COMMISSIONING OF

GENERATOR AND ITS

AUXILIARY SYSTEM

December 31, 2024 PMI Revision 00 1

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

December 31, 2024 PMI Revision 00 2

 STATOR WATER SYSTEM

December 31, 2024 PMI Revision 00 3

 STATOR WINDING
WATER SYSTEM
EXPANSION FLOW DIFF PRESS
TANK METERS SWITCH
GAS TRAP

MAGNET
FILTER FILTERS

FSI
DIFF PRESS. I

CONDUCTIVITY
POLISH UNIT
MAKE
UP
COOLERS

PUMPS
VACUUM
December 31, 2024 PMI Revision 00 4
PUMPS
• Stator water cooling is a closed loop system.
• There are two full capacity single stage
centrifugal pumps with change over facility.
• The pumps are driven by 3Ph. 415V A.C.
motors.
• The stator water cooler is shell and tube type
heat exchanger.
• DM water flows through shell.

December 31, 2024 PMI Revision 00 5

• There are two mechanical filters and one
magnetic filters.
• Mechanical filters are of wire mesh type.
• Magnetic filter is having permanent magnet.
• The expansion tank is a hermetically sealed
container made of S.S.

December 31, 2024 PMI Revision 00 6

• Float valve in the expansion tank maintains
water level in the tank which act as suction
storage tank for stator water pumps.
• Polishing unit (mixed bed ion exchanger)
maintains conductivity of stator water to desired
level.

December 31, 2024 PMI Revision 00 7

• For commissioning, first the system has to be
filled up.
• Prerequisites for filling the cooling circuits:
a) complete circuit should be flushed,
b) hydraulic testing,
c) installation of pump and motors after O/H,
d) filters cleaned and boxed up,

December 31, 2024 PMI Revision 00 8

 e) coolers and all other components are boxed
up,
f) ion exchanger is ready and is in service,
g) all instruments and measuring devices are in
position after calibration.

December 31, 2024 PMI Revision 00 9

• System should be lined up for filling.
• Complete stator water system should be filled
with DM water having required quality.
• All air should be vented from the system before
starting of the pump.

December 31, 2024 PMI Revision 00 10

• Trial run of the stator water pumps is
satisfactory.
• Check the stand by pump for automatic starting
on all interlocks and protections,
• Adjust level regulator in the expansion tank,
• Check all the signaling, indicating, recording,
event logging, metering instruments, alarms and
annunciating devices for proper functioning.

December 31, 2024 PMI Revision 00 11

• Adjust make up water pressure around
2.0Kg/cm2
• Adjust small water flow through the gas trap
• Check there is no leakage of water in the
system
• Take ejector into service
• Take one cooler into service

December 31, 2024 PMI Revision 00 12

• Check emergency switching in circuit of the stand
by water pump
• Check high and low alarm of the expansion tank
• Check high conductivity alarm and tripping
• Check pump discharge pr., filter diff. pr.,
conductivity, flow, inlet winding pr., winding diff. pr.,
vacuum in expansion tank, motors current.

December 31, 2024 PMI Revision 00 13

 SEAL OIL SYSTEM

December 31, 2024 PMI Revision 00 14

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

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

December 31, 2024 CONSTANT PRESS. REGULATORS

PMI Revision 00 15
WITH ORFICE PLATES
• Generator shaft seals are supplied with
pressuerised seal oil to prevent hydrogen
escape at the shaft.
• Oil pressure is kept higher than the gas
pressure.
• AC seal oil pump – one number and DC seal
oil pump- one number are provided which
feed the oil to the seal through cooler and
filter.

December 31, 2024 PMI Revision 00 16

• Both the AC seal oil pumps are 100%
capacity screw type pumps.
• A vacuum pump is provided to maintain
vacuum in seal oil tank.
• There is a additional facility to supply seal oil
from governing oil.
• The seal oil pressure to the seal is controlled
by DPR which maintain specified DP
between oil and hydrogen.

December 31, 2024 PMI Revision 00 17

• Thrust oil holds the seal ring in position
against gas pressure.
• Two seal oil coolers each having 100%
capacity is provided to cool the oil.
• Duplex filter is provided in the oil line.
• Vacuum pump evacuates gases from SOT.

December 31, 2024 PMI Revision 00 18

• Seal oil system will be commissioned when the
following system is ready
1) Generator ready to be filled with hydrogen or air.
2) Machine (TG) ready to be put on barring gear.
• Prior to commissioning make ensure proper
functioning of all the signaling, indicating, recording,
event logging, metering instruments, alarms and
annunciating devices.

December 31, 2024 PMI Revision 00 19

• Seal oil system has to be filled with oil
• Prerequisite for oil filling
1) set all level switches
2) close all stop and non-return shut off
valves
3) open all pressure gauge and pressure
switches isolating valves

December 31, 2024 PMI Revision 00 20

 4) open pressure transducer isolating
valves
5) open isolating valves of impulse lines
of differential pressure regulator
6) bearing lube oil system is in service

December 31, 2024 PMI Revision 00 21

• Open isolating valve of seal oil storage tank
to seal oil system. Oil will start filling the seal
oil system
• Open valves in oil flow path
• Take coolers and filters into service
• After oil is filled up into the system level will
be visible in the gauge glass of the SOT

December 31, 2024 PMI Revision 00 22

• Take governing oil system into service
• Start AC seal oil pump
• To clear air locking seal oil pump should be
switched on and off till its discharge pressure
gauges shows a constant pressure
• Vent DPRV-A and DPRV-B

December 31, 2024 PMI Revision 00 23

• Vent both the coolers one by one
• Vent filters
• Vent pressure gauges, pressure switches
and transmitters
• Set seal oil pressure by DPRV-A
• Stop AC seal oil pump and set DPRV-B
(<0.3Kg/cm2 from DPRV-A)

December 31, 2024 PMI Revision 00 24

• Set thrust oil pressure (0.5 Kg/cm2 more than
seal oil pressure)
• Take vacuum pump into service and adjust
SOT vacuum as recommended
• Check all the meter readings are within limit
• Check seal oil flow is as per system
requirement

December 31, 2024 PMI Revision 00 25

• Check automatic starting of stand by DC seal oil
pump by different interlocks including alarm
• Check function of level switch of SOT, seal oil
storage tank and pre-chambers
• After seal oil temperature reaches 300C start
cooling water flow to seal oil cooler and adjust
the flow in such a way so that the seal oil
temperature is maintained at 400C

December 31, 2024 PMI Revision 00 26

 HYDROGEN GAS SYSTEM

December 31, 2024 PMI Revision 00 27

 HYDROGEN GAS SYSTEM

ANALYZER
H2 DISTRIB
CO2 TO
SEALOIL
DPT
H2 DRIER

FILTER DPI
OP
VAPOURIZER
CO2

HYDROGEN
AIR

DRAIN
December 31, 2024 PMI Revision 00 28
• Overhauling of gas drier has been carried
and the drier is boxed up
• Check all instruments are in position after
calibration
• Functionally check the gas drier system
• Check the availability of adequate no of CO2
filling point and adequate no of CO2 cylinders

December 31, 2024 PMI Revision 00 29

• Check availability of adequate no of
Hydrogen filling points and cylinders
• Functionally check the LLD system
• Check whether the relief valves in the high
pressure valves are alright
• Check the generator is completely boxed up
• Check the seal oil system is in service

December 31, 2024 PMI Revision 00 30

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

December 31, 2024 PMI Revision 00 31

GAS SYSTEM
• Pressurise generator casing with hydrogen
up to its design value
• Recheck hydrogen leakages by detector
• Take drier into service
• Take gas coolers into service
• Vent the coolers and establish flow

December 31, 2024 PMI Revision 00 32

 TESTS ON GENERATOR

December 31, 2024 PMI Revision 00 33

The field tests of the generator include the
acceptance tests and periodic tests.
The Acceptance tests are performed during
the erection and after completion of the
erection.

The periodic tests are carried out during

overhauls, routine repairs and during the time
between repairs.

December 31, 2024 PMI Revision 00 34

Measurement of Insulation Resistance
1. Stator winding: Each phase relative to
the earthed casing (frame) and other phases
earthed. Bus-duct shall be disconnected.
IR measurement at 2500Volts
2. Water headers of stator winding:
After the water connections are mounted and
before the external parts of the cooling system
is connected.
IR measurement at 2500Volts
December 31, 2024 PMI Revision 00 35
a) The insulation resistance of the stator winding
shall be measured with distillate drained from the
stator winding, the water headers being connected
to the ohmmeter screen and isolated from the
external cooling systems.

December 31, 2024 PMI Revision 00 36

b) The value of the ratio R60/R15 shall be at
least 1.3 at a temperature of +10° C to +30°
C. If the value of the resistance R60 or ratio
R60/R15 is below the permissible value, the
stator winding shall be dried out according
to the appropriate instructions, remove
moisture from the winding by blowing it out
with dry compressed air then recheck its
insulation resistance.
December 31, 2024 PMI Revision 00 37
c) Prior to measuring the insulation resistance of
the stator windings make sure that there was no
ingress of water to it during storage’s transit and
erection of the stator (the condition of packaging
will show it.)

December 31, 2024 PMI Revision 00 38

3. Rotor winding: IR measurement at 1000
Volts.
4. Bearing: Insulation resistance is measured
relative to the base-plate, with oil piping
completely assembled, with no contact
between the bearing and the rotor shaft
journal. IR measurement at 1000 Volts.

December 31, 2024 PMI Revision 00 39

5. Resistance temperature detectors:
Insulation resistance of RTD’s is
measured together with the wiring from,
the measuring instrument to the RTDS,
including that running within the
generator. IR measurement at 1000 Volts.
6. Insulation of oil catcher and the
outer end shields of at the exciter end. IR
measurement at 1000 Volts.
December 31, 2024 PMI Revision 00 40
Shaft seal at the exciter end: Insulation
resistance as is measured between the
shaft seal housing and the outer end
shields, with oil piping completely
assembled. IR measurement at 1000
Volts.

December 31, 2024 PMI Revision 00 41

Measurement of A.C. Impedance of
Rotor-winding This should be made with a
power-frequency voltage of 220 V at different
rotor speeds varied in steps from 500 rpm to
3000 rpm and on the stationary rotor. The
results shall be compared with those obtained
previously, the condition of the generator
during the compared measurements being the
same (the rotor is inside or outside the
generator, the stator winding is open-circuited
or short-circuited, etc).
December 31, 2024 PMI Revision 00 42
Leakage Test on Bearing and Shaft-Seal
Housings The leakage test should be
conducted with the use of white wash and
kerosene, the leaks being detected by visual
examination. The shaft-seal housings should
be also tested for leakage with the use of
kerosene . No leaks are permitted, The test
duration is 24 h.

December 31, 2024 PMI Revision 00 43

Leakage Test on Stator Winding
Terminals and Water Connections The
leakage test on the stator winding terminals
should be done in several steps.
First the terminal bars should be separately
tested for leakage and for strength. The test is
conducted with water at a pressure of 2450
kPa (25 kgf/cm2) applied for 1 h. No water
leaks are permitted.

December 31, 2024 PMI Revision 00 44

Leakage Test on Stator Winding
Terminals and Water Connections When
assembling, the terminal bushings, test them
for leakage in a special fixtures (tank) with air
at a pressure of 490 kPa (5 kgf/cm2), gauge,
applied for 1 h. The test shall be made on the
completely assembled terminal bushing, No
leaks are permitted.

December 31, 2024 PMI Revision 00 45

Hydraulic Pressure Test on Gas Coolers
Prior to mounting the gas coolers in the stator
casing, rust-preventive coatings should be
remove from their surfaces and the tube fins
blown with compressed air.
The gas coolers are tested with a hydraulic
pressure of 784 kPa (8.0 kgf/cm2) applied for
60 min. No reduction of the test pressure and
leaks should take place during the test.

December 31, 2024 PMI Revision 00 46

Hydraulic Pressure Test on Gas Coolers
In the gas coolers with installed protectors a
reliable contact between the protectors and
protected surface should be ensured. The
resistance shall not be greater than 0.1 ohm,
The protectors shall not have a joint coating.

December 31, 2024 PMI Revision 00 47

Hydraulic Pressure Test an Stator
Winding
The hydraulic pressure test on the stator
winding is made with DM water at a pressure
of 764 kPa (8 kgf/cm ) applied for at least 24 h.
Before the distillate pressure is increased, to
the required value, the air shall be fully
expelled from the system. No reduction of the
test pressure, no signs of moisture an the
winding, headers, flexible tubes and their
sections are permitted during the test.
December 31, 2024 PMI Revision 00 48
Gas Leakage Tests on Rotor, Stator and
Assembled Generator
After the generator erection / overhauls /
routine repairs wherever dismantling of the
outer end shields or removal of the gas
coolers is involved, the generator and its
separate parts should be subjected to a gas
leakage test.

December 31, 2024 PMI Revision 00 49

Gas leakage Test on the current carrying
bolts (Rotor)
The test should be performed before the rotor
is inserted into the stator. Air is applied in turn
to the gland seals of each current-carrying bolt
through special radial holes in the rotor shaft,
Gas leakage is determined from a drop of the
test pressure.
The detected leaks should be eliminated by re-
packing or replacement of the gland seals by
their.
December 31, 2024 PMI Revision 00 50
Gas Leakage Test on Assembled
Generator
The leakage test is aimed at tracing and
stopping air leakage in the stator casing
assembled with the terminals, gas coolers,
shields, water connections. The air used for
the test shall be dry and clean. The leaks
should be located with the help of soap
solution applied to the welds and to all joints
of the parts and comments.
December 31, 2024 PMI Revision 00 51
After the traced leaks are stopped, the second
step of testing determines the leakage rate and
is per formed at an air-pressure equal to the
rated hydrogen pressure applied for 24 h.

December 31, 2024 PMI Revision 00 52

Note: It should be noted that a 1 ° C
change in the air temperature inside the
generator part under will result in a 1.6
kPa change in the air pressure, the test
pressure being 392 kPa (4 kgf/cm2),
gauge. Therefore, when the leakage tests
are conducted, special attention should
be paid to the variation of air temperature
inside the part under test.
December 31, 2024 PMI Revision 00 53
Testing of rotor vent ducts for free
passage of air .
Mark out the rotor slots in a clockwise
direction (as viewed from the slip rings
end), starting from the big pole tooth
located in that part of the rotor where the
field current lead is connected to the
inner slip rings. Number the vent ducts
in the wedges of each slot, starting from
the retaining ring located at the slip-ring
end.
December 31, 2024 PMI Revision 00 54
TESTING
(1) Using the stoppers, plug all the holes
in the seat wedges
(2) Take out the stoppers from the inlet
and outlet holes of the vent duct be
tested.
(3) Fit the nipple of the inlet nozzle into
the inlet hole of the vent duct, and that of
the outlet nozzle into the outlet hole, the
liquid-filled column micro-manometer
being connected to the outlet nozzle.
December 31, 2024 PMI Revision 00 55
Connect the full-pressure flexible tube to
the "+" nipple of the Liquid column
micro-manometer and the static pressure
tube to the "-" nipple of that micro-
manometer.
(4) Feed air at a pressure and measure
the dynamic pressure at the vent duct
outlet.
(6) Enter the obtained pressure value into
vent duct test sheet. Insert the removed
stoppers back in their position.
December 31, 2024 PMI Revision 00 56
December 31, 2024 PMI Revision 00 57
EXAMINATION OF ROTOR RETAINING
RINGS BY DYE-PENETRANT METHOD
The dye-penetration method of surface
examination is used for detecting cracks
and other types of discontinuities on the
surface of the rotor retaining rings. The
method is based on the ability of some
aniline dye solutions to penetrate into
the various types of discontinuities in
materials.
December 31, 2024 PMI Revision 00 58
Clean the surface to be examined to a
mirror-like condition. Polish out rough
marks or, otherwise, they may affect the
examination results directly before
application of the dye-penetrant solution,
de grease the examined surface area. Apply
a continuous coat of the dye penetration
solution to the examined surface. As the
solution coat dries out, apply another coat.
December 31, 2024 PMI Revision 00 59
After 15-20 min, remove quickly and
thoroughly the dye-penetrant solution
with soft clean cloth. Using a spray
gun or a flat brush, apply a smooth
coat of whitewash. Examine the
surface 5 min after the white wash has
been applied. Appearance of red veins
on the surface is indicative of the
presence of cracks.
December 31, 2024 PMI Revision 00 60
The dry-penetrant solutions shall be
prepared and applied in the open air or in a
properly ventilated room as all the dry-
penetrant solution components are fire-
hazardous. Therefore, no smoking, no open
flame, no sparking and no switching on of
electric device are allowed near the place
where the solution is prepared or
examination is conducted. Rubber gloves
are to be used when preparing for and
conducting the examination.
December 31, 2024 PMI Revision 00 61
ELCID (Electrical Core Imperfection
Detection) test on Stator Core: This test is
conducted to assess the condition of the
stator core by testing for location of any
inter-turn shorting in the stator core
lamination. This test is repeated in every
overhaul involving rotor thread out.

December 31, 2024 PMI Revision 00 62

 ROTOR THREAD-IN

December 31, 2024 PMI Revision 00 63

December 31, 2024 PMI Revision 00 64
December 31, 2024 PMI Revision 00 65
December 31, 2024 PMI Revision 00 66
December 31, 2024 PMI Revision 00 67
December 31, 2024 PMI Revision 00 68
Prior to the initial start of the generator, the
following shall be done:
(1) All civil construction work according to the
design documents shall be completed, the
general and local lighting systems shall be
installed.
(2) Erection of the generator, installation of the
auxiliary equipment, primary and secondary
switching circuits and their associated equipment
should be completed, the completion of the work
recorded.
December 31, 2024 PMI Revision 00 69
(3) All pre-operational electrical measurements
and tests included in the generator acceptance
test program shall be performed.
(4) Water-, gas- and oil-supply systems,
thermal-control, delaying, alarm and indication
circuit shall be adjusted and tested, non-
electrical protections shall be put on guard.
(5) All safety and fire prevention measures
shall be taken.

December 31, 2024 PMI Revision 00 70

The initial start and initial operation of the
generator shall be performed in accordance
with the test and commissioning program. All
work on the initial start and operation should
be done in accordance with this instruction
manual, the relevant operating rules and the
directions of the generator manufacturer.

December 31, 2024 PMI Revision 00 71

Initial Start of Generator
With the rotor stationary, proceed as follows:
(1) Supply oil to the generating unit bearings
and shaft seals and make sure that the oil is
flowing to the drain pipes normally.
(2) Fill the generator with hydrogen so that the
hydrogen pressure reaches the rated value.
Use carbon dioxide or nitrogen to purge air
from the generator before filling it with
hydrogen.
December 31, 2024 PMI Revision 00 72
(3) Ensure that the differential pressure
between the seal oil and gas inside the
generator, as specified, is maintained
automatically. During the initial start (while
accelerating the generator to the rated speed),
measure the vibration on the bearings and
ensure that there is no unusual noise, rubbing,
etc. in the generator. Go rapidly through the
critical speeds at which the highest vibrations
on the rotor are observed.
December 31, 2024 PMI Revision 00 73
With the rotor at the rated speed,
check the following:
(1) Temperature of oil at outlets of all the
bearings, and temperature of the bearing
liners and shaft-seal bushes, vibration on the
generator supports,

(2) Operation of the generator and exciter

brush gear.

December 31, 2024 PMI Revision 00 74

(3) Generator phase sequence and phasing on
the power system, residual voltage, without
application of field excitation of the rotor).
4) Proper circulation of water in the cooling
circuits of, the stator, gas coolers, heat
exchangers.
Abnormalities revealed (if any) after the initial
start and mechanical run may be eliminated by
stopping the generator and inspection of the
bearings.
December 31, 2024 PMI Revision 00 75
The electrical tests on the generator
should be conducted in accordance with
the acceptance test program.

No limitation is imposed on the rate of

raising the generator terminal voltage for
starts form both cold and hot conditions.

There is no need to warm-up the

generator before raising the voltage.
December 31, 2024 PMI Revision 00 76
Measurement of Vibration
The vibration measurements shall be made
with the generator under all operating
conditions - at no load, with and without
excitation, and at different loads. The vibration
should be measured in two variations,
perpendicular to each other, viz.: in vertical
and transverse directions relative to the shaft
center line.
December 31, 2024 PMI Revision 00 77
No-load Characteristic of Generator The
no-load characteristic is determined during the
acceptance tests or after the overhauls
involving the replacement of the generator
rotor/stator winding or the transformer
winding. During this test, the generator should
be excited so as to obtain the voltage equal to
1.15 of the rated value. Then the field current
should be reduced in order to determine the
characteristic.
December 31, 2024 PMI Revision 00 78
No specific limit is placed on the extent of
deviation of the obtained characteristic from
those determined earlier. The test should be
conducted at the rated hydrogen pressure.
During this test, measure and record all the PT
output voltages. Also ensure, measure and
record availability of PT voltages at all
voltage / impedance operated relays.
PT Voltages in the synchronising circuit to be
verified.
December 31, 2024 PMI Revision 00 79
Three-Phase short-circuit
Characteristic of Generating Unit

This characteristic should be determined with

the stator current reaching the rated value.
Prior to obtaining the characteristic, a shorting
link should be installed behind the
transformer. The hydrogen pressure should be
equal to the rated value.
December 31, 2024 PMI Revision 00 80
The deviation of the obtained short circuit
characteristic from those determined earlier
should be within the accuracy of
measurements.

During the SCC testing, measure and record

the reflection of the CT secondary of all the
CTs. Ensure the CT juice is available at all the
relevant relays.

December 31, 2024 PMI Revision 00 81

 • Safety precautions including fire fighting
equipments are available.
• Oil supply to generator bearing and seal
has been established and quality/flow of
oil is as per specification.
• Generator is filled with hydrogen of
desired purity and up to rated pressure.

December 31, 2024 PMI Revision 00 82

• Generator stator winding is charged with
distillate of desired quality. The other
parameters of distillate is as per norms
• Generator gas coolers are charged and the
parameters are normal
• Generator circuit breaker is in open
condition after testing
• All switchyard equipments has been tested
and normalised

December 31, 2024 PMI Revision 00 83

• All protection and control schemes are in
service after callibration and testing
• Excitation system has been tested,
normalised and field breaker has been kept
in open condition.
• Mode of excitation system has been
selected (auto/man)

December 31, 2024 PMI Revision 00 84

• When generator reaches rated speed check
the following
a) bearing and seal temperatures
b) performance of brush gear
c) vibrations
d) any gas, oil or water leakages
e) any abnormalities in generator
performance

December 31, 2024 PMI Revision 00 85

• Switch on excitation system and check for
various parameters and functioning of excitation
system
• After ensuring all parameters are all right and
machine behavior is normal match the
generator’s electrical parameters with the grid
and synchronise the machine when permissive
for the same is available. The generator shall be
switched into the power system at precise
synchronizing.
• Load the machine gradually. During loading also
monitor all parameters.
December 31, 2024 PMI Revision 00 86
 Inspection after Initial Operation Under
Load

• The initial operation under load is considered to

have been accomplished if the generator has
shown normal performance during continuous
operation for 72 hours of switching the
generator into the power system.

December 31, 2024 PMI Revision 00 87

After the 72-h operation, make inspection of
the generator. During the inspection,
disassemble the bearing and shaft
irrespective whether any abnormalities have
been noted or in their performance during
adjustment and testing. The inspection
involves the visual examination of the shaft
journals, babbit-lined faces of the bearing
liner an shaft-seal bushes.

December 31, 2024 PMI Revision 00 88

• Clean the filters of the oil system and stator
winding cooling system. Remove scratches,
marks, etc. on the shaft journals and babbit-
lined faces by polishing or scraping. Stop the
leaks detected in valves, flange joints, etc.
• The generator is to be placed in commercial
operation after completion of the adjustment
and testing, and upon elimination of defects
and workmanship faults revealed during the
inspection.

December 31, 2024 PMI Revision 00 89

 THANK YOU

December 31, 2024 PMI Revision 00 90