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JSC ELECTROSILA

HYDROGEN COOLING SYSTEM OF TBB-200-2T3 TURBOGENERATOR

Operation Instruction Manual 0.467.489

Saint Petersburg 2001

CONTENTS 1. 2. 3. 4. 5. 6. 7. 8. 9. INTRODUCTION.............................................................................4 APPLICATION................................................................................4 SYSTEM COMPOSITION...............................................................4 SYSTEM ARRANGEMENT AND OPERATION...............................5 INSTRUMENTATION....................................................................11 ARRANGEMENT AND MOUNTING.............................................12 INSPECTION OF THE COOLING SYSTEM COMPONENTS........15 SAFETY PRECAUTIONS..............................................................17 MAJOR OPERATING RULES........................................................21

10. PREPARATION FOR OPERATION...............................................18 POSSIBLE TROUBLES AND METHODS OF THEIR ELIMINATION...................................................................22 12. STORAGE AND TRANSPORTATION RULES..............................24 Figure 1. Turbogenerator shaft seals oil supply system principle diagram..............................................................................25 Figure 2. Turbogenerator -200-23 gas supply system principle diagram..............................................................................26 Figure 3. Turbogenerator -200-23 gas supply system principle diagram..............................................................................27 Figure 4. Electric pumping unit with AC motor.............................................28 Figure 5. Electric pumping unit with DC motor.............................................29 Figure 6. Oil cooler.............................................................................................30

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Hydrogen Cooling System of turbogenerator -200-2T3 Operation instruction manual

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Figure 7. Gauze filter.........................................................................................31 Figure 8. Magnetic filter...................................................................................32 Figure 9. Pressure regulator............................................................................33 Figure 10. Balance tank......................................................................................34 Figure 11. Hydraulic seal....................................................................................35 Figure 12. Oil trap................................................................................................36 Figure 13. Centrifugal fan...................................................................................37 Figure 14. Oil control branch pipe.....................................................................38 Figure 15. Sight branch pipe..............................................................................39 Figure 16. Evaporator..........................................................................................40 Figure 17. Gas control panel..............................................................................41 Figure 18. Starting oil pump panel...................................................................42 Figure 19. Position of valves of the gas supply system when operating at transients and with the system filled with hydrogen............43 Appendix (reference). List of components for Figure 1..............................................44 Appendix (reference). List of components for Figure 2 and 3...................................45

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1.

INTRODUCTION

The present Operation Instruction Manual is intended for the attendant personnel to make familiar with the construction of hydrogen cooling system for turbogenerator of TBB-200-2T3 type as well as with the rules of its operation and maintenance. 2. APPLICATION

The turbogenerator hydrogen cooling system (hereinafter referred to as the system) is designed to ensure the turbogenerator operation in compliance with its rated data (See the Turbogenerator Operation Instruction Manual). 3. SYSTEM COMPOSITION

3.1. The turbogenerator hydrogen cooling system consists of the following major units:

electric pumping units; hydraulic seal; oil coolers; gauze and magnetic filters; gas control panel; centrifugal fans; refrigerating units; evaporating devices (hereinafter referred to the evaporator); balance tank; pressure regulator; oil trap; instrumentation and piping valves.

3.2. Supplied together with the system are the spare parts listed in the List of spare parts, tools and accessories included into the set of service documents.

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4.

SYSTEM ARRANGEMENT AND OPERATION

The principle diagrams of hydrogen cooling system are shown in the Figures 1, 2 and 3. 4.1. The turbogenerator shaft seals oil supply system. To prevent the hydrogen escape from the generator housing, the ringtype oil seals are used on the rotor shaft. The seal oil under the pressure exceeding the pressure of hydrogen in the generator housing enters the clearance between the seal bush and rotor shaft and forms the continuous film preventing hydrogen escape from the generator. The greater part of oil, which has passed through the seals, is drained to the air side and only the lesser part to the hydrogen side. To supply oil to the seals from the turbine oil tank, the use in the system is made of the oil pumps: P1 operating pump, P2 standby pump and P3 emergency pump. Pumps P1 and P2 are equipped with AC electric motors, while pump P3 with DC electric motor. The suction piping of the oil pumps are connected with the clean compartment of the turbine oil tank. One of the oil pumps is continuously in operation. The automatic starting up of the standby and emergency oil pumps is accomplished on a pulse from the pressure transducers PS1 and PS2 installed on the pressure piping downstream the oil filters. When the electric motor of the operating pump P1 is out of operation or when the pressure in the pressure piping dropped by 0.15 MPa of the rated pressure specified during the system adjustment, the standby oil pump P2 comes into operation on a pulse from the first pressure transducer PS1. When the oil pressure drops by 0.25 MPa of the rated value or when both oil pumps are out of operation, the emergency oil pump P3 comes into operation on a pulse from the second pressure transducer PS2. The interruption in the electric pumping units power supply shall not exceed 20 s. From the oil pumps the oil is delivered to the oil coolers OC1 (OC2). Either one of the oil coolers or both oil coolers connected between themselves in series or in parallel may be in operation. After the oil coolers, mechanical cleaning filter F1 (F2), magnetic filter F the oil under the specified pressure the value of which is maintained with the help of pressure regulator PR, via the balance tank DT enters the annular clearance between the generator shaft and seal bushes. Provision is made in the diagram for the installation of the balance tank. When changing-over from one oil pump to the other and during the shortterm malfunctions in the oil supply system due to the cessation of oil supply from the oil pumps, the oil from the balance tank is supplied to the generator shaft seals. The pressure of oil, which is in this case is supplied to the shaft seals, is specified by both the height of the balance tank installation and the pressure of gas in the generator housing.
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During the normal operation of the system the oil shall be at the level of piping above the balance tank. The visual control of the oil level is accomplished with the help of sight branch pipes SBP1SBP4. Mounted on this piping is the special valve SV preventing the possibility of siphon action during the oil overflows from the balance tank in case the oil-to-hydrogen pressure drop exceeds the permissible limit. The blow-off pipe DN15 with valve V2 is cut into the upper part of antisiphon pipe of the balance tank. The balance tank is connected in series to the oil pressure piping, thus providing the continuous circulation of oil delivered to the generator shaft seals. To control the oil level in the balance tank, the level detectors LD1LD4 are installed on the pipings. The oil level protection is accomplished as per two of two circuit. The upper level indicators recording the oil level drop in the pipings above the balance tank are the warning level indicators, while the lower level indicators are the emergency ones. Both signals arrive to the unit control board of turbogenerator. At the operation of two balance-tank level indicators (upper and lower), the turbogenerator will automatically stop with vacuum breaking in the turbine. In this case, the hydrogen pressure inside the generator shall be decreased to the atmospheric pressure with changeover to the carbon dioxide by an operators command from the unit control board should the pressure of the seal oil be not restored in two minutes after the protection has operated. The oil, which flows out from the seals to the hydrogen side, is carried along the oil pipings to the float-type hydraulic seal HS. To control the oil drainage from the seals to the hydrogen side, the oil control branch pipes OCBP1 and OCBP2 are provided for on the drain oil pipings. These oil control branch pipes are installed at the turbogenerator elevation. The U-shape loop 500 mm in height which prevents hydrogen circulation through the float-type hydraulic seal, caused by the fact that the rarefaction created by the fans on both sides of the generator rotor practically can not be the same, is provided on the drain oil piping at the turbine end. Hydraulic seal HS ensures the oil drainage to the common oil drain header, thus preventing the hydrogen escape from the generator housing. The hydraulic seal is made as a tank into which the float-type level regulator providing the oil drain when its level exceeds the rated one (approximately the middle of the upper sight glass) is fitted in. The annunciation about the extreme levels of oil in the hydraulic seal is accomplished by means of level detectors. The oil level is visually controlled using the sight glasses of the hydraulic seal. The oil from the shaft seals is drained to the air side to the common oil drain header.

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To control visually the oil pressure for each pump, the circuit provides for the pressure gauges PG6PG8 at the pressure mains as well as the compound pressure-vacuum gauges VPG1VPG3 at the suction mains. Furthermore, installed in the oil supply system are the pressure gauges for measuring the oil at the PG4 inlet and PG3 outlet from the pressure regulators as well as the pressure gauges PG1 and PG5 on the shaft seals. To control the oil-to-hydrogen pressure drop value with the emergency drop signal output to the unit control board, the Designer shall provide for the installation of the pressure drop transducer. When passing through the seals, the oil comes in contact with the air and hydrogen and is capable of absorbing these gases as well as to evolve them when flowing along the pipings. The large cross section of the drain pipings and oil header contribute to the hydrogen and air to evolve from the oil. The gas volumes of the drain oil header and drain oil pipings are ventilated by means of centrifugal fan CF1. The exhaust piping of this fan is cut into the exhaust pipe DN150 brought out to the roof of the TPS powerhouse. The check valve CV1 preventing the possibility of gas circulation from the exhaust pipe DN150 to the drain header is mounted on the exhaust pipe. The gas volume of the turbine oil tank is vented by means of fan CF2. To avoid the accumulation of explosive mixture in any of the above mentioned gas volumes, the fans shall be continuously in operation. Upstream the fan CF1 installed is the oil trap OT, which is the tank inside which the lateral tapered partitions are fitted. The oil vapours settle on the partitions, the oil accumulates in the lower part of the oil trap and is drained outwards via the drainage cock.

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4.2. The turbogenerator hydrogen cooling system. This system ensures the possibility of filling the generator with hydrogen, carbon dioxide or air as well as of maintaining the rated pressure and replenishing the hydrogen leaks inevitable during the generator operation. For the safe filling of generator with hydrogen and for hydrogen displacement from the generator prior to the generator filling with air, the use is made of carbon dioxide. Hydrogen and air are supplied to the generator housing via the headers located in the generator-housing top. Carbon dioxide is supplied to the generator housing via the header located in the generator-housing bottom. The headers used for the hydrogen and carbon dioxide supply are connected with the gas control panel by means of gas pipings. The pipings of the hydrogen and carbon dioxide centralised supply from the receivers as well as the piping of the dry compressed air supply are connected to the gas control panel. The pressure gauges used to control the pressure of gas inside the generator housing and in the hydrogen and carbon dioxide mains are installed in the gas control panel. The safety valve SV designed to prevent the increase of pressure inside the generator housing above the maximum value by 0.03 MPa is also mounted in the gas control panel. In the gas control panel the pipings for the hydrogen and carbon dioxide removal from the generator housing are joined by the common pipe venting the gas to the atmosphere. In this connection, two valves V3, V4 and V5, V6 are installed in series on each of these pipings available in the gas control panel. The control valves V8 and V9 for gas sampling to make the analysis (the analysis of gas taken from the generator top and bottom points) are installed between the valves V3, V4 and V5, V6 at the branch pipe. On the hydrogen line which supplies generator with hydrogen from the mains piping as well as on the line of the compressed air centralised supply the removable jumper used to make the visible break in the piping is provided for in the gas control panel in compliance with the requirements of safety regulations. To dehumidify hydrogen in the generator housing, the cooling method with the application of the refrigerating unit is used. The hydrogen dehumidification installation by the cooling method consists of the refrigerating unit RU, evaporating device E (hereinafter referred to as the evaporator) and the thermoregulating valve TRV. The principle of the dehumidification installation operation consists in cooling the small part of hydrogen circulating in the generator to a condensation point of the basic part of water vapours available in hydrogen. Hydrogen is cooled in the evaporator which is the coil heat exchanger whose principle of operation is described in the corresponding Evaporator Operation Instruction Manual included into the set of service documents. The resistance
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temperature detectors RTD1 and RTD2 for gas temperature control in order to regulate the hydrogen flow rate through the evaporator and to choose the optimum duty of the installation operation are placed at the hydrogen inlet to and outlet from the evaporator. The hydrogen flow rate through the evaporator is controlled by the valve, while the refrigerating unit operation duty is chosen by adjusting the thermoregulating valve TRV. The temperature of hydrogen leaving the evaporator shall be within 0 to +10 0C. The water is drained from the evaporator once 24 hours. When the temperature of hydrogen leaving the evaporator is higher than +10 0C, the refrigerating unit shall be disconnected from the system, having shutoff the valves at the inlet and outlet, for the evaporator thawing. To drain the liquid (water or oil) in case of its penetration into the generator housing and terminal box, provision is made in the circuit for the drainage pipelines, one of which is connected to the lower point of the carbon dioxide header, while two other pipelines are brought out of the stator outer shields. The level detectors giving the relevant signal about the liquid penetration into the generator housing to the unit control board are installed in the lower points of the above mentioned pipelines. To visually control the presence of liquid in the drainage pipelines, the sight branch pipes are installed in the drainage pipelines. The hydrogen purity in the turbogenerator housing is controlled by means of the automatic gas analyzer mounted on the gas control panel. From the generator housing the analyzed gas mixture, passing along the piping via the pressure reducer PR, fine-adjustment valve PRV and flow rate indicator FRI, enters the gas analyzer GA1, and having passed through the gas analyzer is vented to the atmosphere. The discharge to the atmosphere of the spent hydrogen sample as well as of the gas from the generator housing during transients shall be accomplished into the special vent duct separated from the housing common ventilation. During the generator operation and short-term shutdowns the purity control of hydrogen inside the turbogenerator housing may be accomplished by means of chemical analysis. The leaks of hydrogen in the current leads enclosure, in the neutralterminal box, in drain chambers of the shaft seals from the air side, in the noise-protection enclosure as well as in the stator winding water cooling system are performed with the help of stationary gas analyzers. The gas analyzers are installed in the vicinity of the generator. Each gas analyzer automatically samples the gas mixture for analysis alternatively from four points. The separators are mounted to catch the oil vapours from the gas sampled for analysis from the drain chambers of the shaft seals on the air side.

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4.3. Signalling. To signal the failures in the generator hydrogen cooling system, the provision shall be made on the unit control board (UCB) by the Design organization for the operation of the following light-audible signals received from the signalling instruments and devices: abnormal oil-to-hydrogen pressure drop; low oil level in the balance tank; emergency oil level in the balance tank; low pressure of cooling water; abnormal hydrogen pressure; high oil level in the hydraulic seal; low oil level in the hydraulic seal; low hydrogen purity; high content of hydrogen in the air; liquid in the generator housing; centrifugal fan emergency shutdown; gas coolers pumps emergency shutdown; oil pump emergency shutdown; automatic starting up of the standby pumps of gas coolers; automatic starting up of the standby oil pumps.

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5.

INSTRUMENTATION

5.1. The pressure gauges control the pressure of oil in the shaft seal oil supply system. The oil pressure at the suction pipings of the oil pumps is controlled by the compound pressure and vacuum gauges. 5.2. The pressure of gas in the generator housing both during operation and at transients is controlled by the pressure gauges mounted at the gas control panel. 5.3. The pressure of hydrogen in the generator automatically controlled by the pressure transducer PS. housing is

5.4. The purity of hydrogen inside the generator housing, with the annunciation of the parameter limit value, is automatically controlled by the gas analyzer installed at the gas control panel. 5.5. The annunciation about the limit levels of oil in the hydraulic seal and balance tank as well as about the presence of liquid in the generator housing is performed by the level transducers-relays the primary sensor of which is installed at the pipings or components, while the transmitting transducer at the unit control board panel. 5.6. The content of hydrogen in the enclosures of the shielded current leads, in the shaft seal sumps on the generator air side, in the neutralterminal box, in the noise-protection enclosure, in the stator winding water cooling system is controlled by means of stationary gas analyzers. 5.7. The temperature of oil leaving the oil coolers and at the oil inlet to the seals is controlled with the aid of the resistance temperature detectors.

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6.

ARRANGEMENT AND MOUNTING

6.1. The generator hydrogen cooling system components are arranged in conformity with the Design organization technical documents worked out according to the requirements described in the present Operation Instruction Manual. 6.2. The gas pipings and oil pipings shall be mounted in full conformity with the factory drawings. 6.3. An easy access for the mounted gas piping examination and repair shall be provided for. 6.4. All the piping of the gas system as well as of the turbogenerator shaft seal oil supply system shall be made of the steel seamless pipes and shall be reliably fastened. 6.5. During mounting the connection of the gas piping shall be performed by welding; where possible, the flange connections shall be excluded. The number of flange connections in the generator shaft seal oil supply system shall be minimum and shall be defined from the possibility of controlling the pipes inner surface cleanness as well as of conducting the inspection and repair on the equipment mounted on these piping. The bosses and pipe unions for the instruments shall be cut into the previously assembled oil piping. The welded joints of the previously cleaned pipes shall be made with the argon-arc welding without backing rings. No cuttings-in and welding-in on the assembled piping are allowed to be performed. 6.6. After the preliminary assembly the oil piping shall be disassembled, cleaned and handed over to the chemical shop, with the flanges plugged. 6.7. All the portions of the drain piping shall have no loop configuration and shall be sloped by 20 as minimum in the direction of drain. 6.8. When the oil supply system operates with the use of turbine oil, the flange connections on the pressure piping shall be packed with the oiland benzine-resistant rubber gaskets 2.0 mm in thickness, while on the drain piping with the oil- and benzine-resistant rubber gaskets 2 mm to 3 mm in thickness. 6.9. When cleaned and accepted by the chemical shop, the pressure piping shall be assembled and tested with turbine oil at a pressure of 1.6 MPa applied for 30 minutes. The level transducers-relays shall be disconnected. Initially test the drain oil piping of the shaft seals oil supply system for leakproofness with a pressure of 0.8 MPa applied for 30 minutes. There shall be no leaks in the oil piping. 6.10. Prior to assembly clean all the gas piping by purging them with steam or dry compressed air.

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6.11. The flange connections of the gas piping are packed with a oiland benzine-resistant rubber 2 mm to 3 mm in thickness. 6.12. All the portions of the gas system shall have no loop configuration and shall be sloped by 2 as minimum to provide the drain of liquid which may be condensed in the pipes via the drain valves installed in the lowest points of the gas piping. If you cant avoid the loop configuration of the piping (as for example, when laying the pipes to the gas control panel), the drain valves shall be placed on these piping loops and shall be arranged in the places with an easy access for maintenance. 6.13. Prior to installing, all the valves of the gas system are tested for leakproofness with an air pressure of 0.8 MPa, being submerged into water. If there is no air leak, the valves are considered to be gas-tight. The housing, the sump and the sealing surface of the valve shall be subjected to the test. All the valves shall be mounted in the places accessible for maintenance and inspection during operation. 6.14. When the mounting of the gas system is over, the system is tested for leakproofness with an air pressure of 0.8 MPa; in doing so, the generator housing with the carbon dioxide header as well as the pulse tubes of the instruments are disconnected and the hydrogen and carbon dioxide lines, the drain piping and evaporating devices shall be joined by means of temporary jumpers. In this case the leaks are located with the help of soap solution or haloid leak detector. The gas system is considered to be leakproof if at an air pressure of 0.8 MPa the pressure drop in the system during one (1) hour does not exceed 0.66 kPa. 6.15. Perform the gas leakage test of the instrument pulse tubes separately from the gas system. The requirements for the gas tightness of the above mentioned tubes are the same as for the rest of the gas-system gas piping. The gas leakage test of the carbon dioxide header is conducted during the stator casing pressure test or in the course of the final leakage test on the whole generator together with the gas-oil system. 6.16. Install the oil pressure drop regulators strictly vertically at the generator elevation in order to exclude slide valve friction in the box. 6.17. Cut the pipe DN20, connecting the piping DN25 of the regulators PR gas feedback with the seal oil drain piping DN65 at the exciter end, into the upper part of the piping DN65 horizontal portion in the vicinity of the generator shaft seal. 6.18. Mount the balance tank along row A opposite the generator. The piping running between the balance tank and the generator shaft seals shall be as short as possible. The platform for maintenance shall be done near the balance tank. 6.19. Set the primary transducers of the level detectors LS2, LS4 so that the level of the detectors operation is 60 mm to 70 mm lower than the upper edge of the balance tank housing.
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6.20. For ease of operation, arrange the valves V5, V13, V21, V29, V30 and pressure gauges PG3, PG4 in the immediate vicinity of the pressure regulator. 6.21. Place the pressure gauges PG1, PG2 on the pressure piping at a length of no more than 1 m from the seal body after the insulating branch pipe. 6.22. Mount the oil pumps in the immediate vicinity of the oil tank. The suction piping shall be as short as possible and shall have minor number of elbow pipes. The abrupt changes in cross sections as well as the sharp elbow pipes are not admitted. 6.23. Connect the suction pipes of the oil pumps to the clean compartment of the oil tank. 6.24. Drain the oil from the hydraulic seal of the oil pump gland into the turbine oil tank using the pipe of at least DN20. 6.25. Valves V3 and V4 are used to purge the gas volume of the shaft seals. 6.26. Install the pipes DN80 running from the fans CF1 and CF2 in the exhaust pipes DN150 so that the axis of the pipe DN80 end part and the axis of the exhaust pipe DN150 are in coincidence. 6.27. Install the oil filters in the immediate vicinity of the pressure regulator. 6.28. Install the oil control branch pipes at the generator elevation. For ease of inspection, the branch pipes shall be fitted out with the electric illumination made with the use of lamps of explosion-proof design. 6.29. Weld the flanges of the level detector-relay primary transducer separately from the housing of the transducers, having ensured the deviation from their alignment to be no more than 1 mm. 6.30. Perform the gas sampling for the chemical analysis as well as for measuring the humidity through the valves V8, V9, V33, V34 (see Figure 2, 3). 6.31. When performing the filling-in and during the system operation with the use of hydrogen, the visible break (air gap) on the air supply line in the gas control panel shall be made by withdrawing the removable jumper. 6.32. Arrange the refrigerating units in the immediate vicinity of the generator (at a distance of no more than 6 m) in the place not subject to vibration. Using the thermal insulation, insulate the evaporating devices and the parts of hydrogen pipes connected to it at a length of 1 m.

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7.

INSPECTION OF THE COOLING SYSTEM COMPONENTS

When mounting or during the overhaul the following components of the cooling system shall be subject to inspection: electric pumping units; shutoff valves; balance tank; float-type hydraulic seal; oil and magnetic filters; pressure regulator; oil coolers.

7.1. The electric pumping units are inspected in compliance with manufacturing-plant Instruction Manual. 7.2. The shutoff valves of the oil piping shall be inspected in the following order: unscrew the bolts and remove the valve cover; check the connection of the slide valve with the valve stem; the slide valve shall be reliably connected with the valve stem; remove the dirt, rust and foreign matter from the valve housing; assemble the valves and install them vertically, and then in position Closed fill them with kerosine from the inlet side. Note. The valve is considered to be fit for operation if the kerosine does not penetrate into valve cavity from the outlet side. 7.3. When inspecting the balance tank, it is necessary: to remove the covers on the access (inspection) hatches arranged on the end parts of the tank bottom; to check for the absence of foreign matter and dirt inside the tank housing; to install the covers into their places. 7.4. The inspection of the float-type hydraulic seal shall be conducted in the following sequence: remove the float-type level regulator; check the inside of the tank housing for the absence of rust and foreign matter; withdraw the lock screw installed for the period of the hydraulic seal transportation from the level regulator; check manually the stroke (movement) of the lever with the float from the extreme lower position to the upper position as well as from the upper position to the lower one, in doing so, the lever shall move freely without binds.
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Note: Check the hydraulic seal for leakproofness when pressurization the generator. 7.5. The inspection of the oil filter shall be conducted in the following sequence: remove the cover, unlock the washers, unscrew the bolts and withdraw the unit of filter elements; disassemble the unit of filter elements for the separate filter elements; wash the inner cavity of the housing, the cover and filter elements with a washing solution of the following composition (per 1 l of water): 50 g of caustic soda, 30 g of soda ash, 50 g of trisodium phosphate, 50 g of water glass at a temperature of 80 to 90 0C. Wash the filter elements using the hair brush. When the housing is washed with a washing solution, wash the cover and filter elements with hot water (80 to 90 0C) and purge them with dry compressed air; assemble the unit of filter elements, check the tightening of the nuts in the unit of filter elements for tight fitting of the filter elements to each other. The 0.02 mm feeler gauge shall not pass through in the place where the inner casings of the filter elements fit each other along the whole circumference; check the condition of the gaskets and fasteners; assemble the filter as follows: install the unit of filter elements, place the disc, screw up the bolts, lock them with washers, close the cover. 7.6. The inspection of the magnetic filter shall be conducted in the following sequence: remove the cover; screw the eye-bolt into the tapped hole of the magnet-unit grid and withdraw the magnet unit from the housing and then place it onto the clean nonmagnetoconductive surface (for example, onto the wooden boards); screw out the eye-bolts, install the magnet unit with its magnets upwards; clean the surface of the magnets from the adhered ferromagnetic particles. It is necessary to bear in mind that the magnets in the magnet unit are assembled so that each row of magnets has the unlike polarity; install the cleaned magnet unit into the filter housing, install the filter cover. 7.7. Inspect the pressure regulators and oil coolers in compliance with the Operation Instruction Manuals for the corresponding devices, included into the set of service documents.

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8.

SAFETY PRECAUTIONS

8.1. At the electric power stations equipped with the hydrogen-cooled generators one should be guided by safety regulation applicable to the power engineering. 8.2. The hazard of the explosive mixture formation may occur: In the generator housing: when there is no hydrogen purity control and at the severe contamination of hydrogen with air released from the oil; when the generator is not completely purged with carbon dioxide prior to its filling with hydrogen; when hydrogen penetrates the generator filled with air (due to the leaky valves at the gas control panel and when there is no visible break in the hydrogen piping).

In the oil system equipment and pipes: when hydrogen is contaminated with air released from the oil in the hydraulic seal at the high flow rate of the seal oil to the hydrogen side, and when there are no purgings; when air is contaminated with hydrogen released from the oil in the drain oil pipes of the shaft seals, with no required ventilation available. 8.3. To avoid the formation of the explosive mixtures, one should strictly observe the regulations on the generator gas-oil system operation.
8.4. During the generator operation check the content of hydrogen in the generator shaft seal sumps at least once 24 hours. When hydrogen in the quantity of more than 1 % is detected to be present in these sumps, purge them with carbon dioxide and eliminate the causes of the hydrogen penetration.

8.5. The information on the other measurable quantity control is given in the Generator Operation Instruction Manual.

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9. 9.1.

PREPARATION FOR OPERATION Oil pumping in the oil supply system.

When the mounting or overhaul of the oil supply system is over, the oil pipes shall be pumped using the turbine oil. Prior to performing the pumping, it is necessary: to disconnect the pipes from the generator shaft seals, balance tank, oil pressure regulator, oil coolers and hydraulic seal; to install the temporary jumpers onto the disconnected ends of the pipes. In doing so, connect the pipes of the oil supply to the generator shaft seals with the drain pipes using the jumpers. The requirements for the jumper inner surface cleanness are the same as for the manufacture of the basic oil pipes. The pumping shall be performed by alternately using all the pumps of the shaft seals oil supply system. The oil temperature shall be at least 40 0C. The duration of the oil system pumping is at least 48 hours. The pressure of oil in the system during pumping is at least 0.9 MPa. The system is considered to be washed if the oil pressure drop across the filters remains practically constant. 9.2. Prior to starting the generator it is necessary: a) to test-operate the oil pumps; b) to test the reliable automatic starting up of the standby oil pumps; Check the circuit of the automatic starting up of the generator shaft seals standby oil pumps for reliable operation in the following way: stop the oil supply from the operating oil pump; in this case, the standby oil pump comes into operation on a current signal from the pressure transducer; by partially closing the valve on the pressure piping of the operating pump reduce the pressure in the system up to a value of the operate current setting of the second pressure transducer; in doing so, the emergency oil pump comes into operation; disconnect the power supply of the standby oil pump electric motor, in doing so, the emergency oil pump comes into operation. c) to check the operation of the whole signalling system; To check the operation of the whole annunciation system: check the signal High oil level in the hydraulic seal and signal Low oil level in the hydraulic seal by filling the oil into and draining the oil from the hydraulic seal;

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 check the signal Liquid in the generator housing by filling the drain piping with the level detector-relay mounted on it with turbine oil; check the signals about the change of oil levels in the balance tank by emptying the tanks; check the signal Oil pump emergency shutdown when conducting the test operation of the circuit of automatic starting up of the standby oil pumps; check the signal Low purity of hydrogen in compliance with the technical documents for the gas analyzer. d) to adjust all the instruments of the system in compliance with the Instructions attached; e) to adjust the oil pressure regulator. Adjust the pressure regulator without sealing bearings, for which purpose it is necessary: to disconnect the pressure oil piping portion running after the feedback line of the regulator under adjustment and to install at this portion the temporary jumper (flexible hose or steel pipeline) with the valve and pressure gauge and to connect this jumper with the drain oil piping; to place the temporary plugs with the gaskets on the pressure oil piping at the exciter end, on the branch pipes of oil drain from the shaft seals to the hydraulic seal. Then the adjustment shall be performed in compliance with the requirements of Pressure Regulator Operation Instruction Manual included into the set of service documents. Generator transfer to the hydrogen displacement.
9.3.

cooling and hydrogen

The generator shall be transferred to the hydrogen cooling only when the generator together with the gas-oil system is tested for leakproofness. The transfer to the hydrogen cooling shall be accomplished at the generator stopped or at the generator operating without excitation at noload. The hydrogen discharge under emergency shall be begun during the generator rundown. The transients (the process of the generator transfer to the hydrogen cooling or air) shall be performed at a pressure of gas inside the generator within 0.015 to 0.02 . Prior to beginning the transfer, provide the oil supply from the shaft seal via the oil pressure regulator.

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a) Displacement of air from the system with carbon dioxide. The system is filled with carbon dioxide from the central piping of the station gas supply mains via the gas control panel. The pressure measured by the pressure gauge mounted on the carbon dioxide header shall be no more than 0.3 MPa. The air shall be vented to the atmosphere. Prior to supplying the carbon dioxide to the generator, the compressed air supply piping shall be disconnected, having thus made the visible break (air gap) in this piping. The visible break in the piping of the hydrogen supply from the receiver to the gas control panel shall be also made. When performing the filling with carbon dioxide, the samples for the carbon dioxide content shall be taken from the valve V8 mounted on the hydrogen header of the gas control panel. When taking the gas samples from valve V8, valve V4 shall be closed. The generator filling with carbon dioxide is considered to be completed if the sample contains at least 85% of carbon dioxide. b) Displacement of carbon dioxide from the system and filling the system with hydrogen. The system is filled with hydrogen from the central piping of the station mains, in doing so, the pressure upstream the valves at the inlet to the gas control panel shall not exceed 1.0 MPa measured by the pressure gauge mounted on the hydrogen header of the gas control panel. From the beginning and till the end of the generator filling with hydrogen the samples of gas shall be taken for chemical analysis in order to determine its percentage from the valve V9 on the gas control panel, having previously closed valve V5. The displacement of carbon dioxide with hydrogen is considered to be completed if the hydrogen percentage in the sample amounts to at least 98%, whereupon the pressure of hydrogen in the generator housing shall be increased to the rated one. When the generator is filled with hydrogen, purge the gas volumes of the float-type hydraulic seal, pulse lines of all pressure gauges, detectors and gas analyzers. The gas analyzer used to control the purity of hydrogen in the generator housing shall be switched on and the readings of this analyzer shall be checked against the data of the sample taken for chemical analysis. The position of the valves at transients is shown in Figure 19.

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10.

MAJOR OPERATING RULES

10.1. The position of the valves during the generator operation with the system filled with hydrogen is shown in Figure 19. 10.2. The hydrogen inside the generator housing shall have the purity and humidity specified in the Generator Operation Instruction Manual. 10.3. If the purity of hydrogen inside the generator housing decreased below 98%, the generator shall be purged with pure hydrogen. The purging is accomplished manually by opening the valves on the line of hydrogen supply and on the line of gas discharge from the carbon dioxide supply header of the gas control panel. 10.4. Maintain the pressure of hydrogen inside the generator housing and the pressure of oil at the shaft seals in compliance with the requirements of Generator Operation Instruction Manual. 10.5. When the generator filled with hydrogen is in operation, make a visible break in the air supply piping. When there is air inside the generator housing, the visible break shall be made in the hydrogen supply line. To meet these requirements, provision is made in the gas control panel for the corresponding removable branch pipe. 10.6. Generator transfer from the hydrogen cooling to air. At the generator scheduled stopping or at the failures requiring the generator stopping and opening, remove hydrogen from the generator housing and fill the housing with air. Perform this operation in the following sequence: a) When transferring the generator from the hydrogen cooling to air, displace hydrogen with carbon dioxide. In doing so, decrease the hydrogen gauge pressure from the rated value to 0.0150.02 MPa. The rate of the gauge pressure decrease is no more than 0.1 MPa per hour, except for in an emergency. b) The process of hydrogen displacement with carbon dioxide shall be similar to the process of air displacement described in it. 9.3.a. The displacement is considered to be completed if the generator contains at least 98% of carbon dioxide. c) The carbon dioxide displacement shall be accomplished by the supply of pure dry compressed air (with air relative humidity of no more than 40%) to the generator. Take the samples for chemical analysis from the valve V9 in the gas control panel (in doing so, valve V5 shall be closed). The gas displacement is considered to be completed if the chemical analysis shows the total absence of carbon dioxide.
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11. Table 11-1

POSSIBLE TROUBLES AND METHODS OF THEIR ELIMINATION

Trouble

Possible cause

Methods of elimination (remedy) Purge the generator with fresh hydrogen until the hydrogen purity is at least 98 %. Eliminate the leaky places in the oil piping at the pump suction line. Locate the gas leakage and tighten the leaky place.

Increased flow rate of oil in Decrease of the shaft seals to the hydrogen purity in hydrogen side. the generator Air inflow to the oil piping at housing. the pump suction line.

Close the valve V18 (Figure 1). Fill the tank of the hydraulic seal with Failure of the gas system oil to the middle of the sight glass Drop of hydrogen leakproofness. after which half-open the valve V17, pressure in the When in position Closed, adjust the flow rate through this generator housing. the oil level regulator in the valve so that the oil level in the hydraulic seal is leaky. tank of the hydraulic seal remained constant. During the next shutdown of generator remove hydrogen, open the hydraulic seal and eliminate the trouble. Switch off the turbine overspeed governor, decrease immediately the hydrogen pressure and, not waiting for the turbogenerator set Emergency drop of oil pressure in the Failure in the shaft seal unit to come to a full stop, begin the displacement of hydrogen from the seals, which results operation. generator housing. When the in the oil film break, generator is transferred to air, open in the bush babbitt the seal body and eliminate the melting out; low trouble. level of oil in the balance tank. When the generator is transferred Oil pumps failure. to air, find out and eliminate the cause of the oil pumps failure. Failure in the shaft seal unit operation (oil has penetrated into the See the method of the trouble generator housing). Liquid in the elimination in the Turbogenerator generator housing. Failure of the leakproofness Operation Instruction Manual. of the gas cooler tubes (water has penetrated into the generator housing).

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Table 11-1 (continued)

Trouble Possible cause Methods of elimination (remedy) Put the standby hydraulic seal into level operation. At the nearest possibility find and eliminate the hydraulic seal trouble.

Increase of oil level in Failure of the hydraulic seal. regulator.

the

Eliminate the failure in the power The centrifugal fan is The electric motor power supply circuit of the faulty fan out of operation. supply circuit is open. electric motor.

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12.

STORAGE AND TRANSPORTATION RULES

The storage, preservation, depreservation and transportation rules for the system equipment are specified in the Instruction for Transportation and Storage of Electrical Machines and Equipment .458.000 included into a set of service documents.

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Appendix (reference) List of components for Figure 1

Name Designation Q-ty Note

DT PS1, PS2 HS V1V6 V7V10 V11V15 V16V22 V23V25 V26V43 V44V46 C CV1 CV2CV5 SV1 PG1, PG2 PG3 PG4PG8 VPG1VPG3 OC1, OC2 OT P1, P2 P3 OCBP1, OCBP2 SBP1SBP5 PR LS1LS4 RTD1RTD3 OF1, OF2 MF CF1, CF2

Damper tank Pressure sensor 0-1.6 Hydraulic seal Bellows-sealed valve DN15 Stop valve DN25 Bellows-sealed valve DN25 Stop valve DN50 Bellows-sealed valve DN50 Stop valve DN80 Stop valve DN150 Pressure gauge cock Check valve Check valve DN80 Special valve Pressure gauge scale 0-600 Pressure gauge scale 0-1.0 Pressure gauge scale 0-1.6 Vacuum pressure gauge scale 100-0-300 Oil Cooler Oil trap Electric pump unit with AC motor Electric pump unit with DC motor Oil control branch pipe Sight branch pipe Pressure regulator Level sensor Resistance temperature detector Oil filter Magnetic filter Centrifugal fan

1 2 1 6 4 5 7 3 18 3 13 1 4 1 2 1 5 3 2 1 2 1 2 5 1 4 3 2 1 2

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Appendix B (reference) List of components for Figure 2 and 3

Name SCU1SCU7 PRV GA1 GA2,GA4 PS E1, E2 FRI V1, V2, V25, V45V47 V3V6, V22 V24,V26,V28 V30V32, V37 V48V51, V44 V7V21, V27 V33V36, V29 V38V43 CT1CT3 SV PG1, PG3 PG2, PG4 SD1SD3 SBP1SBP3 GD1GD3 PR LS1LS3 S1, S2 TV1, TV2 RTD1RTD4 RU1, RU2 Designation Sample conditioning unit Precise regulation valve Gas analyzer Gas analyzer Pressure sensor 0-0.63 Evaporator Flow rate indicator Bellows-sealed valve DN25 Bellows-sealed valve DN50 Q-ty 7 1 1 3 1 2 1 6 18 Note

scale 90-100% 2 in air scale 0-3% 2 in air

Bellows-sealed valve DN15 Condensate-tapper Safety valve Pressure gauge scale 0-1.0 Pressure gauge scale 0-1.6 Sample drier Sight branch pipe Gas distributor Pressure regulator Level sensor Separator Thermoregulating valve Resistance temperature detector Refrigerating unit

27 3 1 2 2 3 3 3 1 3 2 2 4 2

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