Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0018

NTPC Ref no SIM/1/TS/2/007

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR GAS FILLING
SL. NO

LIST OF CONTENTS

1.0

PLANT DETAILS

2.0

OBJECTIVE

3.0

PROPOSAL

4.0

SERVICES REQUIRED

5.0

SAFETY PERECAUTIONS

6.0

EMERGENCY PROCEDURE

7.0

STATE OF THE PLANT

8.0

METHOD

9.0

COMPLETION CRITERIA

10.0

APPENDICES

Sheet 1 of 12

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0018

NTPC Ref no SIM/1/TS/2/007

Sheet 2 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR GAS FILLING
SL.NO
1.0
1.1

STATUS
PLANT DETAILS
500 MW Generator consists of the following components.
a. STATOR

Stator Frame
End Shields
Stator Core
Stator winding
Hydrogen coolers

b. ROTOR

Rotor Shaft
Rotor windings
Rotor Retaining Rings
Field Connections

c. BEARINGS
d. SHAFT SEALS
1.2

The two pole generator is designed with direct water cooling for
the stator winding, phase connectors and bushings and direct
Hydrogen cooling for rotor winding. Generator losses, such as
iron losses, windage losses and stray losses are also dissipated
through hydrogen. The generator frame is pressure resistant,
gastight and equipped with major components mentioned above.
The hydrogen coolers are arranged vertically inside the turbine
end stator end field.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0018

NTPC Ref no SIM/1/TS/2/007

Sheet 3 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR GAS FILLING
SL.NO

STATUS

1.3

The Generator is provided with the following auxiliaries which are

essential for generator operation.

1.4

They are

Seal oil systems

Gas Systems
Primary Water System
Excitation System

Respective Testing Schedules / O & M manuals are to be referred

for commissioning, operation and maintenance of these systems.
Technical Specification of Generator are given below.
Generator Type
THDF 115/59

1.5

Main Excitor Type

ELR 70/90 30/6-20

Pilot Excitor Type

ELP 50/42-30/16

Generator Apparent Power

588 MVA

Generator Active Power

500 MW

Current

16.166 KA

Voltage

21KV + 1.05KV

Speed

3000 RPM

Freqency

50HZ

Power Factor

0.85 (Lag)

Hydrogen Pressure

3.5 bar

Rated Field Voltage

340 V

Rated Field Current

4040 A

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0018

NTPC Ref no SIM/1/TS/2/007

Sheet 4 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR GAS FILLING
SL.NO
2.0

STATUS
OBJECTIVE
The objective is fill the generator with hydrogen to the rated
pressure and purity and to release it to unit operation.

3.0

PROPOSAL
The objective will be achieved through the following proposals.

3.1

Purging of air with CO2 gas

3.2

Purging of CO2 gas with H2

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0018

NTPC Ref no SIM/1/TS/2/007

Sheet 5 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR GAS FILLING
SL.NO

STATUS

4.0

SERVICES REQUIRED

4.1

Availability of Instrument air

4.2

Availability of CO2 ,H2 gas.

4.3

Availability of man power with required tools

4.4

Availability of lighting/communication

4.5

Availability of Soap Solution for test.

5.0

SAFETY PRECAUTIONS

5.1

Debris in the test area cleared.

5.2

Approach/Stair Case/Platforms wherever required are made

available.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0018

NTPC Ref no SIM/1/TS/2/007

Sheet 6 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR GAS FILLING
SL.NO

STATUS

5.3

Display of board No cutting/welding at all floors made

5.4

Portable fire extinguishers are available in the test area.

6.0

EMERGENCY PROCEDURES

6.1

The test team should be well aware of procedures to be adopted

in case of any abnormality in the activity.

6.2

The test team should know well about the procedures to be

adopted in case of damage to machinery or injury to personnel
connected to the activity.

7.0

STATE OF THE PLANT

7.1

Seal oil system commissioned and put into operation for

continuous running.

7.2

Generator terminal bushings are connected.

7.3

H2 gas coolers not be charged with water.

7.4

Stator winding filled with primary water and primary water tank
kept pressure less. All the valves closed in P.W. System.
All the instruments in gas system are mounted as per scheme.

7.5
7.6

Valves provided in Generator oil drain lines are opened as

follows: (Liquid detector rack)
MKA 21 AA 501, MKA 22 AA 501, MKA 23 AA 501, MKA 24 AA
501, MKA 23 AA 511, MKA 24 AA 511.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0018

NTPC Ref no SIM/1/TS/2/007

Sheet 7 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR GAS FILLING
SL.NO

STATUS

7.7

Vent valves provided in oil drain lines are closed viz., MKA21 AA
502, MKA 22 AA 502, MKA 23 AA 502, MKA 23 AA 512, MKA 24
AA 502.

7.8

Valves provided in gas impulse line for valve A1, A2 in seal Oil
system are opened.

7.9

Ensure that all the shut off valves are in closed condition.

7.10

Ensure that sufficient no. of H2 cylinders and CO2 cylinders are

made available and are required quality.
No. of H2 cylinders ------------- 110 cylinder of 5 m3 vol.
No. of CO2 cylinders----------- 40 cylinder of 20 m3 vol.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0018

NTPC Ref no SIM/1/TS/2/007

Sheet 12 of 12

Plant area: TURBO GENERATOR

PROCEDURE FOR GENERATOR GAS FILLING
SL.NO
8.0

STATUS
METHOD:

8.1

Replacing air in the generator casing by CO2:

9.0

COMPLETION CRITERIA
Leakage test should be carried out for 72 hrs at 4 bar and
average air loss should be calculated. The permissible air loss for
a gas tight system is below 2.4m3 at N.T.P. / 24 Hrs.
If air loss is higher, checks should be carried out for detecting the
leakage areas.

10.0

APPENDICES
The following system drawings to be referred from O & M manual
Gas System
P.W. System
Seal Oil System
Generator Instrumentation Scheme
Waste Fluid System
Waste Gas System

Signatures
NTPC

BHEL

PROCEDURE FOR GENERATOR GAS

FILLING