically isolated and can-
not accidentally be reconnected.
10 Special Hazards
Danger: 6HHEHORZIRUVDIHW\LQVWUXFWLRQVZLWKUHJDUG WRH
Do not start turbine-generator set if OHFWULFFXUUHQWKHDWDQGQRLVH
work is being carried out on or near the
Electric Current
generator or exciter.
(QVXUHFRPSOLDQFHZLWKWKHIROORZLQJLQVWUXFWLRQV
- :RUNPD\RQO\EHSHUIRUPHGE\TXDOLILHGSHUVRQ Danger:
QHO Electric current. The exciter must be
shut down immediately in the event of
- (QVXUH FRPSOLDQFH ZLWKWKHPDLQWHQDQFHDQG
failures.
LQVSHFWLRQ LQWHUYDOVDQGWKHVFRSH RI ZRUN VHW
IRUWKLQWKHRSHUDWLQJLQVWUXFWLRQV
- 2SHUDWLQJSHUVRQQHOPXVWEHQRWLILHGEHIRUHVWDUW - :RUNRQWKHHOHFWULFDOV\ VWHPVRIWKHH[FLWHUPD\
LQJDQGPDLQWHQDQFHLQVSHFWLRQVRUUHSDLUZRUN RQO\ EH SHUIRUPHGE\HOHFWULFDOHQJLQHHUVRUE\
$SSRLQWDVXLWDEO\TXDOLILHGVXSHUYLVRU VXLWDEO\TXDOLILHGSHUVRQQHOXQGHU WKHVXSHUYLVLRQ
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
Siemens
BHEL,Haridwar AG ELR-1.3-0001-0001 / 4
(QHUJ\6HFWRU 0114E
H
Exciter
Components Manual
2 Technical Data
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
Siemens
BHEL,Haridwar AG
(QHUJ\6HFWRU
Exciter
Components Manual
2 Technical Data
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
2.1 Identification
Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU
Exciter Identification Data
Technical Data
Siemens
BHEL,Haridwar AG ELR-2.1-0001-0209
Energy Sector 1011e
0114E
Exciter Rating plate
Technical Data Main Exciter
SIEMENS
Haupterreger 12000209 2011
ELR 70/90-30/6-20 50s-1 rechts
Generator
600V / 7500A 4500kW S1
820V / 10250A 8405kW S2 10s
Eigenerregung 79 / 112V 151 / 214A
Isolierstoffklasse: F IM 7015 IP 40
Copyright Siemens AG 2011 - All Rights Reserved
Siemens
BHEL,Haridwar AG ELR-2.1-0002-0209 / 1
Energy Sector 1011e
0114E
Exciter Rating plate
Technical Data Pilot exciter
SIEMENS
Hilfserregermaschine 12000209 2011
ELP 50/42-30/16 50s-1 rechts
Generator
220V + 10% 195A S1
65kVA cos=0,6 400 Hz
Permanentmagnetpol
Isolierstoffklasse: F IM 5410 IP 40
Copyright Siemens AG 2011 - All Rights Reserved
BHEL,Haridwar
Siemens AG ELR-2.1-0002-0209 / 2
Energy Sector 1011e
0114E
Exciter
Components Manual
2 Technical Data
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU
BHEL,Haridwar
BHEL,Haridwar
Exciter Dimensions and Weights
Technical Data
Weights
Siemens
BHEL,Haridwar AG ELR-2.2-0001-0209
Energy Sector 1011
0114E
Exciter Materials
Technical Data
Materials
TDS 9124 50
Shaft 26NiCrMoV115 -
contains SEW 555*
Rectifier wheel 26NiCrMoV115 TDS 9124 40 -
Armature core M270-50A TDS 13-001 -
Armature winding E-Cu58F20 GEN 754.01 -
Field winding E-Cu57F20 DIN EN 13601 -
Base frame S235JRG2 DIN EN 10025 -
Covers S235JRG2 DIN EN 10025 -
Diodes D690 S26 TT2 TDS 13-033 Manufacturer: EUPEC
Fuses 3NC9 538-2 TDS 13-035 Manufacturer: Siemens
Copyright Siemens AG 2011 - All Rights Reserved
* The TDS 9124 50 contains the SEW 555 and is adapted to rotating rectifier wheels.
26NiCrMoV 11 5 is specified for this scope of application.
BHEL,Haridwar
Siemens AG ELR-2.2-0002-0209
Energy Sector 1011e
0114E
Exciter
Components Manual
2 Technical Data
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
Siemens
BHEL,Haridwar AG
(QHUJ\6HFWRU
Exciter Design Data
Technical Data
Electrical Data
Diode Wheels
Siemens
BHEL,Haridwar AG ELR-2.3-0001-0209 / 1
Energy Sector 1011e
0114E
Exciter Design Data
Technical Data
Breakdown of Fuses
Torques
Torque Unit
Moment of inertia of rotor 566 Kgm
BHEL,Haridwar
Siemens AG ELR-2.3-0001-0209 / 2
Energy Sector 1011e
0114E
Exciter Curves and Data
Technical Data
Manufacturer: Siemens AG
Amount: 3 pages
BHEL,Haridwar
Siemens AG ELR-2.3-0002-0209
Energy Sector 1011e
0114E
Siemens AG Excitation Data Sheet Rev. Printed at
Erreger- und Reglerangaben Druck am
E F PR GN ERF EN 3 YERAMARUS
BHEL 800 MW<< A 2009-11-27
Generated from order data table Erzeugt aus der Auftragsdatentabelle Checked Ka; 2009-11-27
H. Kaluza Geprft
2-pole Turbogenerators Excitation System Voltage vs.
Exciter Field Current
1000
900
800
700
Excitation System Voltage [V]
600
500
400
300
200
100
0
0 50 100 150 200
BHEL,Haridwar
SIEMENS AG Rev. A H. Kaluza
Energy Sector
2-CCC-C01-00001 2009-11-27 E F PR GN ERF EN 3
Exciter
Components Manual
2 Technical Data
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
BHEL,Haridwar
Siemens AG
(QHUJ\6HFWRU
Exciter Operational and Setting Values
Technical Data
The excitation machine goes into protection The control system receives a message that
mode (trips) when certain parameters reach their excitation has been lost, and initiates a fast
limit values. shutdown of turbine and generator. Further
Excitation can be lost because of a malfunction operation is then not possible.
in the excitation system or an open field winding. In Exciter The hydrogen pressure and flow of
such a case, no energy is produced, and the turbine cooling water are maintained.
starts to increase speed.
Setting Value
Operating
Parameter Tag Number Protec- Unit Remark
Control Alarm Value
tion
Cold air temperature +MKC61CT001A/B
- - 48 30 to 43
monitoring
+MKC65CT001A/B
Hot air temperature +MKC65CT002A/B - 83 78 50 to 63
monitoring, main exciter +MKC65CT002A/B C
Hot air temperature +MKC66CT001A/B
- - 78 50 to 63
Copyright Siemens AG 2011 - All Rights Reserved
BHEL,Haridwar
Siemens AG ELR-2.4-0001-0209
Energy Sector 1011e
0114E
Exciter
Components Manual
2 Technical Data
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
BHEL,Haridwar
Siemens AG
(QHUJ\6HFWRU
([FLWHU List of Measuring Instruments,
7HFKQLFDO'DWD Connection points and Consumers
7KHPRQLWRULQJV\VWHPRIWKHH[FLWDWLRQPDFKLQH 7KH F\FOH WLPH LVVHOHFW HG VR WKDWWKHH[FLWDWLRQ
UXQV DXWRPDWLFDOO\ DQGLQWHUYHQWLRQVIURPWKH PDFKLQH FDQEHVZLWFKHGRIIVDIHO\LI WKH VLJQDOV
FRQWURO URRPDUHQRWQHFHVVDU\XQGHU QRUPDO H[FHHGWKHSHUPLVVLEOHYDOXHV
UXQQLQJ FRQGLWLRQV,QSULQFLSOHQRPDQXDO
LQWHUYHQWLRQV DUHUHTXLUHG :H QHYHUWKHOHVV
UHFRPPHQG REVHUYLQJWKH VWDWXV RIWKHH[FLWDWLRQ
PDFKLQHPRUHFORVHO\LIZDUQLQJVDUHLVVXHG
Measuring instruments:
0.&&7$%
0.&&7$% +RWDLUWHPSHUDWXUHPRQLWRULQJDWWKHGLRGH ZLUHFRQQHFWLRQ
ZKHHO
0.'&7 %HDULQJWHPSHUDWXUHPHDVXUHPHQW 7KHUPRFRXSOH
0.'&7 7\SH/
0.'&<
0HDVXUHPHQWRIWKHEHDULQJYLEUDWLRQ 9LEUDWLRQ3LFNXS
0.'&<
0.'&<
0HDVXUHPHQWRIWKHVKDIWYLEUDWLRQ 9LEUDWLRQ3LFNXS
0.'&<
7KHTXDGUDWXUHPHDVXULQJFRLOVXSSOLHVDYROWDJHWKDWLVDOPRVWSURSRUWLRQDOWRWKHRXWSXWFXUUHQWRIWKH
H[FLWDWLRQPDFKLQHDQGWKXVDOVRWRWKHGLUHFWFXUUHQWRIWKHGLRGHZKHHOV+RZHYHUWKHWHPSHUDWXUHDQGORDG
SRLQWRIWKHH[FLWHUDIIHFWWKLVYDOXHWKHSURSRUWLRQDOLW\FDQWKHUHIRUHRQO\EHGHWHUPLQHGGXULQJDWHVWUXQLQWKH
WHVWED\LQWKHPDQXIDFWXUHU
VZRUNV:LWKRXWDWHVWUXQRIWKHH[FLWHULQWKHWHVWED\DFKDUDFWHULVWLFFXUYHRIWKH
TXDGUDWXUHPHDVXULQJFRLOVFDQQRWEHUHFRUGHGDQGVRWKHUHFDQEHQRFDOLEUDWLRQ7KHUHIRUHWKHYROWDJH
VXSSOLHGE\WKHTXDGUDWXUHPHDVXULQJFRLOVLVIRULQIRUPDWLRQRQO\7KHVLJQDOVDUHQHLWKHUUHDGLQWRWKHPDLQ
FRQWUROV\VWHPQRUXVHGIRUWKHFRQWUROOHGV\VWHPRIWKHWXUERVHW+RZHYHUWKHVLJQDOVFDQEHXVHGE\WKH
PDQXIDFWXUHUWRILQGDQGUHFWLI\IDXOWVLQWKHH[FLWHUVHW
$OORFDWLRQXQGZLULQJE\FXVWRPHU
Warning:
Damages to the exciter. The cycle time of the measuring instruments must be selected so that the
exciter machine can be switched off safely when the permissible signal values are exceeded.
Siemens
BHEL,Haridwar AG ELR-2.5-0001-0209 / 1
(QHUJ\6HFWRU 0114E
H
([FLWHU List of Measuring Instruments,
7HFKQLFDO'DWD Connection points and Consumers
Connection points:
List of Consumers:
Siemens AG
BHEL,Haridwar ELR-2.5-0001-0209 / 2
(QHUJ\6HFWRU 0114E
H
Exciter
Components Manual
3 Components
and Purchased Parts
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU
Exciter
Components Manual
3 Components
and Purchased Parts
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
3.1 General
Siemens
BHEL,Haridwar AG
(QHUJ\6HFWRU
Exciter General Technical Description
Components and Purchased Parts
The basic task of the excitation machine is to x Measuring Devices and Supervisory Equipment
provide sufficient electric power for the voltage con-
troller (AVR) and generator rotor winding.
It is a 6-pole excitation machine with a perma- 1
nent-magnet auxiliary exciter (PMG), which is driven
at a speed of 50 rps.
2
1 System
3
The excitation machine is a synchronous AC 10
machine with the field winding in the stator and ro- 4
tating armature coils. The generator rotor coils re-
quire direct current (DC). The induced alternating
current is rectified by rotating rectifiers for this pur-
pose.
The excitation machine has one bearing and two 5
air-water coolers. An auxiliary exciter with perma-
nent magnets is integrated into the system. It sup-
plies the electric power for the main exciter via the
voltage controller.
6
2 Main Components
eserved
Copyright Siemens AG 2011 - All Rights Reserved
Siemens AG
BHEL,Haridwar ELR-3.1-0001-0209 / 1
Energy Sector 1011e
0114E
Exciter General Technical Description
Components and Purchased Parts
1 Coupling
2 Rectifier wheel
3 Rotor of main exciter
4 Fan
Fig. 2 Exciter Rotor
BHEL,Haridwar
Siemens AG ELR-3.1-0001-0209 / 2
Energy Sector 0114E
1011e
Exciter General Technical Description
Components and Purchased Parts
1 2 3
1 Magnet pole
2 Stator
3 Magnetic test coil
Fig. 7 Main Exciter
BHEL,Haridwar
Siemens AG ELR-3.1-0001-0209 / 3
Energy Sector 1011e
0114E
Exciter General Technical Description
Components and Purchased Parts
1 2 3
Copyright Siemens AG 2011 - All Rights Reserved
Siemens
BHEL,Haridwar AG ELR-3.1-0001-0209 / 4
Energy Sector 1011e
0114E
Exciter
Components Manual
3 Components
and Purchased Parts
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
3.2 Cooler
Siemens
BHEL,Haridwar AG
(QHUJ\6HFWRU
Exciter Cooler
Components and Purchased Parts Technical Description
Note:
You will find more detailed informa-
tion in the manufacturers documenta-
tion and in the drawing.
Copyright Siemens AG 2011 - All Rights Reserved
Fig.1-Exciter Cooler
Siemens
BHEL,Haridwar AG ELR-3.2-0001-0209
Energy Sector 1011e
0114E
Exciter
Components Manual
3 Components
and Purchased Parts
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
3. Dryer
Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU
Exciter Dryer
Components and Purchased Parts Technical Description
2 Mode of Operation
The dryer dehumidifies the air within the exciter
enclosure. The dryer wheel is made of a non-
flammable material. On its inlet side, the wheel is
provided with a system of tubular ducts, the sur-
faces of which are impregnated with a highly hygro-
1 Regeneration air outlet 4 Fan
scopic material.
2 Dryer wheel 5 Filter
The tubular ducts are dimensioned so that a la- 3 Heater 6 Dry air outlet
minar flow with low pressure loss is obtained even Fig. 2 Schematic Diagram
at high air velocity; thus there are low friction losses.
The moisture absorbed by the dryer wheel is re- 2.1.2 Regeneration Section
moved in a regeneration section by a stream of hot In the regeneration section of the dryer wheel,
air directed through the wheel in the opposite direc- the accumulated moisture is removed from the dryer
tion of the inlet air and then discharged to the at- wheel by the heated regeneration air.
mosphere.
Uniform rotation of the dryer wheel ensures con-
tinuous dehumidification of the air within the exciter.
BHEL,Haridwar
Siemens AG ELR-3.4-0001-0209 / 1
Energy Sector 1011e
0114E
Exciter Dryer
Components and Purchased Parts Technical Description
BHEL,Haridwar
Siemens AG ELR-3.4-0001-0209 / 2
Energy Sector 0114E
1011e
Exciter
Components Manual
3 Components
and Purchased Parts
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
3. Measuring Devices
and Supervisory Equipment
Siemens
BHEL,Haridwar AG
(QHUJ\6HFWRU
Exciter Measuring Devices and Supervisory
Components and Purchased Parts Equipment
Bearing Vibration
Note:
For more detailed information about
the sensor positioning see drawing
2-7200-441853 in section 3.3.
Copyright Siemens AG 2011 - All Rights Reserved
BHEL,Haridwar
Siemens AG ELR-3.5-0001-0209
Energy Sector 1011e
0114E
Exciter Measuring Devices and Supervisory
Components and Purchased Parts Equipment
Shaft Vibration
Note:
You will find more detailed informa-
tion about the boreholes in the draw-
ing on the following page.
Copyright Siemens AG 2011 - All Rights Reserved
Siemens
BHEL,Haridwar AG ELR-3.5 -0002-0209
Energy Sector 0114E
1011e
Exciter Protection and Monitoring
Description of Components and Auxiliary Ground Fault Detection
Connection to the
pressure area of
main exciter fan
(air inlet)
Carbon brushes
Housing outlet
for air including
coal dust
Fig. 1 Air flow in the brush holder assembly Fig. 2 Carbon brushes in the brush
holder assembly
BHEL,Haridwar
Siemens AG ELR-3.5-0003-0209
Energy Sector 1011e
0114E
Exciter Measuring Devices and Supervisory
Components and Purchased Parts Equipment
Stroboscope
Fuses on the rectifier wheels may be checked The continuous sequence of flashes can be in-
during operation with the stroboscope. A separate terrupted at any time by switching off the flow or
flash tube is provided for each wheel (A and B). The return with the push button. This then gives a sta-
tubes, which are controlled through a common con- tionary image which allows the exact observation of
trol unit, are permanently installed in the rectifier a single circuit breaker.
wheel enclosure. This permits easy monitoring with- The device switches off automatically after about
out any adjustment outside the exciter enclosure 2 minutes. If this time is insufficient for observation,
being required. the device can be immediately switched on for an-
Figure 1 shows the basic arrangement of a fully other 2 minutes by pressing the ON button. This can
transistorized stroboscope. The electronics required be repeated any number of times.
for control of the light signals are contained in the The stroboscope contains 4 plug-in printed cir-
control unit and in the tubular lamps. The tubular cuit boards that can be readily replaced to correct
lamps are connected to the control unit by cables. any malfunctions.
The stroboscope is located adjacent to the recti- The capacitor and high-voltage transformer re-
fier wheel in the exciter enclosure so that the fuses quired to produce the firing pulses for the flash
may be observed from outside the exciter enclosure tubes are located on a printed circuit board accom-
while controlling the stroboscope. modated in the flash lamp socket assembly.
To synchronize the sequence of flashes with the Operating controls are located on the front panel
generator shaft rotation, the system frequency is of the control unit for ease of operation. Selection of
utilized to activate the flashes. A PLL system, con- each button is indicated by an illuminated dot on the
trolled through two pushbuttons causes the flashes surface of the pushbutton.
Copyright Siemens AG 2011 - All Rights Reserved
BHEL,Haridwar
Siemens AG ELR-3.5-0004-0209
Energy Sector 1011e
0114E
Exciter Measuring Devices and Supervisory
Components and Purchased Parts Equipment
Resistance Temperature Detectors (RDTs)
R = R0 x (1 + x T)
Where:
R0 = reference resistance at 0 C
= temperature coefficient and
T = temperature in C
BHEL,Haridwar
Siemens AG ELR-3.5-0005-0209
Energy Sector 1011e
0114E
Exciter Measuring Devices and Supervisory
Components and Purchased Parts Equipment
Thermocouple
and connected to a milli voltmeter calibrated in C. corrections must be added to the calibration figures
of the particular thermo-couple which are referred to
0 C. To do this, add the thermoelectric emf due to
the cold junction temperature to the measured
thermoelectric emf and read measuring pint tem-
perature to obtain the total thermoelectric emf.
Fig. 1 Thermocouple
Siemens
BHEL,Haridwar AG ELR-3.5-0006-0209 / 1
Energy Sector 1011e
0114E
Exciter Measuring Devices and Supervisory
Components and Purchased Parts Equipment
Thermocouple
Thermocouple NiCr Ni
Identification
(acc. to DIN IEC 60584) K
Measuring range (in C) -270 to +1370
BHEL,Haridwar
Siemens AG ELR-3.5-0006-0209 / 2
Energy Sector 1011e
0114E
Exciter
Components Manual
4 Operation
and Supervision
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU
Exciter Turning and Running up
Operation and Supervision
Siemens
BHEL,Haridwar AG ELR-4.1-0001-0209
Energy Sector 1011e
0114E
Exciter Operation under Load
Operation and Supervision
Siemens AG
BHEL,Haridwar ELR-4.2-0001-0209
Energy Sector 1011e
0114E
Exciter Shutdown
Operation and Supervision
Speed Approx. 90 %
BHEL,Haridwar
Siemens AG ELR-4.3-0001-0209
Energy Sector 1011e
0114E
Exciter Standstill
Operation and Supervision General instructions
BHEL,Haridwar
Siemens AG ELR-4.4-0001-0209
Energy Sector 1011e
0114E
Exciter
Components Manual
5 Troubleshooting
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU
Exciter General
Troubleshooting
The details given herein on faults, their possible Unless corrective measures can be taken in ac-
causes and the corrective measures cannot be con- cordance with the following instructions the genera-
sidered complete in every respect, since all possible tor should be shut down.
troubles cannot be covered in advance. If required, the services of the manufacturer
In most cases, the operator will have to decide should be requested. In most cases, however, suffi-
on the measures to be taken. The individual meas- cient details will be found in this manual.
ures required depend on the mode of operation.
Copyright Siemens AG 2011 - All Rights Reserved
BHEL,Haridwar
Siemens AG ELR-5.1-0001-0209
Energy Sector 1011e
0114E
Exciter Ground Fault Detection
Troubleshooting
Exciter voltage response takes longer than 5 s. Fault alarm is automatically extinguished after
removal of cause.
Siemens AG
BHEL,Haridwar ELR-5.2-0001-0209
Energy Sector 1011e
0114E
Exciter Exciter Temperatures
Troubleshooting
Change in the cooling water conditions With a rise in cold water temperature, higher
cooling water flow is required for removal of the loss
heat. Increase cooling water flow.
Siemens
BHEL,Haridwar AG ELR-5.3-0001-0209
Energy Sector 1011e
0114E
Exciter Cooler
Troubleshooting
BHEL,Haridwar
Siemens AG ELR-5.4-0001-0209 / 1
Energy Sector 1011e
0114E
Exciter Cooler
Troubleshooting
1 Plug
2 Tube sheet
3 Cooler tube
4 Tube sheet
Copyright Siemens AG 2011 - All Rights Reserved
Note:
If several defective tubes are identified, it
must be decided right away whether the
heat removal capacity remaining after
plugging of the defective tubes is suffi-
cient for emergency operation.
BHEL,Haridwar
Siemens AG ELR-5.4-0001-0209 / 2
Energy Sector 1011e
0114E
Exciter Fuses in the Exciter
Troubleshooting
BHEL,Haridwar
Siemens AG ELR-5.5-0001-0209 / 1
Energy Sector 1011e
0114E
Exciter Fuses in the Exciter
Troubleshooting
BHEL,Haridwar
Siemens AG ELR-5.5-0001-0209 / 2
Energy Sector 1011e
0114E
Exciter Fuses in the Exciter
Troubleshooting
BHEL,Haridwar
Siemens AG ELR-5.5-0001-0209 / 3
Energy Sector 1011e
0114E
Exciter Stroboscope
Troubleshooting
Faulty stroboscope:
Note:
The voltage values indicated below
may have a tolerance of 15 %.
o o o o o o o
Press the ON button (hold the button if the relay
o o o o o o does not pick up): The circuit board needs to be
replaced if voltage is available at pins 2/3 and 8/9,
8 9 10 11 12 13 while no voltage is available at pins 6, 7, 11 and 12.
A major deviation in the voltages available at the
pins may indicate a short-circuit on another circuit
board. Remove circuit boards 2 to 4. Now, voltage
must either meet or exceed the indicated value at
these pins. Switch off the device, then insert one
circuit board after the other until voltage breaks
down at the measured point again. Replace the
defective circuit board.
o o o o o o
8 9 10 11 12 13
Siemens
BHEL,Haridwar AG ELR-5.6-0001-0209 / 1
Energy Sector 1011e
0114E
Exciter Stroboscope
Troubleshooting
Siemens
BHEL,Haridwar AG ELR-5.6-0001-0209 / 2
Energy Sector 1011e
0114E
Exciter Exciter Dryer
Troubleshooting
Siemens AG
BHEL,Haridwar ELR-5.7-0001-0209
Energy Sector 1011e
0114E
Exciter
Components Manual
6 Maintenance
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
BHEL,Haridwar
Siemens AG
(QHUJ\6HFWRU
Exciter
Components Manual
6 Maintenance
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
*HQHUDO
Siemens
BHEL,Haridwar AG
(QHUJ\6HFWRU
Exciter General
Maintenance
Reliable operation of the exciter will be ensured The assignment and number of Siemens AG
only if maintenance, inspections and overhauls are product service personnel required for an inspection
carried out at regular intervals so that any faults can should be planned well in advance to enable Sie-
be detected and corrected before they result in mens to make the necessary arrangements. In
costly failures. Following each maintenance and addition, the period available for execution of the
inspection, the next one is scheduled. inspection should be indicated.
Provided that commercial tools can be used and The spare parts stored for maintenance, repairs
that no special skills are required for the dismantling and overhauls should be checked at regular inter-
and erection work, the inspections can be per- vals. Components packed in plastic sheeting mostly
formed usually by skilled power station personnel. In contain a desiccant which must be replaced or reac-
all other cases, however, such as for the inspection tivated from time to time.
of the shaft seals and their auxiliaries, the services
of experienced Siemens AG product service per-
Danger:
sonnel will be required.
Machine parts start-up. These may
The shutdown of a exciter for inspection should cause injury to persons. Switch off the
be made in exactly the reverse order of start-up. electric power to the generator and its
Following an inspection, the exciter should be re- auxiliary systems during any work
started in the same way as during initial start-up. performed on them, and take adequate
measures to prevent accidental re-
starting.
Copyright Siemens AG 2011 - All Rights Reserved
Siemens
BHEL,Haridwar AG ELR-6.1-0001-0209
Energy Sector 1011e
0114E
Exciter Standstill during maintenance,
Maintenance Long-term storage
2.2 Operation with hydrogen-filled generator layer of the packaging), fall in the nitrogen pressure
If the generator is filled with hydrogen, then the or change in the colour of the moisture indicators in
exciter set dryer must be run in open circuit. In open the air-tight packaging found during an inspection
circuit, air is sucked out of the machine house via an must be recorded by the responsible personnel.
air filter, dehumidified in the dryer, and fed under the
exciter cover.
BHEL,Haridwar
Siemens AG ELR-6.1-0002-0209
Energy Sector 1011e
0114E
Exciter
Components Manual
6 Maintenance
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
0DLQWHQDQFHGXULQJ2SHUDWLRQ
Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU
Exciter Maintenance Intervals
Maintenance
Maintenance Intervals
Refer to Section
Every 3 months
Every 6 months
Annually
Monthly
Weekly
Daily
Work Required
6.2-
3 Check exciter bearing insulation X
0003
6.2-
5 Check carbon brushes for wear and damage X
0005
6.2-
6 Check fuses of the rectifier wheels X
0006
BHEL,Haridwar
Siemens AG ELR-6.2-0001-0209
Energy Sector 1011e
0114E
Exciter Cooler and Leakage Water Indication
Maintenance
Maintenance intervals
Every 6 months
Every 3 months
Work Required
Annually
Monthly
Weekly
Daily
1 Check the ventilation and the drain pipes of the cooler X
1 General 2 Cooler
Special measures should be taken to prevent During normal operation, the cooling water flows
corrosion damage to the cooler. Cooler sections through all cooler sections. Since the coolers are
having no cooling water flows for some time may be designed for full capacity at maximum cooling water
Copyright Siemens AG 2011 - All Rights Reserved
subject to standstill corrosion. In addition to many temperature, the condition may arise that the cool-
other corrosive influences, such as the different ers are supplied with smaller cooling water flows for
elements of the cooling water, locally differing de- long periods. Depending on the type of the cooling
posits, raw materials, etc., there exists the danger water, this may result in deposits due to the lower
that micro-organisms on the tube walls may die and water velocity in the cooler. To prevent cooler dam-
decay due to a loss of fresh water supply (lack of age, it is therefore recommended to rinse the cool-
oxygen). Ammonia is formed from such decay which ers with the full water flow during short outages. In
may lead to stress corrosion cracking. Corrosion addition, the coolers should be frequently cleaned
damage can only be properly prevented if the cooler with brushes. For heavy cooler contamination and if
is drained on the water side, cleaned, completely operational restrictions and shutdowns are undesir-
dried and maintained in a dry condition. With the able, it is recommended to install a con- tinuous
generator in commercial operation, such measures cooler water purification system. You will find further
are often unfeasible, particularly in cases of short information about the maintenance work required on
outages. In such cases, the measures outlined be- the cooler in the original cooler documentation. All
low should be taken. the instructions it contains must be observed and
complied with.
BHEL,Haridwar
Siemens AG ELR-6.2-0002-0209 / 1
Energy Sector 1011e
0114E
Exciter Cooler and Leakage Water Indication
Maintenance
BHEL,Haridwar
Siemens AG ELR-6.2-0002-0209 / 2
Energy Sector 0114E
1011e
Exciter Bearing
Maintenance
Maintenance Intervals
Every 3 months
Every 6 months
Annually
Monthly
Weekly
Daily
Work Required
pressure of the shaft lift is set so that the shaft never the generator running, the components coming into
reaches more than 50 % of the diametral bearing contact with the shaft are separated from the shaft
clearance. by an oil film, which has insulating properties. Con-
sequently, a non-defined resistance value is set up
the potential measuring point of the bearing sleeve
which is dictated by the magnitude of the resis-
tances of the oil film and insulating parts
BHEL,Haridwar
Siemens AG ELR-6.2-0003-0209
Energy Sector 1011e
0114E
Exciter Air Filters and Exciter Dryer
Maintenance
Maintenance Intervals
Every 3 months
Every 6 months
Annually
Monthly
Weekly
Daily
Work Required
2 Exciter Dryer
Check the filter pads for contamination from time Replacing the Pre-Filter:
to time, clean them in good time or replace. Slightly To inspect or replace the pre-filter, open the
contaminated filter pads should be blown out with door accommodating the pre-filter.
clean compressed air from the clean air side or Loosen wing nuts and then remove filter frame
washed in a water bath at a water temperature of and the two filter pads.
approximately 30 C, adding a neutral detergent. In case of slight contamination the fine filter can
Depending on the operating conditions, the ball be reused if in proper condition.
bearings of the ventilator and the gear motor should In case of more severe contamination, the filter
be filled with new grease every two to three years. pads should be replaced.
For reassembly of the filter, follow the same
Note: procedure in reverse order.
The dryer is not in operation under
load. Consider only the effective oper-
ating periods of the exciter unit dryer
for maintenance.
BHEL,Haridwar
Siemens AG ELR-6.2-0004-0209 / 1
Energy Sector 1011e
0114E
Exciter Operating and Supervision
Maintenance Air Filters and Exciter Dryer
BHEL,Haridwar
Siemens AG ELR-6.2-0004-0209 / 2
Energy Sector 1011e
0114E
Exciter Ground Fault Detection
Maintenance
Maintenance Intervals
Every 3 months
Every 6 months
Annually
Monthly
Weekly
Daily
Work Required
Siemens
BHEL,Haridwar AG ELR-6.2-0005-0209 / 1
Energy Sector 0114E
1011e
Exciter Ground Fault Detection
Maintenance
Note:
1 Carbon brushes should be replaced
with new ones having contact faces
which match the slip ring contour.
Grinding of new brushes to the re-
quired contour should be done using
a model of the ring contour or by
grinding to size at the slip ring when
2 the unit is at rest.
The carbon brushes should be re-
placed in sets of two only. When in-
serting new brushes, make sure that
the carbon layer comes before silver
layer in direction of rotation.
Note:
One brush per slip ring is sufficient to
monitor for ground faults. Two un-
used brushes can be used when
changing the brushes.
Copyright Siemens AG 2011 - All Rights Reserved
Siemens AG
BHEL,Haridwar ELR-6.2-0005-0209 / 2
Energy Sector 1011e
0114E
Exciter Fuses on Rectifier Wheel
Maintenance
Maintenance Intervals
Every 3 months
Every 6 months
Annually
Monthly
Weekly
Daily
Work Required
Fuse Monitoring
With the aid of the stroboscope, whose light fre- The position of the fuse indicator shows whether
quency is automatically controlled, it is possible to a fuse is intact or has blown due to diode failure. If
observe each separate fuse on both wheels. the colour-coded fuse indicator has taken a radial
To activate the stroboscope, press the ON push- position, the fuse has blown. To determine the con-
button. After pressing the pushbutton LAMP 1 or dition of the entire rectifier wheel, it is necessary to
know in which arm of the bridge each blown fuse
Copyright Siemens AG 2011 - All Rights Reserved
BHEL,Haridwar
Siemens AG ELR-6.2-0006-0209 / 1
Energy Sector 1011e
0114E
Exciter Fuses on Rectifier Wheel
Maintenance
2
Copyright Siemens AG 2011 - All Rights Reserved
BHEL,Haridwar
Siemens AG ELR-6.2-0006-0209 / 2
Energy Sector 0114E
1011e
Exciter
Components Manual
6 Maintenance
&RS\ULJKW6LHPHQV$*$OO5LJKWV5HVHUYHG
0DLQWHQDQFHDW6WDQGVWLOO,QVSHFWLRQ
Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU
Exciter General information
Inspection
Siemens AG
BHEL,Haridwar ELR-6.3-0001-0209
Energy Sector 1011e
0114E
Exciter Inspection Intervals
Inspection
Inspection
Major inspection
Intermediate in-
spection
Work Required
1 Dismantle exciter X
2 Check insulation resistance of windings X X
3 Replace fuses X
4 Check condition and performance of rectifier wheels, check stator and rotor windings X X
5 Check coupling flange X
6 Renew the lamination tapes X
Copyright Siemens AG 2011 - All Rights Reserved
7 Check alignment X
8 Check bearing and pipe insulation X X
9 Replace bearing and pipe insulation X
10 Check condition and performance of bearing pivoted segments X X
11 Check bearing surface and Babbitt bonding X
12 Check bearing clearances X
13 Check the hemispherical seat of the bearing shell in the bearing pedestal X
14 Check labyrinth rings and, if required, replace seal strips X
15 Check air filter and, if required, replace air filter X X
16 Check condition and performance of measuring devices X X
17 Check condition and performance of ground fault detection system X X
18 Check performance of stroboscope X X
19 Clean exciter coolers on water side X X
Dismantle exciter cooler, check on water and gas sides; clean, if required; replace gas-
20 X
kets and perform pressure tests
Note:
The operating times between the inspections correspond to these of the generator. If there are deviations
of the scope of inspection from the present generator manual, the requirements stated therein must be
observed.
Siemens AG
BHEL,Haridwar ELR-6.3-0002-0209
Energy Sector 1011e
0114E
Exciter Cooler
Inspection
You will find all necessary information about the In the case of a brief outage, it will mostly be suf-
maintenance work required on the cooler during the ficient to supply the coolers with a small water flow
standstill in the original cooler documentation. The and to flush them with the full water flow twice
instructions it contains must be observed and com- weekly.
plied with. In the case of a prolonged outage, the coolers
Suitable measures must be taken on all coolers should, however, be drained on their cooling water
taken out of service to prevent standstill corrosion in sides and dried.
the cooler tubes.
Copyright Siemens AG 2011 - All Rights Reserved
BHEL,Haridwar
Siemens AG ELR-6.3-0003-0209
Energy Sector 1011e
0114E
Exciter Bearing
Inspection
1 General
The manufacturer must be consulted if scoring is
The bearing-oil circulation must be started up found. It must be ascertained whether the bearing
once per week, and the entire circuit flushed with can continue to be used.
water-free oil. If the oil circulation is activated, the
rotor must driven by the turning gear. If a low insulation resistance has been meas-
ured, the particular bearing must be thoroughly ex-
amined for possible damage caused by cathodic
2 Inspection effects.
The insulation resistance of the insulated bearing The insulation of the bearing cradle must be
must be measured before each inspection. The cleaned, as otherwise the insulating properties
bearings must then be dismounted and cleaned could be impaired.
thoroughly. The bearing shells and shaft bearing
points must be checked to ensure that they are in
good working order.
Copyright Siemens AG 2011 - All Rights Reserved
Siemens
BHEL,Haridwar AG ELR-6.3-0004-0209
Energy Sector 1011e
0114E
Exciter Ground Fault Detection
Inspection
1 Maintenance Measures The mounting parts and the state of the hoses
The brushes of the ground fault detection system between fan and brush holder assembly have to be
should be removed to prevent the formation of rust checked. As required, replace these parts.
on the slip rings in cases where the generator or the The measuring slip-rings and insulating parts
exciter is shut down for more than 2 days. must then be cleaned with a lint-free cloth soaked in
In the case of a prolonged outage, a protective cleaning fluid (Rivolta or similar).
coating should be applied to the measuring slip It is recommended to change the carbon brushes
rings. in the plug-in brush holders of the rotor ground-fault
monitor after each inspection.
2 Inspection The carbon brushes used must match the con-
tour of the slip-ring. After the exciter set has been
Dust and dirt collected on the measuring slip-
assembled, the entire monitoring system must be
rings and the associated insulating parts, and in the
subjected to a functional test.
air duct of the brush holder assembly as far as the
air outlet, must cleaned out with a vacuum cleaner.
Copyright Siemens AG 2011 - All Rights Reserved
BHEL,Haridwar
Siemens AG ELR-6.3-0005-0209
Energy Sector 1011e
0114E
Exciter Make-up air duct filter
Inspection
The filters must be checked regularly for soiling, Place the filter mats in the water bath with the
and cleaned or replaced when necessary. dirty side down (the side that faces into the ma-
Lightly soiled filters should be carefully knocked chine). Then rinse the mats with clean water.
out or blown out with compressed air. Filters must
be blown out from the air intake side.
If this is not adequate, the filter mats must be
washed out. They are washed out in a water bath at
about 30 C, with neutral washing-up liquid added to
reduce the surface tension.
Copyright Siemens AG 2011 - All Rights Reserved
BHEL,Haridwar
Siemens AG ELR-6.3-0006-0209
Energy Sector 1011e
0114E
Exciter Checking the Insulation Resistance of
Inspection RR Wheels
Siemens AG
BHEL,Haridwar ELR-6.3-0007-0209
Energy Sector 1011e
0114E
Exciter Measurement of the Insulation Resis-
Inspection tance on the Rotor, Stator and Exciter
Set Windings
Stator:
The cables must be unscrewed from the terminal
board of the exciter stator.
Rotor:
The measuring brushes in the ground-fault mea-
suring device must be removed from the slip-rings.
The insulation resistances of the individual windings
must be measured against ground by a megger.
BHEL,Haridwar
Siemens AG ELR-6.3-0008-0209
Energy Sector 1011e
0114E
Exciter Insulation Test Report
Inspection
Checking the Insulation Resistances of Rotor 3. If the exciter rotor is not coupled, the ground fault
Windings in Sealed Packing monitor brushes are raised. The rotor winding is
The insulation resistance of the rotor winding connected by the measuring slip-rings which ha-
should be checked after shipment has been com- ve previously been temporarily bridged. The
pleted and at intervals of one month during any bridge must be removed after the measurement
subsequent storage period. The results should be has finished. If the rectifier wheels are accessi-
recorded in the table below. ble, the measurement can also be made there,
as the wheels have +/- potential. Here again a
Notes: bridge must be made.
1. The insulation resistance should be measured 4. All the necessary information about the proce-
with an insulation measuring device, applying a dure for coupled exciters can be found in the
voltage of 100 V, but not more than 250 V. present original generator manual.
2. Prior to each measurement, any static charges 5. After each measurement, any static charges
should be removed by grounding the windings as should be removed by short circuiting the wind-
a precautionary measure (10 minutes). ing through the rotor body (at least 20 minutes).
Date
Name
Company
Storage Area
Temperature in Storage
Area (C)
Relative Humidity of
Ambient Air in Storage
Area (%)
Rotor Temperature (C)
Moisture 50
Indicator in DE 40
Packing
30
blue or
pink? 50
NDE 40
30
Pressure of Nitrogen
Blanket (bar) (if required)
Measuring voltage (V)
15 sec
30 sec
Insulation Resistance (MOhm)
45 sec
1 min
2 min
3 min
4 min
5 min
6 min
7 min
8 min
9 min
10 min
BHEL,Haridwar
Siemens AG ELR-6.3-0009-0209
Energy Sector 1011e
0114E
Exciter Checking the Insulation for Protection
Inspection from Shaft Currents
Siemens
BHEL,Haridwar AG ELR-6.3-0010-0209
Energy Sector 1011e
0114E
Exciter
Components Manual
Special
Assembly Instructions
Copyright Siemens AG 2011 - All Rights Reserved
Siemens AG
BHEL,Haridwar
Energy Sector
Exciter Special Assembly Instructions
Assembly
1 Steady bearing
Until assembly, the exciter shaft is stabilized at
the drive end by a steady bearing. The steady bear-
ing must be dismounted before the RR air ventila-
tion housing can be mounted.
Steady bearing drawing 1-7701-434454b
Note:
The steady bearing cannot be dis-
mounted until the exciter has been
coupled to the generator.
3 Vibration Pickup
The customer should mount vibration pickups to
measure the vibration of the bearing housing and to
record the relative shaft vibrations.
The mounting points of the vibration sensors are
to be agreed with the customer. For more detailed
information about the sensor positioning see draw-
ing 2-7200-441853 in section 3.3 and drawing
4-447277 in section 3.5.
BHEL,Haridwar
Siemens AG ELR-10.0-0001-0209
Energy Sector 1011e
0114E