COMMISSIONING OF GENERATOR AND ITS AUXILIARY SYSTEM

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

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

MAGNET FILTER
FSI I

FILTERS

DIFF PRESS. CONDUCTIVITY MAKE UP

POLISH UNIT

COOLERS PUMPS
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VACUUM 24 May 2012 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.

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 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.

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 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.

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 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,

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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.

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 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.

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 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.

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 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

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 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.

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SEAL OIL SYSTEM

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SEAL OIL SYSTEM

EE BEARING TE BEARING

FLOW M.
FROM GAS SYSTEM GAS EXHAUST

PS PG

TS

ES

TG
SOST
BEARG DRAINS

FR

DPRV

IOT
VACCUM PUMP

DP SW
VACUUM TANK SOP 1 SOP-3 DC

FILTERS

OIL COOLER

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 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.
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 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.
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 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.

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 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.

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 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

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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

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 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

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 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

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 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)

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 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

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 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

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HYDROGEN GAS SYSTEM

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HYDROGEN GAS SYSTEM

ANALYZER
H2 DISTRIB CO2

TO SEALOIL DPT
H2 DRIER

FILTER

DPI
OP

VAPOURIZER HYDROGEN

CO2

AIR

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DRAIN

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 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

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 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

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 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%.

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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

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TESTS ON GENERATOR

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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.
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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
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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.

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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.
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c) Prior to measuring the insulation resistance of the stator windings make sure that there was no ingress of water to it during storages transit and erection of the stator (the condition of packaging will show it.)

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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.

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5. Resistance temperature detectors: Insulation resistance of RTDs 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.
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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.

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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).
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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.
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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.
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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.
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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.
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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.

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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.
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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.
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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 repacking or replacement of the gland seals by their.
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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.
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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.

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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.
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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.
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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.
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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 micromanometer. (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.
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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.
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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.
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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.
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The dry-penetrant solutions shall be prepared and applied in the open air or in a properly ventilated room as all the drypenetrant solution components are firehazardous. 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.
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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.
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ROTOR THREAD-IN

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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.
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(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, nonelectrical protections shall be put on guard. (5) All safety and fire prevention measures shall be taken.
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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.

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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.
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(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.
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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.
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(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.
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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.
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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.
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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.
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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.
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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.
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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.
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 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.

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 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

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 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)

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 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

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 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 generators 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.
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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.

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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.
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 Clean the filters of the oil system and stator winding cooling system. Remove scratches, marks, etc. on the shaft journals and babbitlined 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.

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THANK YOU

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