STATOR WATER SYSTEM

ONE OF THE EFFICIENT WAYS OF TAKING AWAY THE LOSSES

FROM THE WINDINGS OF ANY ELECTRICAL MACHINE IS BY
DIRECT COOLING USING WATER.

EQUIPMENTS INVOLVED IN THE STATOR WATER SYSTEM

EXPANSION TANK

STATOR WATER PUMP

STATOR WATER COOLERS

STATOR WATER MECHANICAL FILTERS

STATOR WATER MAGNETIC FILTERS

POLISHING UNIT

GAS TRAP
 STATOR WATER SYSTEM HEADERS

OUTLET INLET
HEADER HEADER
STATOR WATER TO BUSHING LEADS
 QUALITY OF THE DISTILLATE
CONDUCTIVITY < 5 MICRO MHO, PREFERABLY
< 1 MICRO MHO
PH 6.5 TO 8.5
DISSOLVED OXYGEN MINIMUM, PREFERABLY LESS THAN 100 PPB
DISSOLVED CO2 NIL
AMMONIA MINIMUM, PREFERABLY ZERO
CHLORIDE MINIMUM, PREFERABLY ZERO
DISSOLVED/UNDISSOLVED CU < 20 PPB
DISSOLVED/UNDISSOLVED FU < 20 PPB
DISSOLVED SOLIDS THE WATER SHOULD BE FREE OF
ANY CHEMICALS FROM TREATMENT
PROCESS,SUCH AS HYDRAZINE,
MORPHOLINE,LEVOXINE,PHOSPHATES
 THE EXPANSION TANK
THE EXPANSION TANK IS A HERMETICALLY SEALED CONTAINER MADE
OF STAINLESS STEEL.

THE DM WATER FROM THE STATOR WINDING OUTLET HEADER

DISCHARGES IN TO A SECTION OF THE TANK THROUGH PERFORATED
PIPE.

THE TANK IS UNDER A VACUUM OF 250-300MM OF MERCURY.

THE TANK IS CLEANED DURING ANNUAL MAINTENANCE.

THE FLOAT VALVE OPERATION IS CHECKED BY HAND FOR SMOOTH

AND EASY OPERATION FROM ONE EXTREME LOWER POSITION TO
EXTREME TOP POSITION.

THE FLOAT IS CHECKED BY DIPPING IN WATER FOR 1 HOUR AT A

TEMPERATURE OF 60 DEGREE CENTIGRADE

THE HEALTHINESS OF THE TRANSDUCERS ARE CHECKED.

ALL THE JOINTS ARE CHECKED FOR ANY LEAK.

 EXPANSION TANK

WATER
INLET TANK
GAS OUT LET
FROM
WINDING COVER

LINE
TRANSDUCER REGULATOR
LEVEL
GAUGE

RIB
D
R
A
I
N

WATER
OUTLET TO
PUMPS
 STATOR WATER PUMP
STATOR WATER PUMPS ARE SINGLE STAGE CENTRIFUGAL
TYPE SPIRAL CASING AND OVERHANG IMPELLER .

THE PUMP SUCTION IS ARRANGED IN THE AXIAL DIRECTION

WHILE THE DISCHARGE IS DIRECTLY RADIALLY UPWARD.

THE PUMP IMPELLER AND THE SPIRAL CASING IS OF

STAINLESS STEEL CONSTRUCTION.

NORMALLY THE PUMP IS OVERHAULED ONCE IN 5000 HOURS.

 STATOR WATER COOLER
STATOR WATER COOLER

RUBBER
TUBE UPPER CORD
PLATE WATER BOX VENT
SEALING
CORD
VENT PLUG
STATOR
PARTITION WATER
TUBE OUTLET
OUTER SHELL
SEALING RUBBER
DRAIN PLUG
THERMOMETER

STATOR WATER INLET

LOWER DRAIN
WATER BOX PLUG
 STATOR WATER COOLER-I

THE STATOR WATER COOLER IS SHELL AND TUBE TYPE HEAT

EXCHANGER SUITABLE FOR VERTICAL MOUNTING

THE SHELL IS MADE OF NONMAGNETIC STAINLESS STEEL AND THE DM

WATER FLOWS THROUGH THE SHELL.

TUBES ARE MADE OF STAINLESS STEEL AND THE COOLING WATER

FLOWS THROUGH THE TUBES.

TO HAVE EFFECTIVE HEAT TRANSFER BAFFLES ARE MADE OF BRASS

ARE PROVIDED ACROSS THE TUBE NEST.

THIS GUIDE THE WATER IN ZIG ZAG FASHION.

THE TUBES ARE CLEANED BY NYLON BRUSH.

 STATOR WATER COOLER -II
WHEN PUSHING THE BRUSH THROUGH THE TUBES IT SHOULD ALSO BE
TURNED AROUND SIMULTANEOUSLY

IF THE DIRT DEPOSITS DO NOT COME WITH MECHANICAL TREATMENT

CHEMICAL CLEANING IS NECESSARY.

THE MOST CAUSE OF LEAKAGE IS TUBE PERFORATION OR LEAKAGE.

THE ROLLED ENDS OF THE TUBE ARE LIKELY TO BECOME DEFECTIVE FIRST.

REROLL THE AFFECTED TUBE WITH TUBE EXPANDER.

IF NOT PLUG THE TUBE IF IT IS URGENT .

UPTO 5% OF THE COOLING TUBE CAN BE PLUGGED WITH OUT AFFECTING

THE DUTY
 POLISHING UNIT-I
POLISHING UNIT SERVES TO MAINTAIN LOW ELECTRICAL CONDUCTIVITY
OF THE CONDUCTIVITY OF THE PRIMARY WATER.
POLISHING UNIT IS CONNECTED IN PARALLEL TO THE MAIN CIRCUIT
POLISHING UNIT CONTAINS
1. MIXED BED ION EXCHANGER
2. FILTER
3. FLOW METER
4. CONDUCTIVITY METER
THE BASE SUBSTANCES OF THE EXCHANGER ARE POLYMERS.
THE POLYMERS IN THE CATION EXCHANGER ARE HIGHLY ACIDIC GROUPS
THE POLYMERS IN THE ANION EXCHANGER ARE HIGHLYBASIC GROUP.
WHEN RESINS ARE EXHAUSTED THEY THEY MUST BE REPLACED.
POLISHING UNIT TECHNICAL DATA
CAPACITY 2 M3

DESIGN CONDUCTIVITY AT THE IN LET 1 MICRO MHO/CM

CONDUCTIVITY OF THE WATER AT OUT LET 0.44 MICRO MHO/CM

PH VALUE OF THE WATER AT THE INLET 6 TO 7 MICRO MHO/CM

PH VALUE OF THE WATER AT THE OUTLET 70.2

OPERATING RESIN BED 6 MONTHS

FINAL FILTER SIZE 5 MICRONS

RESIN TULSION T 42

TULSION A-27 MP

REAGENT HCL 30% 20.3KG

NAOH 100% 11.5 KG

 MAGNETIC FILTER-PRINCIPLE

THE MAGNETIC FILTER IS OF PERMANENT MAGNET TYPE

DESIGNED TO TRAP FERRO MAGNETIC PARTICLES

THE FILTER MAINLY CONSISTS OF AN UPPER AND A LOWER BODY

HOUSING THE PERMANENT MAGNET SYSTEM, COMPRISING OF
THE MAGNETS POLE SHOES AND POLE RINGS

THE DM WATER PASSES THROUGH TWO ANNULAR AIR GAPS IN

WHICH THE FERRO MAGNETIC PARTICLES ARE FILTERED OUT.
 MAGNETIC FILTER MAINTENACE

THE UPPER BODY IS REMOVED

WITH HELP OF THE REMOVABLE BOLTS THE POLE RING IS

DISMANTLED .

THE POLE RING AND THE POLE SHOES ARE CLEANED AND THE
ENTRAPPED FERRO MAGNETIC PARTICLES ARE THOROUGHLY WIPED

THE FILTER IS ASSEMBLED AND INSTALLED BACK IN POSITION AND O

RING IS REPLACED , IF IT IS IN DAMAGED CONDITION
MAGNETIC FILTER
 MAGNETIC FILTER TECHNICAL DATA

MAGNET TYPE PERMANENT MAGNET

THE CAPACITY OF THE MAGNETIC FILTER 36M3

MAXIMUM INDUCTION DENSITY 4000GAUSS

PRESSURE RATING NOT MORE THAN 10 KSC

TYPE OF PARTICLES FILTERED HIGHLY AND

MEDIUM MAGNETIC

HYDRAULIC TEST PRESSURE 16KSC FOR 10 MINUTE

PRESSURE DROP NEGLIGIBLE

 STATOR WATER MECHANICAL FILTER
THE FILTER BODY CONSISTS OF CYLINDRICAL BODY HAVING SEPARATE
INLET AND OUT LET CHAMBERS.
A PERFORATED CYLINDRICAL BODY HAVING HOLES ALL ALONG ITS
LENGTH AND PERIPHERY IS SURROUNDED BY THE ASSEMBLY OF 30 TO
34 FILTER ELEMENTS.
THE FILTER ELEMENTS ARE KEPT IN POSITION BY A HELICAL SPRING
WHICH IS KEPT PRESSED BY A COVER.
THE FILTER ELEMENTS CONSISTS OF CORRUGATED BRASS SHEET WITH
A CENTRE HOLE AND TWO SIZES OF WIRE MESH APERTURES 0.224 MM
AND 0.5 MM HELD IN ONE ASSEMBLY BY INNER AND OUTER BRASS
RING.
THE WATER AFTER PASSING THROUGH THE FILTERING ELEMENTS
ENTERS THE PERFORATED CYLINDER FROM WHERE IT FLOWS TO THE
OUTLET CHAMBER.
IMPURITIES GET COLLECTED IN THE WIRE MESH.
THE FILTER IS PROVIDED WITH DRAIN AND VENT PLUGS.
 STATOR WATER MECHANICAL FILTER
TECHNICAL DATA

TYPE WIRE MESH TYPE

RATED DISCHARGE 30 M3
MAXIMUM PRESSURE RATING 12 KSC
MINIMUM SIZE OF THE PARTICLES 0.224
THAT CAN BE FILTERED
PRESSURE DROP 0.1 KSC TO 0.2 KSC
PRESSURE DROP WHEN CLEANING IS
RECOMMENDED 0.4 KSC
MATERIAL OF THE BODY AND
PERFORATED CYLINDER Stainless steel
MATERIAL OF THE FILTER ELEMENT BRASS
SIZE OF THE WIRE MESH 0.224 MM AND 0.5 MM
HYDRAULIC TEST PRESSURE 38 KSC FOR 15 MINUTES
 GAS TRAP

GAS TRAP IS USED FOR DETECTING THE PRESENCE OF HYDROGEN

GAS IN THE STATOR WATER SYSTEM.
PRESENCE OF THE GAS IN THE WATER SYSTEM IS POSSIBLE DUE TO
LOOSE AND LEAK AS JOINTS AS THE WATER PRESSURE IS KEPT LOWER
THAN THE HYDROGEN PRESSURE IN THE GENERATOR CASING.
THE GAS ENTRAPPED IN THE WATER GOES TO THE UPPER CHAMBER
FROM WHERE THE GAS IS SAMPLED FOR ANY MIXING.
TOP POINTS OF THE SUPPLY AND DRAINAGE ARE CONNECTED TO ANY
INLET POINTS OF THE DEVICE.
THE THIRD POINT IS CONNECTED TO PIPE LINE AT THE OUTLET OF THE
GENERATOR.
 GAS TRAP -I

DRAIN PIPE IS CONNECTED TO THE DRAINAGE SYSTEM.

THREE POINTS OF THE INLET ARE CRACK OPENED AND THE WATER IS
ALLOWED TO ENTER CONTINUOUSLY.

THE WATER SO ENTERED WILL BE CONFINED TO LOWER CHAMBER OF

THE DEVICE AND THE EXCESS WATER IS DRAINED TO THE DRAIN PIPE .

IN CASE OF WATER CARRYING HYDROGEN,THE SAME IS LIBERATED AT

THE TOP CHAMBER

THE GAS ENTERS THE SPACE THROUGH THE CENTRE HOLE IN THE
PLUG AND IS DIRECTED TO THE UPPER CHAMBER THROUGH THE SLOT
IN THE PLUG.
 CLEANING & FLUSHING OF PIPING

TREATMENT WITH STEAM / ORGANIC SOLUTION

DEGREASING

FLUSHING / WASHING

DRYING

VISUAL CHECKING & STORAGE

 FILLING & INITIAL OPERATION

FLUSH & FILL THE 5M3 TANK

FLUSH & FILL THE EXPANSION TANK
CHECK THE LEVEL SWITCHES
FLUSH THE COOLING CIRCUIT
SUBJECT THE COOLING CIRCUIT TO HYDRAULIC TEST
TRIAL RUN OF PUMPS AND MOTORS
CHECK AND CLEAN THE FILTER ELEMENTS
INTRODUCE POLISHING UNIT
DISCONNECT PIPE FROM THE GENERATOR INLET &
OUTLET
CONNECT A BYPASS LINE
 FILLING & INITIAL OPERATION
CONTD

TAKE THE COOLERS INTO SERVICE

CHECK THE DM WATER CONDUCTIVITY
RELEASE AIR FROM THE SYSTEM
FLUSH THE SYSTEM FOR 10 HRS.
CHANGE TO STANDBY FILTER IF PRESSURE DROP
EXCEEDS 0.4 KSC
CLEAN THE MAGNETIC FILTER
REMOVE THE BYPASS LINE AND NORMALISE
CARRYOUT THE FLUSHING PROCESS
AFTER COMPLETION OF FLUSHING PROCESS SUBJECT
THE TEFLON HOSES TO HYDRAULIC TEST AT 13 KSC FOR
12 HRS.
CHECKS
PRIOR TO STARTING THE GENERATOR

CHECK THE PUMP INTERLOCKS

CHECK ALL THE ANNUNCIATIONS RELATED TO LEVEL
SWITCHES
CHECK FOR ZERO ADJUSTMENTS FOR ALL GAUGES /
METERS
OPEN THE GAS TRAP
CHECK THE PUMP DELIVERY PRESSURE
CHECK THE FILTER DIFF. PRESSURE
CHECK I / L PRESSURE TO WDG
CHECK CONDUCTIVITY / FLOW
CHECK THE ET VACUUM
 SUPERVISION OF SWS

CONDUCTIVITY MEASURING DEVICE

LEVEL METER DEVICE

FLOW MEASURING SYSTEM

PRESSURE GAUGE / PRESSURE SWITCHES

TEMPERATURE INDICATORS / RECORDERS

 GAS SYSTEM-I
GAS REQUIREMENT 56M3

AMOUNT OF HYDROGEN REQUIRED TO FILL THE GENERATOR 300M3

CASING TO RATED PRESSURE AT NTP-M/C STATIONARY

AMOUNT OF HYDROGEN REQUIRED TO FILL THE GENERATOR

CASING TO RATED PRESSURE AT NTP-M/C STATIONARY 340M3

MAKE UP OF HYDROGEN REQUIRED /DAY 15M3

AMOUNT OF CO2 REQUIRED TO REMOVE HYDROGEN AT NTP 120M3

WHEN MACHINE IS RUNNING 168M3

AMOUNT OF CO2 REQUIRED TO REMOVE AIR AT NTP 90M3

WHEN MACHINE IS RUNNING 112M3

 GAS SYSTEM-II

EACH H2 CYLINDER IS OF CAPACITY 46.7 LITRES AND CONTAINING

APPROXIMATELY 7 M3 AT 150 ATM
NO. OF H2 CYLINDERS REQUIRED TO FILL THE MACHINE
WHEN STATIONARY 50
WHEN RUNNING 56
NO. OF CYLINDERS REQUIRED/DAY 2 TO 3

EACH CO2 CYLINDER IS 30 KGS WEIGHT OF CO2 WITH GAS

EQUIVALENT TO 15M3 OF GAS VOLUME.
NO. OF CYLINDERS REQUIRED FOR PURGING HYDROGEN
WHEN STATIONARY 11
RUNNING 14
NO. OF CO2 REQUIRED FOR PURGING AIR WHEN STATIONARY 8
NO. OF CO2 REQUIRED FOR PURGING AIR WHEN RUNNING 10
GAS DRIER
THANK YOU