POWER PLANT

OPERATION
GENERATOR &
AUXILIARIES

March 28, 2025 PMI Revision 00 1

 Presentation outline
Seal Oil System line up

Hydrogen filling

Stator Water System line up

Generator Synchronization

LP heater charging

Load Raising

LP & HP heater charging

March 28, 2025 PMI Revision 00 2
 SEAL OIL SYSTEM
FLOW M.
EE PS PG
BEARING FROM GAS
TE SYSTEM
BEARING TS ES
GAS
EXHAUST FR
TG DPRV
SOST BEARG
DRAINS

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

CONSTANT PRESS. REGULATORS

WITH ORFICE PLATES
March 28, 2025 PMI Revision 00 3
 SEAL OIL SYSTEM CHARGING
• Commissioning of seal oil system will be required
when the
1) generator to be filled with hydrogen or air.
2) machine to be put on barring gear
• Prior to commissioning make sure that all
instruments and devices are ready for operation
after calibration, overhauling and trial.

March 28, 2025 PMI Revision 00 4

 SEAL OIL SYSTEM CHARGING
• 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
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

March 28, 2025 PMI Revision 00 5

 SEAL OIL SYSTEM CHARGING
• 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
• 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
March 28, 2025 PMI Revision 00 6
 SEAL OIL SYSTEM CHARGING
• 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)
• Set thrust oil pressure (0.5 Kg/cm2 more than seal
oil pressure)
• Take vacuum pump into service and adjust SOT
vacuum as recommended
March 28, 2025 PMI Revision 00 7
 SEAL OIL SYSTEM CHARGING
• Check all the meter readings are within limit
• Check seal oil flow is as per system requirement.
• 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 30 0C 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

March 28, 2025 PMI Revision 00 8

 HYDROGEN COOLING SYSTEM

ANALYZER
H2 DISTRIB
CO2 TO
SEALOIL
DPT
H2 DRIER

FILTER DPI
OP
VAPOURIZER
CO2

HYDROGEN
AIR

DRAIN
March 28, 2025 PMI Revision 00 9
 HYDROGEN COOLING SYSTEM
• PRE CHECHS
• 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.
• Check availability of adequate no of Hydrogen filling points
and cylinders.
• Check whether the relief valves in the high pressure valves
are alright.
• Check the generator is completely boxed up & it’s air
tightness test is successfully completed.
• Check the seal oil system is in service.
March 28, 2025 PMI Revision 00 10
 Purging of Air By CO2
• CO2 is admitted from CO2 manifold to generator casing at
bottom by opening the valves on cylinder and regulator.
• Rate of admission is being controlled normally by regulating
the valves on the manifold.
• To avoid excessive frosting, the CO2 flow rate should be
carefully regulated.
• When CO2 percentage reaches 98%, the filling of CO2 can
be stopped and preparation for filling hydrogen can be
made.
• After achieving 98% CO2 concentration and a pressure of
0.15 to 0.2 Kg/cm2 inside the machine, filling of hydrogen in
machine can be started.

March 28, 2025 PMI Revision 00 11

 H2 FILLING
• Hydrogen is admitted into the generator through hydrogen
feed pipe which is connected to perforated pipe header
inside the generator extending along the length of the
cooling at the top.
• During process of filling with H2 the CO 2 air mixture is
discharged through CO2 feed pipe from bottom.
• During H2 filling, continuously analyze the concentration of
H2 in gas mixture inside the machine.
• Continue purging till hydrogen purity reaches above 98%
and H2 pressure attains rated value.
• Take drier into service.
• Take gas coolers into service.
• Vent the coolers and establish flow.
March 28, 2025 PMI Revision 00 12
 STATOR WATER SYSTEM
EXPANSION FLOW
TANK METERS
GAS TRAP
DIFF PRESS
SWITCH
MAGNET
FILTER FILTERS

FSI
DIFF PRESS. I

CONDUCTIVITY
POLISH UNIT
MAKE
UP
COOLERS

PUMPS
VACUUM
PUMPS
March 28, 2025 PMI Revision 00 13
 Stator Water System
• For commissioning the system the system has to
be filled up first
• Prerequisites for filling the cooling circuits
a. Circuit should be flushed
b. Installation of pump and motors after O/H
c. Filters cleaned and boxed up
d. Coolers and all other components are boxed up
e. Ion exchanger is ready and is in service
f. All instruments and measuring devices are in
position after their calibration

March 28, 2025 PMI Revision 00 14

 Stator Water System
• 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.
• Take trial of the water pumps.
• Check the stand by pump for automatic starting
• Adjust level regulator in the expansion tank.
• Check all the instruments and meters for their
proper functioning.

March 28, 2025 PMI Revision 00 15

 Stator Water System
• 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
• 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
March 28, 2025 PMI Revision 00 16
 GENERATOR
SYNCHRONISATION

March 28, 2025 PMI Revision 00 17

 Check before synchronisation
• CHECK all the generator Parameters are healthy
• Stator cooling water flow more than 21 T/Hr.
• Stator cooling water temp less than 40 oC.
• Cold end hydrogen temp less than 40 oC
• Seal oil pressure at turbine and 5.0 KSC
• Seal oil pressure at exciter end 5.0 KSC
• Seals oil D.P. between1.2 -1.5 KSC
• Generator stator water specific conductivity is less than 5 m
mho/cm
• Gen. hydrogen and stator water coolers are charged and
''Clarified water pressure to hydrogen & stator water coolers
low'‘ alarm is not on.

March 28, 2025 PMI Revision 00 18

 Check before synchronisation
CHECK before closing the field breaker before synchronization
• Turbine RPM is more than 2980 rpm. Generator isolators are
closed from switchyard.
• Generator excitation control is on REMOTE.
• Generator excitation control is on MANUAL OR AUTO.
• AUTO/MANUAL excitation controllers are on HOME position.
• CLOSE the generator field breaker.
• Generator field breaker gets closed & Generator voltage
increases to 10 KV, 15.75 KV approx. on manual / auto
excitation control, respectively.
• RAISE generator excitation manually, to raise gen. voltage.
• CHECK all the generator voltages (phase to phase).
• All the three phases should read equal voltages
March 28, 2025 PMI Revision 00 19
 Synchronisation
• SWITCH-ON the synchroscope to CHECK mode.
• IN-COMING/RUNNING voltages and frequencies start
showing on their Corresponding meters.
• Alternatively synchroscope is put on Check mode and auto
synchroniser can be switched on.
• Synchroscope needle starts rotating at a rate proportional to
difference between the generator and grid frequencies.
• ADJUST turbine speed reference to match generator freq
with the grid (running).
• ADJUST generator excitation to match the gen. voltage with
that of grid.
• As synchroscope needle comes to 11'O clock position
(clockwise), the green CHECK lamp comes on & the red
lamp goes off. At 12' O clock position the check lamp goes
off and red lamp comes on again.
March 28, 2025 PMI Revision 00 20
 Synchronisation
When the voltage and frequency match, the synchroscope will
move very slowly in the clockwise direction. This position
shows that:
i) Phase sequence of generated voltage and system voltage is
same.
ii) Effective values of both the voltage are same.
iii) Frequency of both the system and the incoming m/c is
same.
• CLOSE the generator breaker when the check lamp is green.
• ''Generator motoring'' alarm comes on.
• INCREASE Starting Device to 100%.
• RAISE speed reference slightly to increase Gen load, immediately after
closing the generator breaker.
• Turbine load increases to 20 MW approximately. ''Speed controller''
transfers to 'Load controller'' after some time delay.
March 28, 2025 PMI Revision 00 21
 Synchronisation
• Gen. voltage and P.F., will be maintained by AVR if the
excitation mode is on "Auto", otherwise, maintain Gen.
voltage and PF by varying the field rheostat from the Gen.
control desk. If excitation mode is on manual, then change
over to "Auto" mode after matching the parameters.
• Slowly raise the load on Generator upto 80 MW (Follow the
guide lines given for loading the machine). Now the voltage
and power factor will be maintained by the automatic
voltage regulator (AVR).

March 28, 2025 PMI Revision 00 22

 Unit Supply Changeover From
Station To UAT
• Check that the unit auxiliary supply incoming breakers are
racked in service position, springs are charged and
"Local/Remote" switches are on "Remote" position.
• SWITCH-ON synchroscope to CHECK mode.
• Synchroscope green lamp comes on after the two voltages
are matching
• CLOSE UAT (A/B) incomer to Unit bus.
• ''Unit/Station transformers paralleled'' annunciation comes
on.
• Immediately OPEN the station breaker.

March 28, 2025 PMI Revision 00 23

 LP HEATERS CHARGING
CHECK these conditions are satisfied before charging the LP
heaters.
• Generator load is at least 40 MW.
• All LP heaters are CHARGED from waterside and their bypass
valves are closed.
• All LP heaters airline to condenser, are OPEN.
• All pneumatic drip valves are OPERATIONAL & on REMOTE.
• OPEN LPH-1 Extraction steam block valve ES-1.
• Condensate temperature across LPH starts rising.
• OPEN LPH-2 extraction block valve ES-2.
• Associated line drain valve starts closing after the extraction
block valve opens 100%.
• LPH-2 alternate drain to condenser starts closing.
• LPH-2 normal drain valve starts modulating to maintain the level.
OPEN LPH-3 extraction block valve ES-3.
March 28, 2025 PMI Revision 00 24
March 28, 2025 PMI Revision 00 25
 HP HEATERS CHARGING
• CHECK before charging the HP Heaters:
• Unit load is more than 120 MW.
• HPHs water side inlet/outlet valves OPEN and individual bypass valve
are CLOSED.
• HPHs group bypass valves are IN-SERVICE position and "HPHs
bypassed" alarm is NOT On.
• All HPHs shell drains are OPEN.
• All HPHs airlines to condenser isolating valves are open.
• OPEN HPH-5 extr. steam block vlv ES-5.
• After ES-5 is open, extr. line drain DW-73 closes.
• HPH-5 alternate drain to condenser HD-31 closes
• HPH-5 normal drain to D/A starts modulating to maintain the level.
• Feed water temp after HPH-5 starts increasing.
• Similarly charge HPH-6 and maintain the drip level.
• Put drip level control on Auto.

March 28, 2025 PMI Revision 00 26

March 28, 2025 PMI Revision 00 27
 Capability Curve

March 28, 2025 PMI Revision 00 28

 LOAD RAISING
• Increase the firing rate in the boiler as per the
TSE margin and load schedule.

March 28, 2025 PMI Revision 00 29

 THANK YOU

March 28, 2025 PMI Revision 00 30