4 ner “TIRODA THERMAL POWER PROJECT 1380 ARUBA | TURBINE GENERATOR | “yw (21660 MW PHASE I+ 1<660 MW ) snastemstrcrne | INSTRUCTION BOOK ceecus tess i Project TIRODA THERMAL POWER PROJECT 1980 MW (2x660 MW Phase | + 1680 MW Phase II) | Tiroda, Gondia District, Maharashtra OG a ae i 4 ADANI POWER MAHARASHTRA LIMITED TIRODA, MAHARASHTRA ADANI GROUP ‘Owner's Consuitat : FICHTNER Consulting Engineers (India) Private Limited | and BLACK & VEATCH ~~ Revision PROJECT'DOC.TITLE; TURBINE GENERATOR INSTRUCTION BOOK —— VENDOR DOC. NO. “TRIVQOA460F5720—— Revision & ESS) ESSA SIRE RRAA Les ei apy he sae oe a cHEcKED | APPROVED ee | sash DETAILS OF REVISi DOCUMENT NO.:TR/YQOA460F572 Page 1 of 102 Bate : .Bo By \ THERMAL POWER PROJECT 1980 TURI ENERATOR | "00) 1MW (2660 MW PHASE I+ 1*650 MW INSTRUCTION BOOK Phesell) CONTENTS. Chapter 1 General Description... 1.1 Characteristic of products. 1.2 International standards. 1.3 The Nomenclature of the generator model.. 1.4 Operation condition and environment... 1.5 Main technical performance... 1.6 The conditions of safe operation .. 1.7 Others ... a Chapter 2 Technical Data... 2.1 Basic technical data 2.2 Other technical data Chapter 3 Generator Structure... 3.1 Summary...... . sree 11 3.2 Stator... 3.3 Generator rotor. 3.4 Bracket, bearing and seal oi... 3.5 Structure for centering and locating, 3.6 The monitoring system of generator. Chapter 4 Receiving, Handling and Storage of the Generator 4.1 General ... 4.2 Receiving 4.3 Handling : 4.4 Protection during storage... Chapter 5 Generator Operation..... 5.4 Initial Operation 5.2 Monitoring and attention of operation 5.3 Permitted operation mode and specification (Normal and abnormal operation)....45 5.4 Monitoring stator coil temperature detectors. 5.5 Procedure for the condition monitor after alarm .. 5.6 Protection. Chapter 6 Inspection and Maintenance. 6.1 Preventive maintenance.. DOCUMENT NO.:TRIYQOA460F572 Page 2 of 102“TIRODA THERMAL POWER PROJECT 1080 JE ifs S259 | TURBINE GENERATOR | "HEV Ccrosomw ruase Tr ooo Baneuaimircrae | INSTRUCTION BOOK | Phasell) 6.2 Inspection. se : 54 6.3 Maintenance of hydrogen, seal Oil, cooled water systems and hydrogen coolers 73 6.4 Stator coil water washing and generator backwashing de\ 76 6.5 Precaution safety items..... TE Chapter 7 Collector (Static Excitation)... 78 Chapter 8 Appendix a a 7.4 Collector ring 78 7.2 Collector bushing ..... 7.3 Brush holder and brush rigging 7.4 Collector fan and duct 7.5 Brush..... 7.6 Operation and maintenance of collector. 8.1 660MW Generator technical data sheet. 8.2 Generator installing/removal tools... 8.3 Main tools which prepared by customer (power plant) 8.4 Additional tools and devices recommended for generator installation (prepared by the customer) _ 86 8.5 Attached figures 86 DOCUMENT NO.:TR/YQOA460F572 Page 3 of 102TRODA HERA POWER ROE TT TUERAE GENERATOR | “anverntnnie row Phasell J Chapter 1 General Description This instruction book is applied to QFSN type water-hydrogen-hydrogen turbine generator at rated output 660MW. The generator is driven by steam turbine, and it can be matched with all the type of sub-critical, supercritical, ultra supercritical and nuclear turbines. 4.4 Characteristic of products 4.1.4 Capacity Generator capacity can match the maximum output of corresponding steam turbine. 1.1.2 Efficiency With the rated power factor of 0.85 (lagging), the generator efficiency arrives 98.85%, when static excitation systems is adopted. (See details in the technical agreement) 1.1.3 Ceiling voltage The high initial response excitation system is used. The generator can reach 95 percent of voltage difference between ceiling voltage and rated field voltage within 0.1 seconds when there are failures in power system. The ceiling voltage can be 2 times of rated field voltage when static excitation is adopted respectively, Besides, digital AVR is adopted, it greatly improves the stabllity of the excitation system. Static excitation interface (collector) side - hereinafter referred to as exciter-end. 1.1.4 Rotor damping system The reliable rotor damping system is adopted,it makes the generator higher negative phase sequence current capability. 1.1.5 Convenient shipment The maximum frame width is 4 meters. The maximum shipping weights of stator is 365t (by train using Clamp car) or 345t (by sea) respectively. The generator is optimized design based on the advanced world-class technology transferred from Westinghouse Electric Corp. (WEC). The product possesses the advantages such as large capacity, high efficiency, excellent performance and high reliability etc. 1.2 International standards This instructions book is a document for receiving, shipping, storing, running, maintenance and examination for 660MW water-hydrogen-hydrogen turbine generator. The followings are the standards which should be complied with. GBI7064 “Specific requirements for cylindrical rotor synchronous machines” GB755 “Rotating Electrical Machines — Rating and Performance” 1EC60034-1 “Rotating Electrical Machines — Part 1; Rating and Performance” 1EC60034-3 _ ‘Rotating Electrical Machines ~ Part 3: Specific requirements for cylindrical | DOCUMENT NO.:TR/YQOA460F572, Page 4 of 102 Bia theTURBINE GENERATOR | TODA TWERIIAL POWER PROJECT 10 | aH ABSA | instruction soon | "= ee ee rotor synchronous machines" GB7409 “Excitation system for synchronous electrical machines- Technical requirements of excitation system for large and medium synchronous generators" 1EC34.16 “Rotating Electrical Machines Part 16: Excitation Systems for Synchronous Machines Moreover, other requirements in technical agreement added in contract with customers must be obeyed. 1.3 The Nomenclature of the generator model QFSN-X-2 means: QF stands for turbine drive Generator ‘'S means water inner cooled stator winding N means hydrogen direct cooled rotor winding and stator core X designates rated output in MW 2 means two poles machine For example: QFSN-660-2: Two poles 660MW water-hydrogen-hydrogen cooled turbo-generator 1.4 Operation condition and environment Normal conditions of generator continuous operation are as follows. 1.4.1 Generator shail be installed in indoor places where altitude shall not exceed 1000 m above sea level. Generator can also be operated at rated capacity in altitude above 1000 m sea level only if hydrogen as a primary cooling medium in generator cooling system can remain at rated absolute pressure which is independent of altitude height, and the agreement with our company should be made in advance on sealing, frame and auxiliaries. 1.4.2 For hydrogen cooler and stator coil water cooler, the maximum temperature of secondary cooling inlet water shall not be greater than 36°C generally. When secondary cooling water circle system is applied, the maximum temperature of secondary cooling inlet water shall not be greater than 38 1.4.3 For other technical requirements and data, please see “Technical Sheet of Water-Hydrogen-Hydrogen Turbine Generator’ in delivery document, “Other Technical Data” in Section 2.2 of Chapter 2 and "Generator Operation” in Chapter 5 (Including parameters on operation condition of generator). 1.5 Main technical performance 1.5.1 The generator possesses peak load ability, it can meet the requirements of peak load and two-shift condition. The number of start-stop is no less than 10000 during the lifespan. 1.5.2 The generator can output the nominal rating at the following conditions: Inlet cold hydrogen temperature is not higher than 46°C. Inlet water temperature of hydrogen cooler is not higher than 35°C, when secondary cooling water circle system is applied, the maximum temperature of secondary cooling inlet water shall not be greater than 38°C. DOCUMENT NO.:TRIVQOA460F572 Page 5 of 102 Ajam | TURBINE GENERATOR | TRODATHERWAL POWER PROECTTH5 SB Ries | THREE GENERATOR | Thr cnanomwriae Teo WH Inlet temperature of stator coil cooling water is not Hydrogen pressure is not lower than the rated value, hydrogen purity is not less than 95%. 1.5.3 At above conditions, the generator is capable of operating continuously to match the rated power at 0.95 PF under-excited (leading) 1.5.4 The generator can operate at continuous rated output at rated power factor over the ranges of +5% in voltage and 42% in frequency, as defined by the shaded area of the following figure or specified by the technical agreement. ve 105 1.5.5 The permissible operation duration after loss of stato coil water is 30 seconds, if the spare pump could not recover the water supply within this time, the generater must be tripped from the system automatically. 1.5.6 There is separately a set of hydrogen cooler on both turbine and excitation ends of generator frame, Each set is divided into two sections. Generator can operate continuously at 2/3 of rated load with one section taken out of service. 1.5.7 Short-time overload capability of stator and rotor win« 1.5.7.1 Overcurrent capability of stator winding ‘The generator is capable of carrying a stator current of 150 percent for 30s without damage. The stator overcurrent vs. time expression in this equation: (7 -1)1 =375s where 1. is the stator current per unit (p.u.); 1 is duration in seconds, ‘The relation shall apply for values of ¢ between 10s and 60s. NOTE: It is recognized that stator temperature under above condition will exceed that under rated load conditions, and the design for machine construction is based upon the DOCUMENT NO.:TRIYQOA460F572 Page 6 of 102 Rea tooTURBINE GENERATOR | TRODATHERMAL POWER PROJECT 7080 JB BO | ‘struction BOOK |" ae assumption that the overcurrent conditions shall be not more than twice a year. 4.5.7.2 The rotor winding is capable of withstanding short-time overvoltage vs. time value as follows: duration (8) 10 30 Field voltage (%) 208 146 NOTE: It is recognized that rotor temperatures under above condition will exceed that under rated load and the design for machine construction is based upon the assumption that the overvoltage conditions shall be not more than twice a year. 1.6 The conditions of safe operation 1.6.1 Before the generator is synchronized with the system, the frequency, voltage and phase rotation must be the same as the bus to which it will be connected. 1.6.2 The relative vibration amplitude (peak to peak) of shaft at bearing journal should not be greater than 80m and the relative vibration value(speed) of shaft at bearing pedestal should not be greater than 3.8mm/s. Otherwise, the generator is stil in safety ifthe vibration values are not greater than the values specified in GB/T 7064. However, when the relative vibration amplitude (peak to peak) of shaft is greater than 250um, the generator must be stopped and disconnected automatically. 1.6.3 Before the generator is put into operation, it must be checked whether the pipe diameter between flange of stator terminal box and stator winding outlet manifold or exhaust pipe in the bottom of turbine side is according with the regulation listed in drawing and water system instruction book, and the removable pipe connected to exhaust pipe must be disconnected during operation. The flow and pressure difference of stator cooling water should be in accordance with the requirements, otherwise, there may be a gas blockage on the top of parallel rings, which may cause great failures. For details, see the instruction book of water system of the products. 1.6.4 During operation, the dew point of hydrogen in the generator should be between -25°C to 0'C, to avoid the short circuit failure due to decreasing of dielectric strength of generator and the probable stress corrosion of retaining ring. Hot work in nearby areas must be forbidden when there is hydrogen in generator or hydrogen is being replaced. When the generator is in air conditions, a removable hydrogen supplying duct should be disassembled, which can make hydrogen not enter the generator even if something is misoperated, and eliminate thoroughly the possibilty of forming explodable mixed gas and make the generator more safety. The generator frame is designed to be explosive-safe, that means the frame can withstand an intemal explosion of a mixture of hydrogen and air. The explosion could not DOCUMENT NO.:TRIYQOA460F572 Page 7 of 102 Bee YooRA TIRODA THERMAL POWER PROJECT 1980 JE JERS] | TURBINE GENERATOR | Mw c2xee0 MW PHASE T+ 1660 MN Snmenvleizcrae | _ INSTRUCTION BO Ese e Pees] hurt people, destroy apparatus or factory houses outside the generator. The accident happens only if there is a misoperation when gas replaced. Air can't enter the frame in normal condition because hydrogen pressure is much greater than atmosphere pressure. Hence the generator running at hydrogen condition is safe as long as essential hydrogen purity is maintained. During hydrogen replacing, the hydrogen sampling position in the generator must be confirmed to be correct: the top of frame in replacing He or air by CO; the bottom of frame in replacing CO, by Hp or air. There will be a possibilty that mixed gas explosion by wrong sampling, wrong reporting composition of mixed gases, and so leading to irrelevant pattern indication of high purity. Or in fact, CO. remain in generator, and people entering generators have dangers of suffocating. In running condition, in case that there is a failure of gland seal ring burning or sealing oil loss, hydrogen will inject from gland seal bracket and bearing journal. At this time, the generator must be disconnected immediately and speed-downed. While the two sets of vapor extractor should be start-upped immediately and then at a low hydrogen pressure, the hydrogen in generator should be replaced by COz. In general condition, because high pressure hydrogen rapidly increase volume and absorb a quantity heat energy, there will not be fire disaster in hydrogen injecting, but all sparks should be forbidden in the field. If there are fire disasters happening, CO2 gas or dry powder should be used immediately to distinguish fire. 1.7 Others The auxiliary system matching with the generator will be supplied as supply contract in full set such as static excitation system, collector and excitation transformer, hydrogen system, seal oil system and stator winding cooling water system. At the same time, introduction book of relational system and auxiliaries will also be supplied. DOCUMENT NO.:TR/YQOA460F572 Page 8 of 102 Fa vbw, Mee‘MW (2*660 MW PHASE I+ 1660 MW. TIRODA THERMAL POWER PROJECT 1980 ee es i | TURBINE GENERATOR pa oe | INSTRUCTION Bt Chapter 2 Technical Data 2.1 Basic technical data The basic technical specification and main parameters of the generator are shown in the “Technical Data of Hydrogen and Water Inner-Cooled Turbine Generator” (see Appendix). Technical data of generators will be varied with different capacities, please see the technical data sheet of the generator which is included in the documentation delivered with the generator. 2.2 Other technical data 2.2.1 Weight and shipment size of main components (See table 2-1) Table 2-1 Weight and Shipment Size of Main Components Shipment Size (LxWxH) (mm) tem Weight (t) Rotor (Net Weight 7 Shipping Weight ) Stator Shipping Weight ( Including Shipping Covers and Consoles, | By Train: 365 excluding End Bracket, Coolers, | By Sea: 345 | 10994%4000%4277 Cooler Casing, Lead Box, Seating Plates and Trunnions ) Net Weight of Stator (Heaviest Component ) Each End Bracket ( Weight / Shipping | 5.5/6.4 71183 13000%2140%2120 —| + 337 x" x 11.4¢ Weight) (Approx) | 3590*1880x1140 Each stot hysrogen Cooler { Weight 4.3/5.4 3800%1660%1270 Shipping Weight ) Each Cooler Casing ( Weight / 4114, 40x2980% Shipping Weight} 124114.4 | 3710%2980%2300 Seating Plates (Total Weight /ShIpDING| 4 574.6 | aayg0x ga0x 83 Weight ) ~~ | Box 2.2 (Including 2 Gland Seal / Bearing Weight of Each 0.02 / 0.87 Gland Seals and 2 Bearings) Lead Box Including Main Lead Bushings ( Weight / Shipping Weight ) Total Weight of the Generator 502 Weight of Collector Ring For Static Excitation System ( Weight / Shipping} 12/136 | 332031002770 Weight ) 6.31105 | 3430x2650x3720 DOCUMENT NO.:TRIYQOA460F572 Page 9 of 102 Bea je= | TURBINE GENERATOR | TRODATHERVAL POWER PROJECT 180 | tae INSTRUCTION BOOK | MW @rssomme tiny Te tesso Me Excitation Transformer (Single phase) 24 {6300*3500%3100 Stator Coil Water Supply ( Weight / 92 «: x4 Shipping Weight ) 112.6 5250*3640x4130 Gland Seal Oil Supply ( Weight / 4 Seah) 6.2/8.5 | 4080%3230x2830 2.2.2 Hydrogen leakage It is guaranteed that at rated gas pressure 0.45MPa (g), the generator gas leakage rate shall not be more than 18Nm?/24h, The gas capacity after final assembly is about 98 m? and the gas leakage conforms to the IEC Standard. In the airtight test of water ducts in the generator stator windings, the limit of air leakage at rated hydrogen pressure is 0.2%P'/24h, P' is the initial pressure in the test. 2.2.3 Main characteristic of the excitation system The static excitation system is used. At the rated condition, the generator can reach 95 percent of voltage difference between ceiling voltage and rated field voltage within 0.1 seconds, Ceiling Voltage: 2 times of rated field voltage for static excitation Forcing Excitation Time: 10 Seconds Notes: a) Detailed data of excitation system: Please see “Static Excitation System Introduction’. b) Technical data of AVR: Please see “Automatic Voltage Regulator Introduction’. 2.2.4 Auxiliary System Notes: a) Parameters of the main components of the and Signal System Introduction”. b) Parameters the main components of the Stator winding cooling Water System: Please see “Stator Water Cooling and Signal System Introduction’. ©) Parameters of the main components of the Hydrogen System: Please see "Hydrogen and Signal System Introduction’. Sealing System: Please see “Oil Sealing DOCUMENT NO.:TR/YQOA460F572 Page 10 of 102 BateTiRODA THERMAL POWER PROJECT 1080 5] | TURBINE GENERATOR | "iw (2xoc0 MW PHASE I+ 1*660 MW Phase) ip Sumemvieiscree | INSTRUCTION BOOK Chapter 3 Generator Structure 3.1 Summary Today's large turbine generator has been commonly using hydrogen as cooling medium. It has the following advantages: a) The hydrogen density is low. Pure hydrogen density is only 7 percent of the air density. Even in the generator frame, hydrogen density at 0.5MPa(Q) is only about 60 percent of the air density. So the ventilation loss is reduced greatly. b) An increased output per unit volume of active material is secured because of the high thermal conductivity(about 7 times than airland high relative heat transfer coefficient(approximately 135% of ait)of hydrogen .It is advantage of hydrogen to heighten the generator output capacity by raising the hydrogen pressure, particularly in the hydrogen inner-cooled structure, in which hydrogen contact the heated conductor directly. ) Maintenance expense is reduced because of the freedom from dirt and moisture due to the closed recirculating gas system. 4) The life of the insulation on the stator winding may be increased because the absence of oxygen and moisture lessens the harmful effect of any corona that may be present during unusual conditions of operation. ©) The windage noise is reduced because of the lower density of the gas and because of the closed ventilating system. Nowadays, the using of commercial hydrogen is safe because it is inert, non-explosive and not combustion supporting due to its purity. It must be pointed out that the hydrogen which mixes air should possibly explode if the ratio of hydrogen volume is among 4-75%.Therefore, during the generator structure design, installation and operation regulation, it must ensure that the hydrogen ratio must kept away from the explosion ratio in any operation condition. So the shaft sealing devices are mounted on the bracket at both ends of the frame. The generator adopts the shaft sealing devices with its lower supply oil, lower hydrogen consumption, more floating and has seal oil system and hydrogen replacement with its supply system to separate the hydrogen from atmosphere outside. And considering the explosion accident for misoperation, the frame is designed to be explosion-safe. This generator adopts fabricated frame structure. The insulated bearings are supported by fabricated brackets on both ends of the frame. The ladder shims between the frame foot and seating plate are provided for generator alignment. The load of the generator is symmetrically distributed on the both sides of foundation, attenuating toward middle. Exam the stress distributed of the seating plate on the spot to check and adjust, in order to reduce the unit vibration by means of ameliorating the bearing support stiffness which connects with stator frame. The high-strength spring plates between frame and stator core are used as effective isolated vibration devices. It can reduce the influence on foundation due to the electromagnetic double frequency vibration of the core. The stator DOCUMENT NO.:TRIYQOA460F572 Page 11 of 102 Bet don125 | TURBINE GENERATOR | "RODATRERAL POWER PROTECT Teo ACHES | INSTRUCTION Boo ee eee core and the end structure parts are cooled with hydrogen by axial flow fans. As the effect of water inner-cooled is better than hydrogen, the stator coils, main lead connectors, generator lead bushing and neutral bus are water cooled. The stator shipping sizes can be shortened and the shipping weights can be further reduced. The integral alloy steel rotor forging is adopted. The linear part of the rotor windings is cooled by the gas through the gap, while the end turns of the rotor winding are cooled by two axial ventilation passages. There are multiple parallel ventilation zones in the rotor and stator core, which altemate zones of hot and cool. The gap baffle ring is mounted on the adjustable colligation ring near the rabbet of the end of stator. And the separate ring between the cool zone and the hot zone is used to enhance the ventilation and cooling effect of the rotor. The hydrogen gas is circulated by two axial flow fans, which are shrunk on both ends of the rotor shaff. For this form of ventilation, the gas friction loss is lower, the temperature of the rotor windings is uniform, the average temperature rising and maximum temperature are lower. It has potential to enhance the efficiency and generator output. Thermal hydrogen is cooled by the cooler at both ends of the generator frame. Two-loop flow of hydrogen is almost symmetrical except the lead box at exciter side. To avoid the frame and rotor too long, the hydrogen coolers are installed transversally in the cooler housings at the top of exciter and turbine end. Thus, the stator and rotor transport weight and size can be reduced. The generator equips st excitation system (including automatic voltage regular), hydrogen ‘system, seal oil system, and stator coil cooling water system, etc. 3.2 Stator 3.2.1 Stator frame and the vibration isolation structure In case of explosion the safety of frame which is used in hydrogen-cooled generator must be considered. Although the hydrogen is neither autogenous combustion nor combustion-supporting, hydrogen mixed with air is easy to explode. The relation between the intensity of the explosion and the mixing ratio of two gases Is close to the sinusoid. In the middle of two ratios 4% and 75%, the intensity of the explosion reaches the strongest level. The generator frame is designed to be explosion-safe. This means that frame will contain and withstand an internal explosion of the most explosive mixture of hydrogen and air at the pressure of 0.01~0.02 MPa (gauge pressure) without damage to life or property to the machine. It most probably ocours during gas changing operation due to the misoperation. During normal operation, air is impossible to admit into frame directly, because hydrogen pressure is far higher than atmospheric pressure. The frame is fabricated from the high quality steel plate and the boiler plate. All the gas tight welds should pass the gas leak test. Hydrostatic test, stress relief and gas leak test at 0.5 MPa(g) must be performed per frame. So the operation of hydrogen-cooled generator is very safe unless the babbit of seal ring melt or seal oil supply suddenly interrupted. DOCUMENT NO.:TRIYQOA460F572 Page 12 of 102 Bate aeTURBINE GENERATOR | TRODATHERWAL POWER PROJECT 1080 [MW (2x660 MW PHASE 1 + 1%660 MW INSTRUCTION BOOK Phasell However, equipment and operation rules have very clear measures to prevent the occurrence of such accidents. The stator core is flexibly spring mounted by using flexible elements to connect to the generator frame. The magnetic attraction between the poles of the rotor and the stator core induces a double frequency vibration in the core. These flexible elements reduce the amplitude of the double frequency core vibratory force transmitted to the generator frame and foundation. The long rectangular flanges which are connected to cooler housing are located on the top of frame at both exciter end and turbine end. The flange has rectangular sealing groove filled with sealant to prevent the leakage of hydrogen. The flange connected to the lead box is located on the bottom of frame at exciter end. The manhole at the top of frame and inspection holes at the bottom of turbine-end are sealed with cover. At the bottom of frame there are clean-up frame and the flange of gas changing pipe as well as the pipe connecters of purity inspect of gas, gas analysis sampling, level controller of float type(leak inspect) and hydrogen dryers, etc. The drainage flanges of stator water system are on both ends. As for the flange of the inlet and outlet water manifold piping is located on the frame. 3.2.2 Stator core The stator core is built of 0.5mm thickness, high permeability, low-loss, silicon steel ‘segmental punching. Each punching is insulated on both sides by painting the class F varnish. Frequent pressing of the laminations during stacking provides a tight stator core. Pressure to keep the core laminations tight during operation is provided by the building bolts and insulated through-bolts located at the centroid of the core. The core clamping pressure is distributed over the core surface by heavy non-magnetic finger plates. A magnetic laminated end shield is assembled on the finger plates to shield the core from axial magnetic flux. By acting as a magnetic shunt to diver flux from the end of the core, the circulating eddy current loss is reduced to enable the generator to carry the upstanding operation at leading power factor. In the stator core there are many radial ventilation passages composed of the core surface cooled, multi-path parallel ventilation and 13 wind zones separated, corresponding to the rotor gas inlet and gas outlet. The separating ring at the five sixth of circumference on the top rounding gap between the gas inlet and gas outlet on the inner diameter of the core is provided to improve ventilation. During the installation and maintenance process, please pay attention to the protection of inner circle surface of the core. The short-circuit in the lamination due to scratch is not allowed. As the rotor magnetic potential is strong, core yoke is high, once short-circuit, the core will be suffered more wear and tear, and there will be greater temperature rising for its larger short-circuit. Thus, it will damage the adjacent, as a result of expansion of short-circuit, leading the core burning accident. DOCUMENT NO.:TRIYQOAAGOFS72 Page 13 of 102 Bea hyo aTURBINE GENERATOR | TRODA THERMAL POWER PROJECT 1980 JE HHS] | TURBINE GENERATOR | ip (acoso MIN PHASE T+ 1660 MW iummveiccrnt | INSTRUCTION BOOK 2 3.2.3 Stator winding design The construction of the water-cooled stator coil utlizes both hollow and solid copper strands with rate 1:2. Each strand is wrapped with electrical grade, continuous filament type polyester and glass servings to form a smooth, continuous, uniform insulation over the entire surface. The electric area of top bar is larger than that of bottom bar, it is form from 4 rows, 5 lines; and the bottom bar is form from 4 rows, 4 lines. The strands undergo a 540 degree Roebel transposition with voids in the slot portion of the coil to reduce the circulating and eddy current losses from both the slot and the end turn regions. The results are higher efficiency and a lower coll temperature. The end of the bar use Involute line, it is reduced the distance between the same series and increased between the differ series phases, So there are 7 different specification bars for both top tum or bottom tum of stator winding, Effective cooling of the stator winding is achieved by water flowing through the hollow strands distributed throughout each stator coil. The water flows through the hollow copper strands in the coil and Teflon insulating hoses carry the warm water to the outlet water manifold. The water is returned to the stator water system for cooling, treating, and recirculation. All materials in contact with the treated water are stainless, copper, or Teflon water hoses. The top and the bottom bar are connected by series connections with Si-rubber coat outside, and tied up by glass tape, make sure that the connection are insulated good between each others. hollow strands solid strands FIG 3-1 TOP BAR FIG 3-2 BOTTOM BAR Stator winding has three phases, double bars in one slot, two branches, and Y rejoining method. Thermalastic insulation is an IEC Class 156 insulation system. Effective corona suppression is provided. DOCUMENT NO.:TRYQOA460F572 Page 14 of 102"TRODA THERMAL POWER PROJECT 1980 TURBINE GENERATOR | "hw cexoe0 MW PHASE T+ 1%660 MW Phase) tipea | Saaeuaieicrae | INSTRUCTION BOOK cE sotwedige an os aaa — 5. FIG 3-3 THE ASSEMBLE IN THE SLOT Of equal importance with the insulation system is the method of slot-fill and bracing used to protect the stator coils from the vibratory stresses experienced during steady-state operation and from the transient disturbances which can be experienced during abnormal operation conditions. The IEC standard set the requirement for steady-state operation and defines the abnormal operating conditions which must be met. Each coil is secured in the slot by high strength mold pressure wedges, which assembled in wedges grooves in the slot. Prestressed driving strip is a wavy, glass-fiber epoxy strip located directly under the slot wedge, and maintains radial pressure on the coils and slot wedges. In the part of the wedges there are small holes used to checking the decrement of the grooves. ripple spring conformable layers. winding insulation copper strands FIG 3-4 BARS IN THE SLOT At the bottom of the slot and between top and bottom bars, there are slot conformable layers solidify at the high temperature, to make sure that the bars solidify together with the shim blocks, also on the side of the slot, the shim blocks is assembled to make the surface of the bars gating in touch with the slots. Every slot between top and bottom bar, there are two temperature detectors (one for preparation), also the temperature detector is installed | DOCUMENT NO.:TRIYQOA460F572 Page 15 of 102 Bate(MW (2*660 MW PHASE I+ 1660 MW. TURBINE GENERATOR | TRODATHERNAL POWER PROJECT 180 L Phasell) at the end of the insulation pipes to obtain an indication of the operating temperature, supporting hoses adjustable ring ination cone laminated end held y{ water manifold intulation braets stl brackets stator core | os FIG 3-5 RIGI-FLEX STRUCTURE. Stator winding uses the RIGI-FLEX end-winding bracing system. The heart of the RIGI-FLEX bracing system is a filament-wound cone that provides a solid structural backbone to which all the other end winding component can be consolidated. The cone is designed to be thermally compatible with the coils and end winding bracing system. Retightenable radial bands or studs are used to consolidate the coils and conforming material to the large cone. A compact arrangement of parallel rings structure is supported to the cone by means of bakelite plate. These flex plates allow the end winding to expand and contract with thermal changes, but are very stiff radially to accommodate transient electrical events. In the end of the core (both EE and TE end), there is a wind shield to limit the air into the air gap. 3.2.4 Main leads ‘Stator parallel rings, phase leads, and main lead bushings are water cooled. The main lead bushings are assembled in a gas-tight main lead box iocated below the frame at the exciter end. Bushings can be replaced without removing the generator rotor. The six main lead bushings extend from the lead box, three of which are used for the main leads connecting to the main transformer and other three of which are used to form the neutral tie. The bushing and the neutral tie both are water cooled, and the bushing is air seal to the waterway and lead box. DOCUMENT NO.:TRIYQOA460F572 Page 16 of 102 Soa Joo———— (SB Eee] VERE SeIEEATOR [areca ar FIG 3-5 BRUSHINGS Each bushing can be provided with bushing mounted current transformers suitable for metering, relaying, or regulator service. The main lead box is welded by diamagnetic steel, it is explosion protection and also with enough rigidity, that can securely support the main lead bushing and the current transformers. The use of diamagnetic steel materials is to reduce the eddy loss in the ste! plate which induced by the large current. 3.2.5 Waterway of the stator 3.2.5.1 The inlet and outlet water manifold pipes The inlet and outlet water manifolds are assembled in EE and TE respectively, they are insulated to the ground, and when the generator operates, they are connected with the ‘ground. The inlet and outlet of the water manifold is upside of the generator to avoid the generator becomes too hot when the water broken. It is connected with the outside pipes. There are temperature detectors on the water manifolds, the temperature detectors are ‘connected with the ports outside the generator. 3.2.5.2 Stator winding waterway The stator coils, parallel rings, main lead connectors, generator lead bushings, and neutral bus are water cooled. Cold demineralized water is piped into a circumferential manifold in one end of the generator. Inside the generator, water flows from the inlet manifold into the coil ends through Tefion hoses. Water discharges form the stator coils at the other end, and collected by hoses and a discharge manifold, and is retuned to the water tank. A parallel path of water flows through the parallel rings, main lead connectors, generator lead bushing, and neutral bus to coo! those components. This water discharges DOCUMENT NO.:TRIYQOA460F572 Page 17 of 102 Faesumer eiscrnt | INSTRUCTION BOOK | W660 MV PHASE T+ t=550 MW ( “Ejigee | TURBINE GENERATOR | TROPATIERNAL POWER PROZECT ao ii into a separate manifold in the lead box and retumed to the water tank. Thus, all the stator winding components are cooled intemally by water. Thermocouples and thermostats are provided in the inlet and outlet water manifold piping for temperature monitoring and alarm. 3.2.5.3 The leakage of the He into the waterway Usually in generator, the pressure of the Hy is larger than that of the stator coil cooling water, so when there is a small crack in the pipes, insulation pipes, connections, the water would not leak into the generator, however, the Hz would leak into the waterway, accumulate in the storage water tank, and then release to the air through the valve on the tank. In our company, we install a dial to check the leakage of the Hz. It is important for us to release the H, from the waterway. Because of the leakage in insulated pipes, the leaking Hz must to be conttolled below 0.14 m® per day. If the leaking He more than 0.87m* per day, it need to pay attention to the leakage and need to find suitable time to stop the generator and find the real problem; but if the leakage more than 11.3m* per day, it must to stop the generator immediately and do well restoration to the generator. 3.2.6 Hydrogen cooler and housings FIG 3-6 HYDROGEN COOLER AND HOUSINGS FIG 3-7 HYDROGEN COOLER ‘Two hydrogen coolers are mounted horizontally in the hydrogen cooler housings on the top of the frame. One is in exciter end; the other is in turbine end. Each cooler has two sections, standard design permitting temporary, part-load operation at 2/3 of rated KVA with ‘one of the four cooler sections out of service. Hydrogen cooler housings are fabricated from stee! plate, which is formed arch structure. They are horizontally symmetrically mounted on the top of both ends. This way can reduce the axial length of generator,,the transportation weight and size of the stator. Housing is fixed with screw on the frame. The seal groove on the joint face is filled with ‘sealant. The hot gas inlet vent of cooler is located at the hot gas outlet vent of the edge of core at the top of frame. Cold gas outlet vent of cooler is located at the cold gas inlet vent of DOCUMENT NO.:TRIVQOA460F572 Page 18 of 102 Bra YaoTURBINE GENERATOR | TRODATHERWAL POWER PROJECT 7080") INSTRUCTIONBOOK |W 2™00 MN DNASE T+ i000 NaH tipeSs the top edge frame. The first clapboard at the edge of frame, inner bracket and the wind leading ring make up of the low pressure at the former and back of the fan on rotor. The pipes of hydrogen charge and discharge are mounted on the hydrogen cooler for its top position of the generator. On the exciter end, a pipe for sampling is provided to check the hydrogen purity. On the bottom of the frame, a pipe for sampling provided to analyze the gas. All the joints of the pipes are located on the bottom of frame. Parameters of cooler are showed in the factory file “technical data of generator," or in this Appendix Table. Cooler have to be passed 1.4 MPa hydrostatic tests before leaving the factory. On scene the working pressure and acceptance test pressure is less than 0.8 MPa. To prevent leakage, B10 nickel brass pipe which is good corrosion resistance is adopted (specifically requirement by the contract) to prevent corrosion. Each pipe should be passed the vortex detection to guarantee quality. Tube plate is made of the anti-corrosion Navy copper. Expanding tubes process is used. Strictly control the assembly size between copper pipe and the brass plate and carefully expanding tubes. Such questions as thermal expansion, pollution discharge, sealing, installation, maintenance and etc are fully considered in cooler's structure. The front water chamber of cooler is rigidly fixed on the frame of hydrogen cooler housing (at the top of the generator) by bolts. Inlet and outlet manifold connect on the front section of the front water chamber. There are four exhaust vents on the top of the front water chamber and two freeing ports on the bottom. The back water chamber of cooler is supported on the right frame of hydrogen cooler housing by block. And the outside of the back water chamber is sealed by frame shape partition board and steel plate. After the cover and the cover plate of back water chamber are taken down, the finned pipe of cooler can be checked. In order to prevent cooling water from leaking into the frame directly, a labyrinth type partition board is provided between cooler and frame. And there are Ro1/2 screws on the bottom of cooler housings on two ends of front and back water chamber, which connect With the float level controller (leak detection alarm) to detect whether the cooler leaks or not. 3.3 Generator rotor The rotor components consist of rotor shaft, rotor winding and its connecting parts, retaining ring, end plate, fans, coupling and damping system and so on. 3.3.1 Rotor shaft The cylindrical type rotor forging is made from chromium, nickel, molybdenum, vanadium alloy steel and is poured with the vacuum degassing process. Forging materials are ultrasonically tested for compliance with rigid quality assurance specifications. Two pole rotors have their pole faces slotted so as to equalize flexibility and to reduce double-frequency vibration. 3.3.2 Rotor winding DOCUMENT NO.:TRIYQOA460F572 Page 19 of 102 Rake :‘MW (2860 MWV PHASE 1+ 1660 MW. ZS] TURBINE GENERATOR | TRODATHERWAL POWER PROJECT 58 JB Bo | ‘Instruction sooK prac t Rotor winding components are subjected to stresses both from rotation and from thermal expansion and contraction. It is essential that these stresses be accounted for and limited in the rotor design. During startups, shutdowns, and load changes the rotor winding will move relative to the rotor structural parts. Built-in clearances and slip layers allow for this motion while reducing the frictional forces which could cause distress or shaft vibration, Hard-drawn, creep-resistant, silver-bearing copper and glass-laminate turn-to-tum insulation reduces the chance of permanent winding deformation or shorted rotor turns. The winding is held firmly against rotational forces by nonmagnetic retaining rings and high-strength rotor slot wedges. In the rotor end turn area, custom fitted glass epoxy blocking and spacers maint alignment of the winding components. The end winding curved sections- potentially high stress areas- are arranged with brazed connections located well away from the curves. Axial expansion is controlled by allowing for expansion to occur and by including teflon slip layers in the rotor slots and under the retaining ring, to limit the friction that opposes axial motion. The field winding is manufactured from cold drawn silver-bearing oxygen free copper. This alloy copper contains the necessary metallurgical creep-resistant properties to minimize distortion during operation. There are 8 coils per pole, and every tum of rator coil consists of 2 copper bars. The slot pertion of rotor coils is cooled with gap pickup ventilation system, and there are 2 rows of milled slanting duets along the axial direction of copper bars in rotor slot portion, n the end portion of rotor colls, 2 concavity bars of one turn make a cooling duct, inlet holes are machined on the windward side of coils just outside of rotor body, and outlet holes are machined at the middle of coil arc portions, all of that make the inner ventilation system. The windings are placed in rectangular slots which are lined with ‘one piece, molded insulating slot cells. The slot cells are teflon lined on the inner surface to permit the rotor copper to move axially due to thermal expansion and contraction. The insulation between tums consists of glass laminate bonded to the copper. The glass laminate exhibits excellent wear characteristics and has a high coefficient of friction, which reduces relative slippage between coil tums that causes wear and copper dusting. Instead, the entire coil slot structure acts as a unit rather than individual turns. After the rotor is pressed and cured, fitted, high-strength slot wedges are driven into the top of the slots. 3.3.3 Retaining rings The rotor end tums are supported radially against rotational forces by 18Mn18Cr nonmagnetic retaining rings shrunk onto the rotor body. This alloy is highly resistant to corrosion and stress corrosion cracking in the presence of moisture and other corrodents. These retaining rings are nonmagnetic steel forging. These floating-type retaining rings, with teflon surfaced insulating liners, prevent distortion of the rotor copper and abrasion of the rotor coil insulation. The rings are shrunk and keyed onto machined sections at the ends of the rotor body with a firm fit at overspeed and rated temperature, The heavy shrink fit provides a low-resistance electrical path for induced rotor surface currents, thereby | DOCUMENT NO.:TR/YQOA460F572 Page 20 of 102 Reaver _EJ eB] | TURBINE GENERATOR | "DMEM TOUTES om Saaeuaicircrae | _ INSTRUCTION BOOK Phase) reducing heating due to rotor surface currents. A circumferential locking ring is provided to prevent axial movement of the retaining ring. This method of support permits the shaft to flex without causing fretting at the joint or overstressing the rotor winding and is used to eliminate the effect of shaft deflection on the rotor end winding assembly. 3.3.4 Damping system There are three damper slots on each pole face. Beryllium copper wedges are used in all damper slots, in the first rotor winding slots which are close to pols faces, and in both ends of rotor winding slots. All beryllium copper wedges are connected to the retaining rings at the ends of rotor slots. This design meets the requirements of the industry standards for negative-phase-sequence current capability. 3.3.5 Coupling The generator rotor has a shrunk-on coupling on the turbine end. 3.3.6 Fan The rotor has two axial fans, shrunk on the rotor shaft at both ends. Blade of fan is made from alloy aluminum forging. The static guide blade ring is designed far higher efficiency. 3.3.7 Balancing and testing The completed rotor is dynamically balanced. It is carefully baked and seasoned at running speed to promote lasting stability of the rotor winding components. Standard equality contro! tests are made on every rotor before and after over-speed tests to verily that no shorted rotor turns have developed. It is performed by means of a continuous impedance test as the rotor speed is increased from rest up to rated speed and back to rest. ‘The rotor is then carefully inspected and a final high-potential test is performed. 3.4 Bracket, bearing and seal oil This type of generator adopts bracket and bearing construction, which means that the bearing and seal ring holder are supported by bracket. This construction is an imported advanced technique, it has some advantages like short span in axial direction, good support rigidity and the bearing centerline close to the end face of the frame, which ensure the least deformation of the bracket when it supports the weight of rotor shaft and the hydrogen pressure and the reliability of gas tightness. Bracket, frame, lead box and hydrogen cooler make up of explosion-safe container. As a part of pressure resistant container, bracket is designed to weld by thick steel plate, gas tight for welds. Gas tight test for welds and annealing is need after the weld as well as DOCUMENT NO.:TR/YQOA460F572 Page 21 of 102 BatheFg HIE; | TURBINE GENERATOR | TRODATHERWAT POWER BROTECT 1505 AGHBEBSI | nstructionBoox | eager hydrostatic test. We perform gas tight test for every bracket, every kind of pipes and defoaming tank in order to ensure the gas tightness of the whole generator. The seal for upper and lower half bracket and the joint face of the frame is in the means of seal groove with sealant. To increase the joint rigidity of the halves, the double-line joint screws are used in the joint faces. The retumed oil of hydrogen side from seal ring flows into the defoaming tank. The oil flowing is isolated in defoaming tank, the hydrogen returns back to the frame by the top channel, the oil of hydrogen side flows back in oil box on the device which supplies seal oi, after passes hydrogen oll pump and filter, the oil flows into hydrogen side oll loop. The returned oil of air side from shaft flows into bearing seat and flows back into main oil tank with bearing's oil. The oil first drain to the loop seal tank , where the bit of hydrogen in oil is sealed up by U-shape oll seal pipe, and pumped out by oil pumping fan, ensuring that there is no hydrogen in bearing oil in the main oil tank, consequently safety. The air side pump exhausts some oil from air side oil tank, which flows back into seal bearing rim after passing oil cooler and filter. Three emergency oll sources are set in seal oil system to make sure the supply of seal oil and running safety. The oil level in defoaming tank adopts over-flowing control, we must be careful to not let oll level too high or oll overflow back into frame. The height of oil pipe out of the tank ensures the lowest oll level, and the highest oil level is controlled by alarm system, which will give an alarm when oil level is over, then deal with it in time. To avoid oil seep in frame base some measurement must be taken as following when bearing purging: fil-up temporary strip firmly between seal ring holders and rotor; rotor could not be rotate; oil level alarm system should be in its position. Generator bearing has lift oil system; high pressure oil lifts up shaft. Oil film forms between bearing pad and journal in order to reduce the friction when start or shut down. We can monitor the bearing pad temperature by thermometric element on the site of the highest pressure. Thermometric element probe extent close to Babbitt alloy, Provisions for mounting of vibration detector probe are provided. Seal ring is assembled in the groove of seal ring holder, which is mounted on bracket, and is insulated and seal with bracket. Be careful, to prevent seal cil into frame, seal ring hold joint face should be coated with sealant according to standard when under installation! Bearing the type of double-flows-double-rings, is tilling pad bearing, its upper half is cylindrical bearing, the lower half is two titing pads made in two pure Cu for base with good heat conductivity. Bearing and gland seal insulation is provided at the following places on both ends of the generator to prevent shaft currents from flowing through the bearing between the bearing pad and the bearing seat; between the gland seals and brackets; between the bearing oil seal and the brackets; and at the top dowel and bearing key. Terminals are provided for checking the bearing insulation resistance on the excitation end. There is double insulation between bracket and bearing or oil seal on this type of | DOCUMENT NO.:TR/YQOA460F572 Page 22 of 102 Aster“TIRODA THERMAL POWER PROJE ESE S| | TURBINE GENERATOR | Thy xcoo mw pHAse T+ 000 MW Buaticnmetecrae | INSTRUCTION BOOK Phasoll) generator's excitation side. The shaft seals are of double oll flow construction with separate air and hydrogen side il supplies to reduce hydrogen consumption. Double rings divides seal ring into two parts axially, there is a 0.23~0.28 mm radial gap between seal ring and journal, and a 0.306~ 0.385 mm axial gap between circles in order to reduce chances of the wearing to journal, which is useful fo run safety. To prevent rotation with shaft, a stop-dowel is installed on outside circle of seal ring. which is located in the seal holder. 3.5 Structure for centering and locating ‘The generator frame is supported by frame feet along its length on foundation seating plates. Shims between the frame foot and seating plate are provided for generator alignment with respect to the steam turbine generator shaft system. A number of jack bolts are also provided in the generator frame feet for vertical alignment. Provisions in the frame feet and in the seating plates allow engagement of axial anchors (embedded axial anchor plates provided by the foundation designer) to allow for thermal expansion of the generator in both axial directions. 3.6 The monitoring system of generator The monitoring of generator includes temperature, vibration, insulation resistance against ground, leakage, hydrogen humidity, inner partial discharge and part overheating, etc. Thermoscopes are important in the generator running. They can monitor the temperature test point at real time though computer system. Little else has been know about the internal condition of the generator. Today, there is more instrumentation which can be used to determine the condition of the generator. 3.6.1 The detectors of inner temperature PT100 resistance type for the top of tooth, middle yoke, press finger and magnetism shield of the end core of stator. The quantity and the position as “The Thermoscope Arrangement DWG" show. ‘Two simplex PT100 resistance type for each slot armature windings, 84 total. One simplex PT100 resistance type, in each stator coil bar cooling water outlet. 84 totals. One simplex PT100 resistance type, in each bushing circuit water discharge, 6 totals. 3.6.2 The detectors of temperature in water manifold of stator winding One type E duplex thermocouple or duplex PT100 resistance type for the stator coil cooling inlet water at exciter side and the stator coil cooling outlet water at turbine side, 2 totals. 3.6.3 The detectors of hydrogen temperature of hydrogen cooler DOCUMENT NO.:TRIYQOA460F572 Page 23 of 102 FaheTURBINE GENERATOR TIRODA’ TaAL POWER. Feoicr 1980 aE | instruction soox |e Met One duplex resistance type for each hydrogen cooler outlet cold gas. One duplex resistance type in common hot gas inlet to hydrogen cooler. 3.6.4 The detectors of bearing temperature ‘One duplex thermocouples or duplex PT100 resistance located in the bearing metal of each generator bearing. 3.6.5 Monitor the shake of shafting ‘One non-contact vibration pickup for each bearing, 3 totals. 3.6.6 Monitor the insulation of the bearing For double-flows-double-rings oil seal construction, at exciter side double insulation is adopted between the bearing pad and the bracket, between the gland seals and the bracket, between the seal ring and the brackets. The corresponding leading wires attached them are used to monitor the insulated resistance during the generator operation. At turbine side single insulation is adopted. 3.6.7 Monitor the leakage of cooling water The ball float level controller for the leakage of cooling water. 3.6.8 Monitor partial discharge inboard The monitor point provided for the partial discharge of the generator coil or other electric parts. 3.6.9 Monitor inside dampness of hydrogen A set of hydrogen dampness instrument on line for dampness of hydrogen. DOCUMENT NO.:TR/YQOA460F572 Page 24 of to2_|“Efi 26 | TURBINE GENERATOR | "ODA THERMAL POWER PROJECT ae0 Foc INSTRUCTION BOOK | M @7sen ane teety T+ txean uw Chapter 4 Receiving, Handling and Storage of the Generator 4.1 General The generator is dismantled for shipment between the factory and the job site. If via railway, to ensure the safely the rotor should be packaged properly into special train and transported with the stator in the same train. The transportation weight of the integral stator is 365t. It can be shipped by Schnabel train. Because our company is located beside the Huangpu River, the rotor and stator can also be shipped separately. The wound core and stator shipped as a unit with protective sheet metal covers placed over the ends of the frame in order to seal or fil with nitrogen. The four lifting eyes in the stator frame should be dismantled when transportation by train and mounted again when arriving at destination. The lead box, rotor, cooler, cooler cover and bearing brackets will be shipped separately. 4.2 Receiving When the generator arrives, the purchaser should inform our company and check against the shipping lists along with our representatives. This will avoid delays in installation. It is: suggested that when unpacking the purchaser and our representative should check out the key items according to the documents provided for clients in order to control the quality and distinguish the responsibility. The checking includes whether there is other things or wastes. After receiving, the goods should be stored according to the requirement of this chapter. To insure the installation quality, the people in charge should inspect and test completely and carefully before installation. The purchaser should also examine the shipment immediately and if damage is noted, file claim as soon as possible with the delivering carrier. 4.3 Handling Means are provided for attaching lifting devices to all parts, with the exception of the rotor, that must be handled by overhead cranes. When lifting the various parts of the machine, be careful not to nick or otherwise damage any finished surfaces. The rotor should be lifted by slings placed around the rotor body with protective pad between the rotor body and the slings, the finished surfaces should be protected by other suitable materials. The rotor poles should be in a vertical plane in order that the weight is bome by the pole face. Under no circumstance should the sling be secured about the retaining ring, nor the weight of the rotor should be carried by the retaining rings .The only available handing location in rotor body can be referred to the installation drawing “Rotor lifting”. Care must be taken to avoid bumping or damaging the retaining rings, bearing journals and collector rings. The protective coating which is applied to the journals at the factory should not be DOCUMENT NO.:TR/YQOA460F572 Page 25 of 102 Fea IreTOR | TRODATH SOWER PROJECT 1980 MW (2x660 MW PHASE I + 15660 MW OOK Phasell removed until the unit is nearly installed in order to prevent the journal from damaging and rusting. 4.4 Protection during storage 4.4.1 General information Ifthe generator is to be stored outdoors a temporary shelter should be provided to limit temperature changes within the generator and to protect the outside finish. The shelter should be so constructed that an air space exists between the cover and the generator to provide ventilation. The temperature in the shelter should be guaranteed not lower than sc 4.4.2 Stator The stator of a generator shipped with the rotor removed is sealed from exposure to moisture by metal covers on each end of the stator using seal gaskets between the covers and the frame. The lead box is also sealed by a suitable gasketed steel cover. Silica gel is placed inside the stator in the same manner as generators shipped completely assembled. The storage made in air or nitrogen depending on the length of storage. The open ends of stator coil water manifolds should be covered with masking tape in order to prevent the entrance of dirt and moisture. This masking tape should of course be carefully removed from all openings before the generator is finally assembled for operation. The sealed cover of water manifold fiange on frame should be open when join external water pipe. To avoid the stator winding cracking by low temperature, we use the pure ethanol to replace water and air dry for the inner water cooled winding before transportation. If the user has pumped water and the temperature of storage is low, it is suggested that pure ethanol be used to replace water then air dried. This will protect the winding against cracking for freeze. 4.4.3 Storage in air The stators are shipped with a suitable desiccant or silica gel to keep the parts dry for 3 or 4 months at less than 50 percent relative humidity. The frame is equipped with a humidity indicator showing the presence of moisture. If i is over-humidity, the silica gel can be removed and restored to normal condition by drying in an oven held at 135’C temperature for about 3 hours time and can then be returned to the generator for additional usage. The silica gel may be removed through the generator manhole at the top of the frame on the turbine end. If the generator can be stored near the permanent foundation, it may be convenient to make temporary pipe connections to the gas dryer so this unit can circulate air through the drying agent in the dryer. This requires making an adapter to connect one end of the generator to the air inlet on the reactivating blower and the return line at the other end of the generator to the reactivating air discharge valve. When the dryer requires reactivating, it will be necessary to disconnect the lines to the generator and plug them during the reactivating period. Some other desiccation method is also easy, for instance hot water desiccation [ document NO.:TRIYQOA460F572 Page 26 of 102 RaneRAY TIRODA THERMAL POWER PROJECT 1980 EF jfm S854 | TURBINE GENERATOR (MW (2660 MW PHASE I +1660 MW Bawcnveiccree | INSTRUCTION BOOK Phasell) method is convenient if available. 4.4.4 Storage with nitrogen The shipping covers are provided with gaskets in order to make the generator gas tight for approximately 1-1.5kPa pressure. The nitrogen can be supplied by means of a nitrogen regulator taken from a power transformer. The nitrogen fillng device on the blind joint of generator bottom can be used for admitting the gas. We have experience and records that have been kept in good condition for a long time by using this mathod. In order to monitor the insulation of generator winding in long time storage, there is a lug plate displaying the data of resistance on transportation cover. 4.4.5 Rotor The journal of shaft, coupling end face and gas tight surface should be covered with grease and antirust. All parts of shaft covered in the storage period. It can be removed before finishing installation and circulating oil For domestic short shipping, rotors shipped separate from the stator are shipped in a knitted laminating antirust enclosure, laid on the stow-wood in the iron wood box. The rotor should be lifted out when mount into the stator. After lifted out, the rotor body should be placed on the stow-wood. Note: The rotor poles should be in a vertical plane in order that the weight is borne by the pole face, the small tooth or the protuberant wind catcher on the wedge (if there is) should be shielded and not pressed directly. The rotor should be wholly placed in the shed in workshop, the shed could be wood construction, covering with oilcloth which is dampproof, dustproof. Place space heaters around and underneath the rotor so as to keep the temperature of the parts at least 5° above the ambient temperature but less than 75°C absolute temperature. The heating capacity depends on the weight of rotor, every 13.6t needs about 1kW quantity of heat. The space heaters should be mounted on asbestos board or bricks and secured in place so as not to accidentally touch combustible material. Heaters should be placed at least 15 to 20 cm away from combustible parts with holes provided at the top of the enclosure for ventilation. The rotors which are shipped distantly are placed inside a iron wood box, the rotor should be first wrapped by a knitted bag, then 2 layers of aluminum foil bag which is vacuum The middle aluminum foil bag is filed with silica gel and the outer aluminum foil bag equipped with a humidity indicator. Rotors shipped in this manner should be left in the shipping container until the rotor is to be installed in its stator. If the rotor is left in the original shipping container, the humidity indicator should be checked weekly, and if the indicator shows moisture in excess of 50% relative humidity, the desiccant should be removed and dried out. Retaining rings must be kept dry at all times to prevent possible corrosion cracking. If the packing of the rotor is neither vacuum nor equipped with humidity indicator, the rotor winding insulation resistance should be checked periodically with 500V megohmmeter, if the insulation resistance is lower than 10MO, the hea DOCUMENT NO.:TR/YQOA460F572 Page 27 of 102 jo commernecmvenenrsTURBINE GENERATOR tae INSTRUCTION BOOK ‘FIRODA THERMAL POWER PROJECT 1980 MW (2660 MW PHASE I+ 1660 MW. Phase) desiccation is needed, the container should be opened, reactivate the desiccant and mount space heater for the rotor. 4.46 Protection of single parts The machined surface of bearing brackets, seal ring holder, cooler, cooler cover and lead box is daubed with antirust oil before shipping. These parts which stored in sunproof rainproof and dampproof place should be checked for the oil coat, grease or antirust should be daubed again if necessary. The sealed insulated gasket of seal ring holder is placed horizontally in the plastic bag and sealed, then fixed with upper and lower hardboard, finally placed horizontally in the ‘wood container. These parts should be stored dryly, and unpacked until installation. DOCUMENT NO.:TRIYQOA460F572 Page 28 of 102 Rea gooRA TIRODA THERWAL POWER PROJECT 1080 JE} BS | TURBINE GENERATOR Mw (2x660 MW PHASE I+ 1660 MW Gavonaretecrae | INSTRUCTION BOOK Phasell) Chapter 5 Generator Operation The generator should be operated in accordance with the capability curve. Many factors were considered when the capability curve was figured out. For an ‘example, the hot spot temperature of stator winding, rotor winding and stator core should be in a suitable temperature, however these hot spot temperatures can not directly measured from the temperature detectors, so the capability curve integrated the test result into the design calculation, and it defined the output ability of generator unit under different operating condition. It is known that the measured temperature by detectors might not be the hot spot temperature. The difference between the hot spot temperature and the detector reading is always a various value, which depends on the hydrogen press, output, cooling method, and the ventilation system of the generator, so it is not suitable to regulate the output capability of generator only relying on the detector reading ‘The safety in operation is of first importance, and must rely on the automatic control systems, for the generator with its auxiliary systems. The entire system and control device should be erected completely, before the generator unit puts into service. But on the other hand, the safety in operation depends to a large extent also on high sense of responsibility and subjective activity of the power station personnel. One must closely observe and follow the tracks of different patterns of principal operational parameters during operation so as to find any hidden trouble at an early date by tracing the change emerging in the parameter patterns and to correct it without delay so that one can get twice the result with twice the effort. For example, if any temperature differential between the maximum and minimum detector reading of the same group water cooling circuits or any temperature of the stator winding exhibiting an obvious change in comparison with those recorded under the same operation condition brings quickly to personnel's vigilance and make him go about studying and analyzing for corrective action, it will surely raise the safety in operation greatly due to taking preventive measures in time. Therefore, beginning with the initial operation during commissioning records of various operation parameters at different stages in succession should be carefully examined and corrected item by item for reliability and filed as trustworthy reference for comparison of monitoring data during operation later on 5.1 Initial Operation Before the unit is first started, final checks by the end of erection should be executed and initialed in succession as per check lists of the delivered documentation “FINAL INSPECTION’ for different stages of preparing for commissioning. The following points should be rechecked, however, when the unit is first started 5.1.1 Hydrogen, oil and water systems Make sure that the bearing, seal oil, and stator coil water systems are operating normally and the generator is filled with hydrogen at the proper pressure. DOCUMENT NO.:TR/YQOA460F572 Page 29 of 102 Beate[ST TURBINE GENERATOR | TRODA THERMAL POWER PROJECT 1080 860 MW PHASE 12660 MW EJB TI | ‘Instruction soox | Phasell) In order to avoid the gas blockage parallel ring, exhaust pipe outside the lead box must be erected in accordance with the specification as follows (for details please reference Fig 5-1): (1) The exhaust pipes should be ©48°3.5; (2) Radius of the bent pipe should be greater than or equal to 1.5 times of the nominal diameter; (3) The exhaust pipes connect the interface X and Z, and their length should be less than 5 meters. FIG 5-4 5.1.2 Temperature, hydrogen purity, oil and water quality Generator temperature, hydrogen purity, hydrogen and water moisture content, oil impurity, stator coil cooling water inlet temperature and electric conductivity should be checked, all these parameters should be in accordance with the value stated on Table 5-1, Section 5.2.1.6. When cooling water is supplied to the stator winding cooling water system, itis very important to check whether the air in water system is thoroughly discharged, this is the key to avoid gas blockage in the parallel ring of stator winding. Warning: When cooling water is supplied to the stator wi system, all the pipes, facilities and detecting points should be discharged the air. Open the exhaust valves at the top of the stator winding, discharge the air for the whole stator winding cooling water system. By repeat to open and close the exhaust valve, to make sure that the air in water system is discharged thoroughly. | pocunenr NO.:TR/YQOA460F572 Page 30 of 102 Re, the‘MW (2*860 MW PHASE T+ 1660 MW. 7 = | TURBINE GENERATOR | TRODATHERWAL POWER PROJECT 1580 tae INSTRUCTION BOOK Phase) There is a specific requirement in Section 5.2 for gas discharge of the stator coil Please strictly obeys our recommend so as to avoid the gas blockage. 5.1.2.1 The cold hydrogen temperatures measured by temperature detectors at the hydrogen cooler outlet should be balanced and should not exceed the value stated on the nameplate, Cold hydrogen temperature differential between any two hydrogen cooler outlets should not be higher than 2K at any load. 5.1.2.2 Control the humidity and purity of hydrogen, and the vapor extractor put into operation The purity of hydrogen should not be lower than 96% in general, maintain 98% when efficiency test or performance test is carried out, and will alarm at 90%, When the hydrogen sides pump stops, the hydrogen purity of 90% will be allowed. The hydrogen dryer in hydrogen supplier side should make the hydrogen humidity not bigger than the dew-point of -35 'C. The hydrogen dryer in generator side should make the dew-point in generator from -25 to 0 'C. Before start up, the vapor extractor on air side must be put into operation, to avoid hydrogen enters main oil reservoir and to ensure safety. 5.1.2.3 The stator coil temperatures should be monitored before load is applied. ‘Temperature difference would indicate a defective temperature measurement and must be corrected before operation, for details see Section 5.1.8 for instruction on monitoring. 5.1.2.4 The seal oil temperature (both air side and hydrogen side seal oll) leaving the coolers should be maintained at a temperature between 43 and 49 °C, temperature differential between air side and hydrogen side shall not be higher than 2.2K. In case of shaft abnormal vibration, this oil temperature differential shall not be higher than 1K 5.1.2.5 The moisture in seal and bearing oil should be not bigger than 0.05%. Otherwise, the oil quality should be treated, to avoid the moisture of oil entering into generator. During the oil flushing, the impurity get from bearing oil drain should be in accordance with pertinent requirements. 5.1.3 Hydrogen cooler At first, the air in the exhaust pipes must be discharged thoroughly. All of the water chambers and the pipes must be filled with water. Total cooling water flow supplied to the hydrogen cooler is 900 cube meters per hour. Each section of cooler should be adjusted to have the same water flow, to prevent fault of the tubes due to excessive water velocity. To accomplish this, adjust the throttling valves on outlets of each section to ensure the same pressure drop across it. The pressure drop across a section is the difference between the reading of the pressure gauges on the inlet and outlet of a given section. The adjusted range for the cooling water and hydrogen temperature should not be too excessively, to prevent intense vibration due to deformation of stator frame. 5.1.4 Seal oil cooler, stator winding water cooler, water and oil heaters Be sure that the seal oil cooler and stator winding water cooler are adequately supplied Bea ol DOCUMENT NO.:TRIYQOA460F572 Page 31 of 102URBINE GENERATOR | "RODATHERNAL POWER PROWECT 8 ie AGJBEBNT | nstRucTION BOOK | Mee ee with cooling water at proper temperature. The oil temperature controller should be sensitive enough to response the oil temperatures both of hydrogen side and air side, and there temperature difference. The water temperature controller should also be sensitive enough to control the stator coil inlet cooling water temperature in accordance with the defined value. When the unit will be started, if the oil or water temperatures are much lower than the minimum temperatures defined in Table 5-1 “Generator operation parameters’ of Section 5.2.1.6, the oll or water heater can be temporary started under the condition of the seal oll flowing normally. 5.1.5 Requirements for hydrogen, water and oil systems under various conditions during starting and operation. For details see Table 5-1 “Generator operation parameters” in Section 5.2.1.6. 5.1.6 Bearing insulation The excitater end bearing is provided with double layers of insulation, in order that the insulation can be tested while the unit is in operation, as well as during shutdown with the turbine shaft coupled. Terminal junction and test procedure, see additive Fig 8-8. During operation, the bearing insulation resistance to ground should be measured using @ 1000V insulation tester (Megger) at monthly intervals. Connect the megger to ground and alternately to cach test terminal to measure the insulation resistance directly. 4 megohms or greater are expected. A value of less than 0.5 megohms is unsatisfactory and may result in the flow of shaft current which could damage the bearing. The generator should be shut down immediately. The bearing insulation should be checked at monthly intervals and values recorded for comparison at a later date. A reduction in values indicates a deterioration of the insulation and requires maintenance to be performed before the minimum acceptable value is obtained. Each time the bearing insulation is removed and reassembled, the insulation must be checked before applying excitation to the generator. It should be recognized that the insulation test terminals only check one of the two insulated paths. After the failure of one path, it is no longer possible to check the other insulation path. Continued operation of the generator at this time is a serious risk, and the unit should be shut down to avoid possible bearing damage due to shaft current, 5.1.7 Phase rotation Before the generator is synchronized with the system, the phase rotation of the generator must be the same as the bus to which it will be connected, The phase rotation is given on the technical agreement. 5.1.8 Temperature detectors monitoring during start-up During first start-up after the generator was erected, or any start-up later on, as the stator cooling water system has already put into operation, it is recommended that all of the Be te DOCUMENT NO.:TRIYQOA460F572 Page 32 of 102EJeeSy | TURSINE cenewaron | Maefatidi anaes Baneweeret | INSTRUCTION BOOK Phasell) detectors in stator coll water outlets and stator coil slots should be monitored. (The readings in control room should be calibrated based on the readings from detector terminal junctions) 5.1.8.1 Stator water circuits with regard to stator winding temperature monitoring. Stator winding cooling water enters the inlet manifold at excitation end from which it flows through insulating Teflon hoses into stator winding in three different ways as described below: Water circuit A (Upper bar cooling water circuit) Stator coil water directly flows into the top bars of the EE end winding, through slot portion coils, then comes to TE end winding and at last through Teflon hoses discharges to the outlet manifold at TE. Water passes only one Top bar (that is a half tum of coil) in every water circuit A. There are such 42 circuits in parallel Water circuit B (Bottom bar cooling water circuit) Stator coil water directly flows into the bottom bars of the EE end winding, through slot portion coils, then comes to TE end winding and at last through Teflon hoses discharges to the outlet manifold at TE. Water passes only one bottom bar (that is a half turn of coil) in every water circuit B. There are also such 42 circuits in parallel Water circuit C (Parallel rings and main leads independent water circuit) Water directly flows into parallel rings, then through Teflon hoses, comes to the main leads which located in the lead box, then through Teflon hoses, comes to the tubular copper ‘conductor in bushing, at last, through Teflon hoses, comes to the minor outlet manifold in lead box, and turns into six parallel branches. This water circuit C is an independent water circuit Note: bus bars of neutral leads are water inner cooled series connected with the water circuit of main lead respectively. All the temperature detectors for outlet water in water circuits A, B and C were erected in the water joints of outlet manifold. For details, see relevant drawings. 5.1.8.2 Key points for monitoring a) Because of different areas, ampere densities, and eddy current losses between the top and bottom bars, the existence of several degrees difference between water average temperatures in circuit A and B is normal. As to circuit C, it is also proper for different average temperature. It is most important to monitor all the temperature detectors in outlet water circuits and slots, b) It should be firstly adopted to make a ourve of outlet temperature VS stator current for each temperature detector. So the detected temperature can be compared with these curves at any load, and a failure of cooling water blocked could be inspected in time. ©) Besides above clause, another method to comparing the maximum with minimum. temperatures in the same group water circuits can also be adopted, for example, if the temperature differences between top or bottom bars, or total temperatures exceed the limitation stated in Table 5-2 of Section 5.4.3.2, it must be corrected. Do remember that only DOCUMENT NO.:TRIYQOA460F572 Page 33 of 102 Bea hoTURBINE GENERATOR | TRODA THERMAL Powen pROUECT ian eS fae | INSTRUGTIONBOOK! | Gaeec tc una same group water circuits can be compared, for example, the outlet water temperatures of top bar should be only compared with top bar. d) Compare the temperature of embedded slot detector with the temperature of outlet water circuit detectors. If any slot embedded detector displays an abnormal temperature, the corresponding stator coil outlet water temperature must be checked to see if the stator coil bar is blocked or the instrumentation in the main control room is incorrect, and to record all of these data. If the temperatures of stator coil outlet water is abnormal, the temperature of the slot embedded detector should be checked in the same way. €) The temperatures of independent water circuit C should be lower about 3 to 5 degrees than that of circuits A and B in normal condition, adversely, if they are higher than that of A and B, a careful check must be carried out, to avoid the gas blockage in water circuit C. All the temperature readings of outlet water circuit and slot embedded detectors from terminal junctions and main control room must be recorded at the first flushing the stator winding cooling water system and the startup before application of excitation, for reference to judge the instrumentation is correct, and the unit can be put into operation. 5.1.8.3 Clarify an abnormal condition by means of increasing load step by step During the first start-up for a new unit, increase load in increment of 5% step by step up to 15% rated full load and at the same time read continuously all temperature detectors at each step as soon as temperatures go stable with all readings taken at the same load. The difference between maximum and minimum temperatures from the embedded slot temperature detectors should not exceed 3K; otherwise the corresponding outlet water temperatures should be compared each other to find and correct all the existing problems. The predicted temperature difference between maximum and minimum temperatures from the outlet water temperature detectors in the water circuit A or B should not exceed 4K, however, and in the water circuit C, maximum and minimum temperatures should be in corresponding with the longest and shortest branches, and the max temperature should be lower than the outlet water temperatures in water circuit A or B. Increase load in increment of 20% step by step up to rated full load and at the same time read continuously all temperature detectors at each step as soon as temperatures go ‘stable with all readings taken at the same load. During load up, if any detector temperature rises faster than other of certain water circuits as a group, a blockage of water path shall be suspected, the cause of defect must be clarified and removed. All the foregoing data shall be preserved. If one stator bar is seriously blocked, the readings of slot embedded temperature detectors will be more credible. If all the stator bars are blocked thoroughly, the reading from the outlet water circuit detectors will be the water temperature of outlet manifold, not the outlet water temperature of stator water circuits. During load up, all the temperatures from outlet water and slot embedded detectors should be record at each step, corresponding stator currents should also be record, Ae DOCUMENT NO.:TR/YQOA460F572 | Page 34 of 102 49 "c) lwithin 2.2K; (1K when! hibration Increasing) |The differential pressure lbetween hydrogen and oil \(MPag) [0.084 '0.05—0.092 0.035 L- (il pressure is higher than] \hydrogen pressure) Hydrogen DOCUMENT NO.:TR/YQOA460F572 Page 38 of 102 Bea hePROJECT 1980 TURBINE GENERATOR INSTRUCTION BOOK -jmmananaid Expected Min—Max. [Alarming [Trippin aren ___Wvalue_|value pale elas Cold hydrogen temperature (°C) |Caution: temperature} lciference between outlet|46 oe «ia, 50 Jcold hydrogen temperatures jof any two section coolers| lshould be within 2K Hot hydrogen temperature|Varied with Ic) ldifferent [4580 [_ L load lHydrogen pressure (MPa) (can be lower with load decreasing) At GO0MW Rated power] 0.85 Power factor 0.45, }0.42—0.48 0.42,0.48 lHydrogen purity (%¢) lee Jo—99 No t00 [Hydrogen humidity dew| lpoint temperature under} rated hydrogen pressure} ae ie EB (CC) — Reading of Condition], IMonitor 100% a 75% ie \Cooling water of hydrogen cooler niet water temperature CC)[85 38 |Water flowim*7h) i900 Design max pressure 0.6) lOperation water pressure| (max. pressure — during| ldrop (MPag) JO-055MP@ acceptance test or after maintenance) |Temperature of stator coil water and stator coil Higher than] Inlet water temperature (‘C) [004 l45~50 53 | nlet water temperature (‘) lhydrogen hemperature! (Temperature of exhausting| lwater from outlet manifold] 1 Eo EE (ma) A The allowable value of shaft and bearing pedestal vibration refers to GB/T-7064. The details refer to Caution 6 of Section 5.2.1.2 2X The allowable value of bearing insulation resistance refers to GB/T-7064. The details refer to Section 5.1.6.2 5.2.2 Summary of operating instructions The generator should be operated in accordance with the capability curve. At the same time, the temperature of the cold gas from the hydrogen coolers should be maintained at the value. Stated in Table 6-1 Generator Operating Parameters of Section 6.2.1.6. The operation of hydrogen-cooled generators involves an appreciation of the significance of the various operable temperatures. In modem machines, which use intensive cooling method, the observable temperatures do not provide reliable indications of the significant temperatures in the machine. Other means of controlling these internal temperatures must be adopted. 5.2.3 Temperature li The capacity of a hydrogen-cooled generator is limited by the hot spot temperatures in various elements of constructions, euch as the stator winding copper, the rotor winding copper, and the stator iron, and by the temperature differential across the insulation of the winding. Any one of these point may be the limiting factor, depending on the load, power factor or gas pressure, being carried on the machine. Generally, hot spot temperature can not be measured directly, so that, temperature must be measured at point as close as possible to the predicted hot spot point. The difference between the observed temperature and the actual hot spot is a variable which is dependent on the configuration of the particular design, as well as on the load. Temperature limits of various elements of constructions and coolant are shown in Table 5-1 Operating Parameters of Section 5.2.1.6. tions vf DOCUMENT NO.:TRIYQOA460F572 Page 41 of 102 Ba ke ae = eiTURBINE GENERATOR | TRODATHERWAL POWER PROJECT 1980 ABET] | linstrucrionpoox |e een) ad 5.2.4 Stator winding temperatures Generator stator winding temperatures are measured by temperature detectors of Resistance Temperature Detectors (RTD), the exact pitch number, location and number of which refer to the DWG's of Generator Outline Supplement, Generator Wiring Diagram & Generator Terminal Board Arrangement. Generator with water-cooled stator coils is provided with a small resistance temperature detector at the extreme end of each water discharge nipple to measure the temperature of the discharge water coming from the top and bottom coil sides of the same coil. In each stator core slot, one RTD is embedded between top and bottom stator coil sides of different coils to measure the layer temperature between top and bottom stator coil sides of different coils. To be able to effectively monitor and locate abnormal coll by synthesizing the readings from RTD's embedded between coil sides in slot and RTD's immersed in water discharge nipples. All stator winding and cold hydrogen temperatures detectors should be connected to a Digital Temperature Data Log which has the function of memory with recorder and printer and monitoring continuously in the center control room. ‘To monitor the temperature various or temperature difference of embedded slot RTD's and immersed in water discharge nipples RTD's, the operation persons can control the operating condition in time. Monitor and control Procedures are detailed in Section 5.4 Monitoring Stator Winding Temperature Detectors. 5.2.5 Stator differential expansion The capability of the stator winding is limited not only by total temperature but also by the effects of cyclic differential expansion within the stator winding and between the stator coils and the stator core. Differential expansion is a function of temperature rise of the winding. This requires that the maximum load of the machine be limited so as to limit the differential expansion. The Generator Capability Curve indicates the limits of generator load for operation with satisfactory differential. 5.26 Stator core temperature During operating at leading power factor, that is, under-excited operation, the flux distribution in the generator is such that high losses occur in the first few centimeters of iron at the ends of the stator core. Under these circumstances, the temperature of the core becomes the limiting factor in operation, rather than the stator or rotor winding temperatures. Here again, the generator capability curve provides a guide by limiting operation so as to maintain safe stator core temperatures. 5.2.7 Cold hydrogen temperature and humidity The cold gas temperature in the generator is determined by the capacity of the hydrogen coolers to absorb heat and by the amount of heat to be removed. The difference between the average hydrogen temperature and the average water temperature depends upon the losses to be absorbed. Thus, when the load on the generator is increased without DOCUMENT NO.:TRIYQOA460F572 Page 42 of 102 fu jheTIRODA THERMAL POWER PROVEGT ToB0 ES 1] | TURBINE GENERATOR | Mi Cxccomw pnace Te tace0 mW | Bumcuacarcree | INSTRUCTION BOOK “Phasell) changing the gas pressure or the cooler water conditions, the temperature difference between the gas and the water must increase, with the result that the cold gas temperature goes up. At a given load, if the hydrogen pressure is increased, the temperature rise of the hydrogen gas in the generator is reduced, as is the gas temperature drop thru the coolers. This will result in a slight decrease in the cold gas temperature. In the generator frame, if the hydrogen gas humidity is quite high, especially during shutdown, the condensation will occur. It is severe danger to safe operation for stator insulation and rotor retaining ring. The hydrogen gas humidity should make the dew point in generator from -25 to 0 'C. During normal operation, the hydrogen dryer should be put into operation, or dry hydrogen be supplemented to lower the humidity. The supplied hydrogen gas humidity should not be bigger than the dew-point of -35 °C. 5.2.8 Stator coil cold water temperature The stator coil cold water temperature is determined by the ability of the stator coil water coolers to absorb heat from the demineralized water, assuming a constant supply of cold water at a fixed temperature to the stator water coolers. The maximum stator coil cold water temperature is given in Table 5-1 Generator Operating Parameters of Section 5.2.1.6. At all loads, the stator coil cold water temperature should be maintained below this value by varying the cooler water flow. 5.2.9 Generator capability curve The generator capability curve is drawn so as to limit the hot spot temperatures in the stator and rotor windings, and in the stator core, to practical operating values, and to limit the temperature differential across the insulation of the windings. These capabilities are determined by calculation and shop test, and, as explained above, are not directly determinable from the usual observed temperatures during commercial operation. Operation in the range between zero P-F. over-excited and rated P-F. is limited by rotor winding temperature. This curve gives operation with the field amperes constant at the nameplate value corresponding to the gas pressure under consideration. The region between rated PE. (over-excited) and 0.95 P.F. (under-excited) is limited by stator winding temperature. In this region, the field current will vary with load and power factor but will always be less than the maximum allowable value. Operation in the under-excited range at any power factor between 0.95 PF. and zero PF, will result in the stator core temperature being the limiting factor. 5.2.10 Shaft alignment The turbine, generator, and collector device shafts are solidly connected by means of bolted flanged couplings. During operation, these shafts must be closely aligned. Misalignment may cause higher than normal shaft stresses, and a redistribution of the bearing loading, both of which may be excessive and lead to a mechanical failure The variation in elevation of the generator shaft is function of the temperature of its supporting members. The temperature of the bracket and the frame that support it varies directly with the cold hydrogen temperature. Consequently, the generator shaft elev Ay too DOCUMENT NO.:TRIYQOA460F572 Page 43 of 102TURBINE GENERATOR | TRODA THERMAL POWER PROJECT 1080 INSTRUCTION BOOK | MW ("680 MUIPHASE I+ tx550 MW tipes varies directly with the cold hydrogen temperature. The generator should be operated so as. to minimize the possibility of misalignment between the generator and turbine shafts during load changes. ‘Aconsideration of the relative elevations of the generator and turbine due to the effects of variation in the cold hydrogen temperature indicates that, during normal operation under load, the cold hydrogen temperature should not exceed the value given in Table 5-1 Generator Operating Parameter. Under unusual operating conditions for a limited time, the temperature may exceed this maximum by a few degrees without adverse effects on the system. 5.2.11 Frame distortion Changes in the cold hydrogen temperature and the hydrogen gas pressure cause distortion of the frame ends, with consequent working of the mechanical joints and gaskets. This may result in increased hydrogen leakage and create a need for more maintenance. The performance of the gaskets is also adversely affected by high temperatures. The generator should be operated so as to limit frame and gasket distortion by maintaining a substantially constant cold gas temperature and hydrogen gas pressure. 5.2.12 Hydrogen cooler The flow of water should be controlled by valves in the outlet lines from the cooler sections with definite means provided to prevent excessive pressure in the cooler. Excessive water pressure might result in damage to the cooler tubes; therefore, care should be exercised in closing these valves to avoid building up pressure higher than the maximum value given in Table 5-1 of this chapter. The control of the water flow to the hydrogen coolers provides a means of regulating the cold hydrogen temperature at various loads. The water flow is adjusted to maintain the cold gas temperature at or below the limit cold gas temperature, at a substantially constant value. Differential expansion is somewhat greater with the constant ambient temperature method of operation than it is with the constant winding temperature operating method. However, constant ambient temperature operation has the advantage of keeping the winding at a lower total temperature at partial loads, which is favorable to the life of the insulation. The hydrogen coolers are arranged so that they may be operated with one section taken out of service. The maximum load which may be safely carried with one cooler section out of service and at rated hydrogen pressure is 2/3 of the rated load at rated power factor. The water flow to the remaining sections should remain at its normal value so that the water velocities will remain unchanged. The cold gas temperature may be allowed to go to a maximum of 48°C under these conditions. During operating, normal hydrogen pressure is higher than water pressure in cooling tubes, it is hard to aware of water leakage for cooling tubes. The damage of coolers will lead hydrogen leakage to cooler circulating water path, therefore the hydrogen monitor, alarmer and safe discharge measurement must be set up in the out water circuit of Bea Je DOCUMENT NO.:TRIYQOA460F572 Page 44 of 102INSTRUCTION BOOK | MW sso ME DASE T+ x660 MW : T TIRODA THERMAL POWER PROJECT 1980 EieS | TURBINE GENERATOR hydrogen cooler. When water leakage alarming in the generator from the hydrogen monitor system, if the generator operates in a lower hydrogen pressure, cooler water leakage may be a reason, please pay attention to it. It can be judged by closing the water path of each cooler one by one during operating. If water leakage of a cooler section is confirmed, it should be closed, and waiting for handling during shutdown. The instruction of maintain of cooler are shown in Overhaul of Hydrogen Coolers in Generator Maintain and Overhaul of Chapter 7. Water leakage of a few tubes can be handled to make the coolers continue operation by blocking two end of tube. 5.2.13 Stator coil water coolers Water must normally be circulated thru the stator coils whenever electric load is being carried. In normal condition, hydrogen pressure must be maintained higher than water pressure preventing the potential risk of water leakage. The minimum stator water pressure ‘should not be less than 0.15 MPa in case the generator would operate at very low hydrogen pressure due to disordered gland seal oil system, it is allowed that the generator can only operate for a short time, but itis not recommended for continuously operation The stator coil water system consists of two water coolers. They are stand-by for each other. Each cooler is capable of carrying 100% rated load. Air must be vented before water passes thru the stand-by unit. Caution The stator coil water system must be vented to prevent the gas blockage in stator coils not only at the stage of first start-up for new generator but also after any pump of stator winding coil water system shut-down. 5.3 Permitted operation mode and specification (Normal and abnormal operation) 5.3.1 Normal operation mode The parameters at rated condition please refer to the technical data sheet of the generator which is in the documentation delivered with the generator. The parameters at normal condition refer to Table 5-1 “Generator operation parameters” at Section 5.2.1.6. 5.3.2 Unbalanced operation ability Refer to the Technical Agreement. 5.3.3 Ranges of voltage and frequency Refer to “range of voltage and frequency” stated in GB/T 7064. 5.3.4 Short time overcurrent capability of stator winding and short time overvoltage capability of rotor winding Refer to “Overcurrent Capability of Stator Winding and Overvoltage Capability of Rotor Winding” stated in GB/T 7064. 5.3.5 Forcing excitation operation It should be in accordance with the data stated in Setion 2.2.3 of chapter 2" Technical Data” 4a ho DOCUMENT NO.:TRIYQOA460F572 Page 45 of 102JE 3658S | TURBINE GENERATOR | Ao cco mn PHASE T3060 Mi Semen stecree | INSTRUCTION BOOK _ Phasell) 5.3.6 Loss of excitation operation The generator must be reduced to 60% of rated load within 60 seconds and to 40% of rated load within 90 seconds after loss of excitation. The total operation time from loss of excitation must not be more than 15 min, or refers to the Technical Agreement. 5.3.7 Operation at leading power factor Please refer to "Generator Capability Curve” and “Generator VEE Curve" which are in the documentation delivered with the generator. 5.3.8 Requirements at loss of stator coil water The permissible operation duration after loss of stato coil water is 30 seconds, if the spare pump could not recover the water supply within this time, the generater must be tripped from the system automatically. 5.4 Monitoring stator coil temperature detectors 5.4.1 General During operation, the temperature detectors provides a measured temperature level of the stator winding, perhaps more useful but less known is its function of providing a temperature pattern. A change in the temperature pattem of any detector may be the result of a developing internal coil failure, such as blockage or leakage in a stator coil water path. 5.4.2 Record and alarm 5.4.2.1 Original record During stator winding assembling, the water flow for each stator coil side will be measured, recorded and placed on file, after stator winding assembly completed, the hot water flow test will be made in factory .to clarify if the stator coil is blocked. During the generator is first commissioned on site, the temperatures of each part, generator active power (MW), apparent power (MVAR), stator current, stator voltage, hydrogen pressure and cold hydrogen temperature for each section of cooler should be recorded and placed on file, under no-load and different load with different hydrogen pressure. All of above original data are very useful to clarify if the stator coil water circuits, bushing water circuits or stator core are in abnormal situation later on 5.4.2.2 Record and alarm setting During normal operation, generator operating parameters, and temperatures difference shall be recorded. If any temperature detecting point discloses abnormal situation, monitoring at that point shall be intensified by shortening its recording interval During normal operation, the operation condition parameter and temperature in a certain hour should be recorded and placed on file at a month intervals. At abnormal operation, relational record in each hour even each half-hour should be saved. The format of record is computer printed file. Bea, ho |_ DOCUMENT NO.-TRIYQOAGGOF572 Page 46 of 102TURBINE GENERATOR | TRODA WERHAL POWER PROJECT iso ‘iff eo INSTRUCTION BOOK panamaa phased) ee The alarm value is set previously. It should be two sets of setting values for stator ot temperature monitoring, to protect the stator coils during normal operation or abnormal operation. The first is the alarm value of Max. difference among embedded slot RTDs or water discharge RTDs of either water circuit A or B, which is used for detecting the abnormal condition developing inside the stator coils, to reduce hidden damages, and to avoid extra failure. The second is the alarm value of temperature limits. In case of continuous overload or abnormal condition, if any displayed temperature rise is higher than expected value, alarm signals shall be initiated. Because of itis very important that the temperature pattem and temperature difference will change. To detecting an abnormal operation condition, the digital temperature cycling monitor should be used to measure and record automatically, rather than to rely on a high alarm setting only. Besides to set alarm value for stator coil temperature, it is needed to set alarm value for some other important parameters also, for example, the temperature of cold stator coil inlet water should be ranging from 45 ‘C to 50 C. Alarm signals shall be initiated when it exceeds 53 C. Alarm setting values please refer to Table 5-1 “Generator operation parameters " in Section 5.2.1.6. 5.4.3 Monitoring procedure for water inner cooled stator winding 5.4.3.1 General In order to measure the temperature of water leaving each stator coil, the resistance temperature detectors (RTDs) are provided in each stator slot layer, each top and bottom coil discharge water nipple, each bushing discharge water nipple and both inlet and outlet manifold. The monitoring shall be used for: a) To clarify that all the stator coil water circuits are expedite in hot water flow test at factory. b) To monitoring operating temperature for all generator parts. ) Abnormal operation condition could be effectively monitored by comparing the readings of slot embedded RTD and coil discharge water nipple RTD. General, the reading coming from coil discharge water nipple RTD is more sensitive to partial blockage of coil water circuit, The RTDs used in the stator winding slot are made of platinum wires with a resistance of 1000 at 0 C. The small RTDs made of platinum wires with a resistance of 1000 at 0 °C are used in the coil discharge water circuits. These detectors not only display the temperature level of stator coils during operating, but also provide more useful temperature pattern. If a significant variety is displayed in any temperature pattem, it may be caused by failure inside the stator coils, it must be intensified. If the Condition Monitor alarms at the same time and after itis confirmed, integrating the variety of temperature pattern a serious of blockage in stator coil water circuit shall be suspected and must be corrected as soon as Possible, such as, to trip the generator from the system, shutdown and to open it for inspection and then to remove defects, Ie, A /,] DOCUMENT NO.:TRIYQOAAGOF572 Page 47 of 102Feastel DOCUMENT NO.:TRIYQOA460F572 Page 48 of 102 a TIRODA THERMAL POWER PROJECT 1980 JE SBS | TURBINE GENERATOR | “ay (2x60 MW PHASE 1+ 1*850 HWY Samvenaerccree | INSTRUCTIONBOOK |" Phase ll) It is shown by experiences, that stator coil temperature, temperature pattern, temperature rise and max. & min, temperature difference must be monitored seriously and exactly. In this way, base on some abnormity behavior in generator, analyses and correcting action could be done in time to ensure safe in operation before a serious failure will be developed. In order to avoid unscheduled shutdown, the readings from MCR meters and temperature detector terminals at generator terminal board must be calibrated at a half year interval at least 5.4.3.2 Limits of max. and min. temperature difference and max. temperature of stator winding Although the method monitoring max. & min. temperature difference and max. temperature of each water circuit is not as sensitive as the method monitoring the changes of temperature pattem one by one. But itis also a practical method. During monitoring, the limits of stator coil Max. and Min, temperature difference and Max. temperature are shown in Table 5-2. It is used for stator coil temperature monitoring. Limits of temperature and temperature difference for stator coils see Table 5-2 ‘Table 5-2 Limits of temperature and temperature difference for stator coils Monitorin Limits The difference between max. and min. | temperature of water discharge RTDs in either | 8K water circuit group A or B. The difference between max. and min. slot embedded RTDs temperature 10K Max. slot embedded RTD temperature soc | Max. outlet manifold exhaust water 85C Alarm | temperature ; Temperature rise of outlet manifold exhaust sik water to stator inlet cold water Max. water discharge temperature of top or asc bottom coil Max. temperature tise of independent parallel rings, main leads and bushing water outlet to 31K stator inlet cold water The difference between max. and min. temperature of water discharge RTDs in either 42K water circuit group A or B. Trip The difference between max. and min. slot 14K embedded RTDs temperature Max. water discharge temperature of top or} oc bottom coil fs Max. temperature of independent parallel rings, \ main leads and bushing water outlet 90°C |TIRODA THERWAL POWER PROJECT 1980 FESR EBT | TURBINE GENERATOR | yw cxaoo MW PHASE T+ 13660 MW Bunonaiciccrae | INSTRUCTION BOOK _Phasell) 5.4.3.3 Stator Coil Temperature Alarm, Disposal And Trip Generator From the System, shutdown Ifthe difference between max. and min. temperature of water discharge RTDs in either water circuit group A or B. reaches 8K, or the difference between max. and min. slot ‘embedded RTDs temperature in reaches 10K, or the temperature rise of independent parallel rings, main leads and bushing water outlet to stator inlet cold water reaches 31K, or the temperature rise of outlet manifold exhaust water to stator inlet cold water reaches 31K, or any water discharge temperature of top or bottom coil reaches 85°C, or any slot embedded RTD temperature reaches 90'C, alarm signals shall be initiated. The disposal after alarm refers to A in this section. Ifthe difference between max. and min. temperature of water discharge RTDs in either water circuit group A or B. reaches 12K, or the difference between max. and min. slot embedded RTDs temperature reaches 14K, or the any water discharge temperature of top or bottom coil reaches 90°C, it is not allowed that the generator operates in high temperature. It is strongly recommended that immediately lower the load to make the temperature difference or temperature lower than the limit value, and then clarify whether the reading is true. If the reading is true, the generator should be arranged to trip from the system, Corrective Action after Alarm A) The difference between max. and min. temperature of water discharge RTDs reaches 8K, less than 12K,or max. water discharge temperature of top or bottom coil or max. outlet manifold exhaust water temperature reaches 85°C, or Ma temperature rise of independent parallel rings, main leads and bushing water outlet to stator inlet cold water reaches 34K , The difference between max. and min. slot embedded RTDs temperature reaches 10K and less than 14K, or slot embedded RTDs temperature reaches 90°C. After alarm signals initiated, the intent of following inspect steps is to ensure whether the readings are true. Following measures are recommended. a) To measure and record the readings of all temperature detectors in the main control room, under stable load. b) To measure and record above readings of all temperature detectors directly at generator temperature terminal board, and to Compare them with corresponding readings in item “a’, in thie way, to calibrate the readings from the main control room. If corresponding readings disagree, probably a defect existing in the monitoring system. The RTD should be checked whether high resistance connection exists. The resistance of three-wire RTD is equal to total resistance minus wire resistance. c) Check the terminal connection on the terminal board with care. Any trace of looseness or corrosion might cause incorrect reading. During directly measuring per Clause b, the terminal connection on terminal board must be in good condition. During no load operating, it could be judged whether corrosion existing in the terminal connection. The reading of all RTDs should be same. If there are still abnormal reading difference among RTDs, corrosion may be occur in the terminal connection, the generator Ben shel DOCUMENT NO.:TRIYQOA460F572 Page 49 of 102| lm jig Efe | TURBINE GENERATOR | PROPATHERUALFOWER PROJECT io80 ip MW (2x660 MW PHASE T+ 1660 MW Suatcnaiaccrne | INSTRUCTION BOOK Phe) should be shutdown as soon as possible, to displace away the hydrogen inside of generator, and then the terminal connection could be clear up. If some unstable reading of RTDs exists, it is recommended to trip from the system immediately. After terminal connection re-installed, check the tightness with gas leakage detector not soapy water, because of corrosion of terminal connection will still occur by soapy water. If this is a distressing problem always, please ask for Technology Advisory Services Section. d) Increase or decrease15~20% rated load in increment of 5% step by step (not to exceed rated load), keep constant power factor and voltage, the load at each step should be held enough time to get stabilized readings of RTDs. Under this condition, temperature readings should be changed in a regular way with load. If any individual detector displays abnormal readings from the beginning to the end, a defect may exist in this RTD. If no defect between generator terminal boards and the main control room, a defect might be inside the generator. Then it should be scheduled that the generator should be tripped from the system and check the generator inside. @) After having carried out above-clause: a ~ e, if it is still not certain whether high temperature difference is caused by monitoring system, it is recommended to trip the generator from the system, and open generator to go further examination. The time when the generator shutdown depends on trustworthiness of RTDs readings and close to 12K of temperature rise limit or 85 °C of temperature limit. ) After tripping the generator from the system, if a coil discharging water temperature decrease rate is lower than others in same group or is not decrease that a fault is in this stator coil water circuit. Otherwise a fault may be in detector or its monitoring system, Recommend to inspect as follows after generator is shut down and opened. 1) Measure the insulation resistance of RTDs. 2) Check the back of terminal board (note the requirements of gas tightness). 3) Check the RTDs fitted in water discharge nipples. 4) Check any blockage inside Teflon hoses with their nipples. 5) Check the water flow for every stator coil water circuit B) The difference between max. and min. temperature of water discharge RTDs reaches 12K, stator coll water discharging temperature reaches 90°C, or slot embedded RTD temperature difference reaches 14K When close to tripping limits, load should reduced to decrease the temperature rise or temperature difference in limits, and the inlet cooling water temperature should be checked also. At the same time, to compare the water pressure between water inlet and outlet manifolds, solution ratio of oxygen with their limits. Some abnormal among them may impact the cooling water flow of the stator winding and water outlet temperature (inner wall of hollow conductor deposits because of dissolved oxygen). Then it is recommended to take contact with us. To protect the generator from more destroy, if the difference between any two coil water discharging temperature reaches 12K, any coil water discharging temperature Bea fq] DOCUMENT NO.-TRIYQOA4G0F572 Page 50 of 102“TIRODA THERMAL POWER PROJECT 1980 JE SERS] | TURBINE GENERATOR | Mw coxeco MW PHASE T+ 1»660 MW sunt cizcrat | _ INSTRUCTION BOOK heey reaches 90°C or outlet manifold exhaust water temperature reaches 85°C, it is recommended to reduce the load of generator unit at least 10% at once, to make temperature difference or temperature lower than limiter to check the truth of readings. If it is a defect in stator coil, the unit must be arranged down for checking, ) Parallel rings, main leads and bushings as well as neutral connection bus Because of the difference hydraulic resistance among parallel ring, main leads, bushings and neutral connection bus it is not recommended to compare each other. The temperature changing should be monitored (stator current versus temperature curve). If the temperature reading deviates from the normal than 5K, or higher than water coil discharging temperature, further investigate and analysis should be done. The alarm value of cooling water temperature rise should be set in 31K. If any temperature of them reaches 90 ‘C, itis recommended to reduce the load for distinguishing the truth of reading. If itis a defect here, the unit must be tripped from system. D) Temperature Difference Exhibits Change If the high to low or either one to average temperature difference exhibits an unusual change, or if a particular detector exhibits a change (may be high or low), that detector should be continuously observed. A increase or (as well as a decrease in the relative temperature of an individual detector compared to the other temperatures can also be a signal of a developing intemal problem. This change in pattern of a particular detector could be masked within the highest and lowest temperature and not result in a high-low differential indication until serious damage has occurred. A continuous print-out, switching it to a trend recorder or continuous observation is recommended. (Switching to a visual display is not recommended if it cancels the hard copy print out). A record is needed for later analysis. Warning Any sudden change, erratic behavior, or continued increase, of the temperature indicates an abnormal behavior and could be a signal of an internal problem. If this occurs, the generator should be removed from the line as soon as possible. Under no circumstances should the temperature of water outlet be allowed to reach 90 ‘C without tripping the generator. The procedure stated in paragraph A clause a) to e) should be followed as it will provide valuable diagnostic information. 5.5 Procedure for the condition monitor after alarm Please refer to the instructions of the Condition Monitor 5.6 Protection Protection Mode shall be designed by Electric Institute, following protection must be set at least during operation. 5.6.1 Relay protection 5.6.1.1 Longitudinal differential protection of short circuit between generator stator winding as well as main leads Bes Ya DOCUMENT NO.:TRIYQOA460F572 Page 51 of 102TIRODA THERWAL POWER PROJECT 7980 JE} BBS] | TURBINE GENERATOR | U'hiw (2x60 mw PHASE I+ 1660 MW mmcraveiscrat | INSTRUCTION BOOK | Phase I 5.6.1.2 Generator stator winding single phase grounding protection 5.6.1.3 Generator stator winding over-ourrent protection 5.6.1.4 Generator rotor winding over-voltage protection (when static excitation system is adopted) 5.6.1.5 Negative sequence current overload protection 5.6.1.6 Loss of excitation protection 5.6.1.7 Reverse-power protection 8.6.1.8 High temperature protection 5.6.1.9 Bearing insulation monitor Check the insulation resistance of bearing at excitation side, high pressure oil jacking piping, seal bracket, baffle ring and end shield periodically according to “Guiding drawing {or insulation test of endshield bearing assembly’. If insulation resistance is lower than 0.5 MO, it is recommended that the generator should be immediately tripped from the system and checked. If doubting that one insulating layer of double-layers insulation may be harmed, it is recommended to check according to” other methods for examining” of Section 5.1.6 “Bearing insulation’ 5.6.1.10 Abnormal shaft vibration of generator and collector Alam at first, trip form the system as soon as exceeding tripping limit, details as Table 5-1 ° Generator operation parameters " in 5.2.1.6 and Caution 6 in 5.2.1.2 5.6.2 Hydrogen, oil and water system protection Please see instruments. DOCUMENT NO.:TRIYQOA460F572 Page 52 of 102TURBINE GENERATOR | TRODA THERWAL POWER PROJECT INSTRUCTION BOOK se aoseo en ne 1+ Om ee tips Ba Yoo DOCUMENT NO.:TRIYQOA460F572 Page 53 of 102 Chapter 6 Inspection and Maintenance 6.1 Preventive maintenance 6.1.1 General ‘An effective preventive maintenance program can minimize undesirable service interruptions. Knowledge of turbine generator parts which need periodic adjustment or are susceptible to troubles, and of the means for evaluation of their condition, is essential in planning such a program. Preventive and corrective maintenance generally consists of regular periodical inspection during operation and planned outages, complete inspection after the first year of operation, minor or temporary short-time inspection during planned or unplanned outage for some reason, and planned thorough inspection every 3 to 5 years. Before doing any generator system maintenance, the manufacturer should be consulted. 6.1.2 Preventive maintenance program ‘Awell balanced preventive maintenance inspection program is based on evaluation of the insulation systems by effective test methods supplemented by visual inspection. Vieual inepection is essential to detect foreign objects, mechanical damage caused by loosed parts, or wear, or deterioration of components due to vibratory forces or thermal, electrical, or magnetic forces. Most prominent of these parts are the electrical insulation systems. These are complex structures which are subjected to mechanical and thermal stresses of varying magnitude. The reliability of a machine depends to a very large degree on the condition of the electrical insulation. In the field of generator testing no single test has yet been discovered which would permit an overall evaluation of insulation condition. There are, however, a number of suitable tests which help evaluate specific properties or insulation components, as listed in Table 6-2 “ STANDARD GENERATOR MAINTENANCE TEST *. In applying any of these tests to a composite maintenance inspection program, the following criteria should be carefully considered a) The tests applied must be capable of disceming insulation weakness. The adoption of tests at too low a level is entirely misleading, as their results tend to inspire a confidence which may not be justified. Any test which does not stress the insulation at more than service potential is a waste of time and money. b) Tests should have a direct reference to service experience. If one particular property of an insulation system has been found to be suspect, then tests which seek out this weakness should be performed. ©) A preventive maintenance program should attempt to detect any deterioration of insulation due to any of the following causes:(MW (2x60 MW PHASE I+ 1660 MW. TURBINE GENERATOR | TRODA THERWAL POWER PROJECT 1080 | e tigen INSTRUCTION BOOK "Phasell) 41). Thermal aging from cumulative time-temperature effects. 2) Overheating, from causes such as overload or high ambient temperature, 3) Excessive moisture or contact most volume of oil. 4) Contamination by conducting materials. 5) Over voltage, such as switching or lightning surges. 6) Mechanical damage from short circuit, out of phase synchronizing, physical shock or vibration. 7) Mechanical damage due to over speed. 8) Mechanical damage due to the presence of foreign matter. 6.2 Inspection 6.2.1 Regular periodical inspection (during operation or shutdown) The inspection includes cleaning, examination, performance check, and testing. These items are all done when stator end brackets are not removed, The generator should be periodically cleaned, otherwise accumulated dirt, grease, oil and other matter can lead to fire and contamination. The accumulation will also hide the evidence of the troubles. Maintenance test should be shown in program so as to examination, test and maintenance are carried on during operating or shutdown. Successive regular inspection is helpful to keep the generator operating for a Jong time without fault shutdown. Attention: Besides visual examination, listening, touching and smelling should also be used in the inspection. If abnormal occurrence is inspected, the causes should be identified and eliminated. Otherwise, the fault will lead to serious damage for the generator. The check should be carried on the generator and its auxiliary system one time every shift, and the following should be recorded on the ‘inspection daily’ a) mechanical damage b) the relaxation and the abrasion of parts c) the leakage of hydrogen, oil and water d) electric arc damage @) abnormal noise ) abnormal local temperature The operating parameters must meet the requirement in Table 5-1 in chapter 5. The following parameters may be periodically recorded in normal operation (not only these parameters, others such as the parameters of collector in static excitiation system could refer to the Chapter of ‘Collector’) to prevent the abnormal phenomenon from developing. If the test result is abnormal, the test time should increase. Bate fF DOCUMENT NO.:TRIYQOA460F572 Page 54 of 10251 TIRODA THERMAL JE} HS | TURBINE GENERATOR | “iiv‘oscoo mw puase To 080 MW sumerimecree | INSTRUCTION BOOK | Phasell) Table 6-1 Test Items & its interval in generator maintenance SN Test Item Interval Rotor vibration Bearing Pedestal vibration [Stator coil differential temperature & temperature of 2 [both the embedded and stator coil water discharging |Once Each hour \detectors of each group of water circuits. \Once Every shift 3 Bearing babbit temperature |Once Every shift 4 [Bearing olf outlet temperature [Once Every shift 5 _ [Seal oll infet pressure at air side & Hz side [Once Every shift 6 |Seal oil inlet temp. at air side & Hz side |Once Every shift 7__ |Hydrogen gas pressure [Once Every shift 8 [Hydrogen purity zs |Once Every shift ‘9 _ [Humidity of He inside frame and supply [Once Every shift 40 (Hydrogen leak rate (Once Each day 41 [Hydrogen cold gas temp. ~ [Once Every shift 12 _ [Conductivity of stator coil water [Once Every shift 13 _ [Flow rate of stator coll water [Once Every shift 14 _ |inlet and outlet water pressure of SCW [Once Every shift 15 [inlet and outlet water temp. of SCW |Once Every shift 16 _ |Gas flow meter of stator water tank |Once Every shift 17 _ [Pressure drops of SCW across water cooler INGIUdING [oo Every shit jwater filters [Cooling water pressure drop across each hydrogen |G... Every shit icooler. 8 Pressure arop oF seal ol across oll Cooler InGIUAING OH OS eyery shit Insulation resistance’s of bearing, gland seal brackets, |Monthly, at least 20 puffer ring & outer ol seal at EE. (Refer to Attached | once while Fig.9) shutdown [Once start and 21 |Shaft voltage (with field excitation) Ishutdown, at least jonce for a month 22__ [Check rotor grounding detecting system [Once Every shift 23 _ [insulation Resistance of stator & rotor winding [Hime teet whl [shutdown 24 Potential of embedded RTD to ground for checking monthly ‘slot coil coating deteriorated by corrosion ; [Time test while 25 [Hydrogen content inside the ducts of isolating buses. [Te est Attention: a) Because the teflon insulation water pipe can infitrate the hydrogen, the normal hydrogen Bea te DOCUMENT NO.:TRIYQOA460F572 Page 55 of 102“Eye | TURBINE GENERATOR “nue a | sumdny eizcrnt | INSTRUCTION BOOK | MW 760 MVEDIASS I ‘asso discharge exits in stator cooled water tank. If the hydrogen pressure is over than 0.035 MPa, the hydrogen would be discharged through the safety valve and its flow would be recorded by gas meter on gas discharge pipe. Because gas tight test for stator water system has been carried on before the new generator's operation, the record of actual daily flow at beginning could be considered as normal hydrogen discharge (for stator water system) of this generator. Ifthe value on gas meter changes obviously, the causes should be identified and eliminated. For normal operating, the reading of gas meter on water tanks is 5 ft° (0.14m°) . The planning shutdown should be carried on to check the leakage spots while the reading is 20 ft'(0.57m’). The shutdown should be immediately carried on to check the leakage spots while the reading is 400 ft (41.3m’). b) While the generator is full of hydrogen, the blower on back oil tank at air side should be ‘operating all along to prevent hydrogen in oil from entering major oil tank. c) The causes should be identified and eliminated when hydrogen content inside outer cover of isolating buses is over 1% 1d) Hydrogen seal system should be monitored. If hydrogen leakage rises obviously, the causes should be identified and eliminated immediately. ) While the generator operating over two months, if there is a shutdown chance, it is proposed that the waterway in stator coil winding should be washed and backwashed to keep the water pipeline unobstructed. ) If stator coil temperature or temperature difference rises obviously and the reason is considered that coils are blocked, unit load should be reduced to keep temperature not over alarm value and the temperature should be monitored more frequently until the fault is eliminated or shutdown inspection is carried on (See Section 5.4). g) If the conductivity of stator coil water suddenly rises, the cooler should be inspected if water leakage exits and make-up water is good. The causes should be identified and eliminated. fh) If the insulation resistance of bearing is less than 0.5 megohm or the voltage of shaft suddenly rises while operating, the shutdown inspection should be carried on to identify and eliminate the causes, otherwise shaft current will damage the shaft and the bearing. i) In winter the temperature of the generator body should keep over 5’C to prevent stator coil and cooled-water system from freezing. j) It would hurt the insulation and the retaining ring if hydrogen humidity is too high. Hydrogen humidity should meet the requirement in Table 5-1 in chapter 5, otherwise the method such as using the Hz drier or supplying fresh hydrogen should be adopted. In addition, the coagulation should be prevented in the maintenance during the shutdown (See Section 6.3.1). k) The maintenance of the lubricating oil and the seal oil need be paid more importance, and water content and impurity in oil must be strictly controlled. |) For,the problems discovered in daily maintenance, every unplanned shutdown should be Bea toa DOCUMENT NO.:TRIYQOA460F572 Page 56 of 1022 | TURBINE GENERATOR | TRODATHERWAL POWER PROJECT so39 AJB SBTI | Tinstrucrion soo | !™ 0 one) fully used to repair the parts of auxiliary system and those outer parts of the generator. 6.2.2 Planned or unplanned short-time shutdown inspection-The minor inspection or temporary inspection a) Between two major inspections, the preventive maintenance and inspection should be carried on during a suitable shutdown--the minor inspection or temporary inspections to ensure the generator’s safe operating between two major inspections. Minor inspection is ‘once cach year, and temporary inspection is for need b) During minor inspection or temporary inspections, worker should enter inside the generator without the rotor and the end brackets removing. Without removing the parts fe the frame are inspected for the evidence of oil dirt, mechanical damage, abrasion caused by relaxation, local color change caused by abnormal temperature, water accumulation in frame, oil accumulation in frame etc. If necessary and allowable, workers could remove the upper brackets and examine the end fastening conditions of stator coil such as relaxation, yellow powder caused by abrasion, bolts fastening, insulation in nose end, the radial gap between blades and blower hubs, the gap between the oil seal and rotor. Having finishing the examination, record and analyze the data and then check the examination again. Next, after removing the bearing, inspect the tungsten surface of bearing, and the gap between bearing and rotor, and between upper bearing and bracket should be recheck. Check the freedom of the gland seal ring. The gap between the bearing and gland oil ring, the insulation resistance between outer oil seal and grand, the gap between plastic seal of outer oil seal and rotor should be tested before the bearing is removed. If the gaps are out of range, it should be dealt in time. L-shape copper washers and fasten bolts on each shell of the bearing should be fasted before removing the tilted shells. ¢) The abnormal occurrence discovered in daily inspection should be analyzed and identified. If the time is possible and the situation is bad, the parts in frame should be removed and inspected. If the upper bracket and other parts are removed, process, notice, inspection requirement, installation records must be meet strictly the requirement. NOT damage the insulated seal gasket, especially the Q-shape seal gasket near the seal pedestal 4d) Test system of stator temperature should be checked according to the method in Section 5.4.3.3 to ensure its reliability during the shutdown, @) The stator coll DC or AC voltage test need not be done in the minor inspection or temporary inspection, but the insulation resistance of stator coil must be tested. Then the insulation resistance of stator coil and rotor coil must be tested once before cleaning inside stator frame and after cleaning inside stator frame. If necessary, the coil insulation should be dried by hot water or hot air. {) fin the minor inspection or temporary inspections, water pressure in major inlet pipe and major outlet pipe of stator coils is discovered to drop obviously, or some pipe is considered to be blocked, the blocked pipeline should be washed and backwashed according to Ba Se | DOCUMENT NO.:TR/YQOA460F572 Page 57 of 102TURBINE GENERATOR | TRODATHERWAL POWER PROVECT i080 EHBSBTT | struction soon | ™ wonever) enw Section 6.4. If heat-transferred ability of hydrogen cooler drops obviously or water leakage exists in hydrogen cooler, front cover and back cover of the cooler could be removed to clean and serviced (refer to Section 6.3.2), 9) After all inspection and maintenance, gas tight test for the whole generator and auxiliary system should be done if any part inside the frame referring to gas tight has been removed The test items refer to Table 6-2 ‘Standard Maintenance Test Items’ h) After the minor inspection or temporary inspections, the ‘maintenance report’ needs including all maintenance and inspection records. i) The preventive inspection for auxiliary system should be carried on during each shutdown, referring to the manual for all systems. Attention: the inspection and records should be carried on according to the manufacturer’s requirements while removal or installation. If technical requirement is discovered out of range while removal, the cause should be analyzed and eliminated. Technical requirement should be met while re-installation. 6.2.3 Planned thorough Inspection a) The new generator should shut down and be thoroughly inspected after operation for one year. This inspection is similar with major inspection. The new generator is completely evaluated on structure design, manufacturing process and installation process after operation of one year. And the evaluation also includes auto monitor for generator and auxiliary system. All kinds of the problems discovered in the inspection should be dealt with to ensure safe and long operation of the generator, b) The interval between two major thorough inspection should be generally 3~5 years, but it is suggested the interval is 4 years to match major inspection of the turbine. During the period of turbine major inspection, all inspection and maintenance for generator can be finished well. While major inspection, the brackets, collector should be removed, and the generator should be disassembled. And all auxiliary system should be thoroughly inspected, ©) Preventive maintenance program should be worked out for the generator and auxiliary system, including: 1) thorough direct inspection 2) thorough maintenance and test 3) essential overhaul d) It is suggested that for better inspection, the program should include completely recording the monitoring data and assembly conditions of major parts before shutdown. Especially, for the foundation elevation will change, the actual alignment before rotor removed must be recorded for reference while installation. 6.2.4 Thorough direct inspection a) Generally, except for stator frame and lead box remaining in place, end bracket, rotor and major parts are removed according to inverse of installation procedures, and the records should be kept and compared with the data of installation, from which the problems Ra So [| pogumenr NO.:TRIYQOA4G0F572 Page 58 of 102TURBINE GENERATOR | TRODATHERWAL POWER PROJECT 1080 ‘MW (2*660 MW PHASE I+ 1660 MW INSTRUCTION BOOK Phase!) fipes can be found and dealt with. The thorough direct inspection should including stator end coil and coil joint fastening, stator wedge fastening, Inner and outer stator core, finger plate, magnetic shielded structure, radial fastening screws on top of clamping ring for stator core, and end of stator core including nut, epoxy glass-cloth washer and epoxy insulation sleeve of through-bolts. Especially pay attention to color change caused by overheating and the evidence of yellow powder which means the relaxation has led to abrasion. If the relaxation occurs in the stator core, please consult our technology service department. b) The rotor surface should be examined for local overheating, and also on contact surface between retaining rings and rotor body. If the retaining rings are found to have evidence of overheating, the damaged parts should be detailedly examined and the fitting conditions of the retaining rings with the rotor body should be judged over again. Sometimes, it is necessary to get help from the manufacturer. The end coil under the retaining ring and J-conductor connected with the poles should be examined by Industrial endoscope. If necessary, the blower hub should be removed for directly visual examination with reflective mirror. The insulation on the J-conductor should be cleaned, and lead bolts and its nuts should be checked for fastening. The blades, the surface of journals and the couplings should be checked for evidences of damage. The following inspection, test and maintenance are also recommended: 4) Check rotor blades for crack After visual inspection, penetrant test, magnetic powder inspection or X-ray inspection may be chosen for crack detection according to the material character. 2) Magnetic powder inspection may be carried on rotor shaft if necessary after visual inspection. 3) Checking the bushing for water leakage or crack, and the ceramic sleeve and current transformer for overheating or connecting relaxation, and terminal box and outer cover of neutral bushing for welding, 4) Check the wing pipe in hydrogen cooler for relaxation, abrasion or rubbish. Check the pipe if blocked or leak. If necessary, itis helpful to wash the pipe or block the leakage pipe or reinstall the pipe. 5) Check the blower shroud and stationary blades for damage or relaxation. 6) Water pipeline in stator winding should be washed and backwashed, The auxiliary systems such as collector device, excitation system, hydrogen system, oil system, water systems and temperature monitoring system must be thoroughly examined by visual inspection. 6.2.5 Standard generator maintenance test (Table 6-2 Standard Generator Maintenance Test List) Bat DOCUMENT NO.:TRIYQOA460F572 Page 59 of 102| “Efi Sj | TURBINE GENERATOR TIRODA THERMAL POWER PROJECT 1980 MW (2660 MW PHASE 1+ 1%660 MW sanded cent | INSTRUCTION BOOK Phasell) 6.2.5.1 Insulation resistance test see Table 6-2-1 Table 6-2-1 Insulation resistance test Test Expected Item Voltage (V)| Results Remark _—— by Megger| (MQ) RTD 250 25 T.C. Detector 00 3100 Bearing insulation 1000 Refer to note in | Test according to Gland seal & bearing bracKet| . 4 |theattached | attached Fig. 9 insulation Fig. 9. 10-50 (Permissive Value before Rotor winding 500 | generator commissioning is equal to or less than 1 MQ) Stator through-bolts 1000 100 TERiomin / Rimin <2 & - i Regs / Rige <1.3, it oa 2500 oe Wal 12) | shows stator winding sapenichitaieae insulation is affected by damp. Collector Installation a (For Static Excitation System) | _ 50° 10 * For generator rotor, when the insulation is affected by damp (or <10 MO), for safety, don't make AC test over 400V . 6.2.5.2 Withstand voltage test see Table 6-2-2 Table 6-2-2 Withstand voltage test Test Level | Expected Item an eter) Remark Surface potential test over 5 insulated connectors of stator | 99 ip 2e0 ee end winding which are lapped by ) * hand voltage tests ‘fier rotor Stator winding DC test voltage installed & (min) 55(0C) before AC voltage test Stator winding AC test voltage(min) 33 (AC) Rake DOCUMENT NO.:TR/YQOA460F572 Page 60 of 102“E Jfj G25 | TURBINE GENERATOR | TRODA THERWAT POWER PROWECT ato = MW (2*860 MW PHASE 1 + 1660 MW Banana ciecrac | INSTRUCTION BOOK Phase) 6.2.5.3 DC resistance test see Table 6-2-3 Table 6-2-3 DC resistance test Item ea, Results Remark Test done after 1. ” removing outer Platinum RTD 100 at orc pe eel ee wire. aia = Refer to test value in Product Rotor winging certificate for shipment Stator winding UrUe Refer to test value in Product ViV2 certificate for shipment WrWe 6.2.5.4 Other electrical test see Table 6-2-4 Table 6-2-4 Other electrical test Item Remark Performance test of surface anti-corona section in stator coil When the wedges not assembled, test surface resistance by numerical multimeter. When the wedges had assembled, inspect by move of the Ultrasonic Detector probe to judge the imperfection & position of the surface anti-corona section. Shaft voltage test with field excitation before shut down or after startup AC impedance of rotor winding ‘Compared with former test values to check the turns insulation. Test after the rotor removed Rotor winding short-tums test Use hatch transformer instrument to examine. 6.2.5.5 Other non-electrical test see Table 6-2-5 Table 6-2-5 Other non-electrical test item Test Level Expected Value Remark 20 kPafh or no te! Gas fort diwes leakage alarm with | Test after the eps Helide detector set at | rotor removed. ie a 10° missec. Ih conducting state. Before the Thermocouples | By the multimeter. | Temperature reading to | enclosing 2 be in conformity with the | __ bearing a yf, | DOCUMENT NO. TRIYQOAAGOFS72 Page 61 of 102——— EBB | VERSES [When eae stable temperature brackets inside Gen. frame. assembled. No al ith Halide —o lo alarm with Halide | enclosin Air leakage & eee | celesor set at tearing. tight test of Gen. | (ai pressure 10° ~10° mls, brackets with auxitary |e ieee Air Leak: assembled & systems . i <2.5m*/24h seal oil abet (For 0.45MPa) system's feeding. 6.2.6 Recommended test items for special maintenance The following items are recommended according to special requirements: 6.2.6.1 Stator core loop test Magnetic density in the yoke is about 1.4T and short-circuit locations in core lamination are inspected by infrared thermograph. 6.2.6.2 Check whether the soft copper strands of stator main lead broken or not. 6.2.6.3 Ultrasonic inspection, for example: a) Retaining ring detecting. Detecting the rings per overhaul, (Check surface defects by liquid penetrant test.) b) Check interior of rotor forging with ultrasonic inspection after operation of about 10 years. c) The period of ultrasonic inspection for rotor wedges dependent on operation mode of the unit such as peakload mode or basic-load mode (no frequent start and stop). For a peakload mode, test the wedges per overhaul. For a basic-load mode, a longer test period may be adopted according to operation condition. d) Bearing tungsten-base alloy ‘Check whether the shells are separate by the ultrasonic inspection and penetrant test. 6.2.6.4 Vibration exciting test if the vibration values are too large, check natural frequencies of generator components whether near the range of double operation frequency. For example, joints of stator end winding, phase-parallel ring, main lead, blower shroud, inner end bracket, terminal box, neutral enoloser, cooler encloser, stator frame and so on. 6.2.6.5 Analysis of frame vibration and noise If the noise of the generator and vibration of the frame are increased, it is necessary to measure the noise and vibration on the different positions around the generator and slip ring during the operating condition with load. 6.2.6.6 Check whether the water pipeline is unblocked with the method of hot water flow. This test is proposed to be done after replacing coils or insulating water hose. 6.2.6.7 Stator winding gas pressure test, gas tight test or hydraulic water pressure test. If the stator windings are repaired and coils are disassembled, the parts which are closely interrelated with water sub-circuit, such as insulated water hose, etc., the sub-circult flow test should be carried out until its result is qualified, and then carry out the gas Bache DOCUMENT NO.:TR/YQOA460F572 Page 62 of 102“Ee | TURBINE GENERATOR | TRODATHERIAL POWER PROTECT 8p Senurminecrnt | INSTRUCTION BOOK | _MYsen ane rise 1+ 1690 MW pressure test, gas tight test or hydraulic pressure test in whole winding. It also could be the preventive test for overhaul. 6.2.6.8 Check connected bolts, nuts and pins of the couplings using x rays (if suspected damage). 6.2.7 Brief introduction of overhauling main component In order to evaluate the actuality of the generator after disassembly and eliminate the defect, the following work must be done before the generator shutdown and disassembly. a) Before disassembly, list the related gap test-values, referring to ‘the Shafting Alignment Drawing’ by steam turbine factory, and our documents, for example, drawing of blower shroud, drawing of assembly method of oil seal & bearing and bracket on T.E. and E.E. If there is much more difference, analyze the reason and take measures to prevent it again. b) Visually inspect components, get rid of the oil, humidity, rust or corrosion, then record the state before and after cleaning up. ©) According to Sections below (not limited to this), check up the quality of generator components. d) Maintenance tests of generator components are required according to the Section 6.25 and below. e) Replace damaged parts with that in storage and make a list for parts changed for need, ‘so as to prepare the new ones. f) Preserve the removed ones temporarily, referring to the reserving method in Chapter 4 and 6. Attention: process and technical requirements in major overhaul and re-assembly are the same as assembly, but process procedure in disassembly is inversed to assembly, All torques applied to the bolts and nuts should correspond with our provided drawings. In addition, check whether all nuts have been locked. If you have any trouble, please contact us. 6.2.7.1 Inspect the fixation of stator winding in slots After the generator operation for one year, or during a major inspection, the fixation of stator bars in slots should be examined. For stator slot, the fixed structure is designed, of which insulated ripple spring plates. are filled under slot wedges. From the small holes on the slot wedges, the fixing state of the bars can be judged by the difference between wave peak and wave trough measured by ‘special dial indicator. The difference was controlled not greater than 0.7mm before the product shipped. After one year's operation or in the period of overhauling inspection, retest the fixing state in the slot, remeasure the difference of wave peak and wave trough simultaneously. Moreover, feed back all the record to the manufacturer. About the inspection method and judgment standard in detail and manipulation scheme to the loose slot wedge, please contact us for technical help. The anti-corona structure of stator coils are designed as low-resistance Be % DOCUMENT NO.:TRIYQOA460F572 Page 63 of 102 ~*~ay “TIRODA THERMAL POWER PROJECT 1980 _ Efe | TURGINE GENERATOR | "PAT ommmnce ieoeol EHANGHAI ELECTRIC INSTRUCTION BOOK Phasell) semiconducting layer in straight portion, while middle-resistance and high-resistance ‘semiconducting layers in end turns. The insulated ripple spring plates are designed for radial fixation, epoxy glass-fabric plate and conformal material for the fixation between the top and bottom bars, conformal material for fixing bottom of the slots, and low-resistance glass-fabric semiconducting plates for fixing two sides of bars. So the surface of stator bars can ensures close contact with the slot, to avoid that the gap ionization gradually deteriorates and even damages the insulation of bars under high voltage. 6.2.7.2 Inspection fixation of stator end winding The support structure for end winding is designed as mature and reliable rigid-flex banding fixation, please see Section 3.2.3 for structure details. During operation, besides the possible deformation induced by longtime thermo-aging of insulated components, there maybe exits relaxation of bolls induced by steady and transient electromagnetic force. Further, they will induce main insulation abrasion of stator bars and lead to grounding faults. Firstly, check whether the relaxation exits in fastening parts such as nut, screw etc, carefully inspect above parts and bar insulation whether damage or abrasion as well as the generating yellow powder dust. Early discovering the relaxation or damage and eliminating the defect immediately can ensure reliability and availability. Secondly, insulated brackets, metal brackets, and flat spring are also jointed by bolts, ‘Check if there is abnormity in these components and relaxation in the fastening pieces. Flex device should be firmly bonded radially to the end core. Moreover, it cannot prevent end coils from axial thermal expansion Attention: all fastening pieces in the end winding are high-strength insulating material, if the replacement needed, the material performance should be checked and accord with the design requirements, 6.2.7.3 Inspection of stator end winding, parallel rings, joints and the insulation ‘Check the stator end winding, parallel rings, joints and their insulation surface for evidence of damage and overheating, for evidence of corrosion caused by discharge spark. Carefully examine the insulation of the winding for evidence of peeling and delamination. Examine the tightness of joints insulation, and also check if relaxation or abrasion exists in the support of parallel rings and spacer blocks. Because unexpected vibration frequency caused by relaxation will possibly result in faligue rupture of winding parallel ring assembly, itis suggested that yellow dust caused by insulation abrasion and the evidence of insulation abrasion should be inspected carefully. Furthermore, it is important to measure the insulating resistance of stator winding, please see table 6-2-1 in Section 6.2.5.1. As for other electric test of insulation, we suggest as following a) Voltage measure on the hand-lapped insulation surface of end winding connectors refers to Table 6-2-2 in Section 6.2.5.2. b) Concerning withstand AC/DC voltage test, please see Table 6-2-2 in Section 6.2.5.2. In Bean DOCUMENT NO.:TRIYQOA460F572 Page 64 of 102TIRODA THERMAL POWER PROJECT 1900 ES | TURBINE GENERATOR | "Nii Croco mw erase Tr toot MW suntimercree | INSTRUCTION BOOK Phasell) early inspection, if the insulation is tested as early as possible, the defect can be eliminated in time. c) Resistance value measure of stator winding can be found in Table 6-2-3 Section 6.2.5.3. 4d) Please refer to Table 6-2-4,Section 6.2.5.4 and do test on anti-corona of the stator bar surface. 6.2.7.4 Inspection of stator core and frame housing There are many factors which affect the quality of stator core, such as electric and mechanical property of core material being degenerated or senescent, mechanical relaxation, damage in unreasonable disassembly and reassembly, and rubbish in the stator housing. To check the stator core, the inspection region can be divided into three portions: inner circle, outer circle, and the ends. a) Check mechanical damage along the inner circle of stator core, paint film color-changed caused by local overheating, or burning marks. Repair the lamination layers induced by short-circuit, for in a high magnetic-flux, short-circuit of any point on the inner circle will lead to local heat spot in this area. Under a vicious circle, short-circuit will extend rapidly and bum the core, so short-circuit in laminated sheets should be checked and repaired carefully. If necessary, by means of inductive loop test to heat the core, and use the infrared thermograph to find out the over-heating points caused by short-circuit. b) Check the stacked laminations in the area of the core teeth, if local relaxation exits, stutt up the location with epoxy glass laminated sheet. c) After repairing, power plant can also inspect the stator core with infrared theromgrah and examine the repair quality to secure safety operation. d) Examine the bond relaxation of air-gap clapboard arranged al the inner circle of core, ageing of material, and check imputity whether entered the core cooling duets, @) Examine block clamping plate, magnetic shield, building bolt nuts of ends, especially the structure such as through bolt nuts, insulating washers etc, whether have local heating and existence of yellow dust. If yellow dust is discovered, find out the relaxation place and take measure to tighten it. £) If abnormal vibration of stator found in operation, check the welds located in the wall plate of housing, ribbed plate, outer-housing plate, footing piece and cooler cover. g) Check the relaxation of bonded flexible building bolts arranged at the outer circle of stator whether movement and drop-off of clapboard arranged at the cooling area between the wall plate of housing and the outer circle of core. To eliminate impurity between the housing and outer core circle, worker should enter from manhole or cooler frame-space at ends. Due to smaller space, only lesser figure man be adaptive; moreover, some region is unreachable, so this kind of check needs overcoming much difficulty. h) Remove the inspection cover of top housing, check the relaxation of clamping bolts attached to supporting ring, tightening it when needed. Attention: A thorough major inspection of the tightness of stator core must be done Bayh DOCUMENT NO.:TRIYQOA460F572 Page 65 of 102 er(MW (2*660 MW PHASE 1+ 1660 MW TURBINE GENERATOR | TRODATHERWAL POWER PROJECT 1980 | i¢ ERPS | INSTRUCTION BOOK Phase) after operation of one year. Contacting our technical support dept. for help and entrusting us to check the tightness of stator core is advised. If necessary, we will eliminate the relaxation by special tools in time, so as to prevent a furthermore damage leading to a great accident. 6.2.7.5 Insulating inspection and maintenance of stator core through bolts a) Insulated core through bolts The stator core is tightened uniformly into a single monobloc by through-bolts located at the yoke and bullding-bolts located at the outer diameter, which stretched by hydraulic torque wrench and their nuts clamped against the block plate. To ensure that the insulation of through bolts is absolute reliable, we install high-strength, high-thermal with class F epoxy glass tape washer and epoxy insulating sleeve under the nuts, with enough overlapping distance between the bolts and insulating sleeve. b) Insulating inspection of stator through bolts The insulation resistance of the stator through bolts should be checked during maintenance inspections by megger (1000V DC). Values in excess of 100 megohms are characteristic of insulation in good condition. If dirt accumulations build up on the outer side surface or if insulation becomes moisture laden, the resistance will decrease below this value. Each through bolt can stand one ground point without adverse effects on the machine operation. However, where a condition of low insulation resistance exists, it is not possible to ascertain whether one or more than one point is involved. In view of the extensive damage which may result due to a through bolt insulation failure, itis desirable to maintain the insulation resistance at conservatively high values. The following values are recommended as representing conservative operating practice. Table 6-3, Megohms Condition of insulati 700.and above __| Normal ee Indication of slight dit or moisture contamination, the | 10 to 100 correction of which may be postponed to some convenient time ~~ | Relatively severe ditt contamination, the correction of 1t0 10 which should be scheduled for the next maintenance outage, Definitely hazardous condition, requiring immediate Below one correction to avoid abnormal operating hazards. ¢) Maintenance requirements of insulated bolts Check all through bolts for insulating resistance in normal overhauling or middle repair. Fearful of insulation low-resistance checked out, take enhanced examination such as inspection per year or per half year. If insulating washers are cracked, replace it with new one of identical material. Disassemble the nuts and clear the creepage surface polluted, but be careful not to turn the Bada [_pocumenr NO.:TRYQOA460F572 Page 66 of 102Fe GE TIRODA THERMAL POWER PROJECT 1980 Ede | VERE SeneeaoR | Toner Tescae Phasell) bolts or damage the insulation. The core yoke around through bolts is mostly solid. It is designed and considered that different material and coefficient of expansion have an effect on the clamping force of the core at operational temperature. Hence tighten the nuts of through bolts according to the designed force, so as to meet the requirements of uniform compression in any operating mode. 6.2.7.6 Inspection of rotor assembly a) It is recommended to detect the alignment (including elevation) between the generator rotor and the steam turbine rotor, and between the generator rotor and collector shaft before the generator rotor is disassembled. b) A brief introduction of rotor structure is given in this manual. An overall inspection should be taken for journal of the shaft, blower hub, rotor blades, retaining ring, rotor wedge, rotor body and coupling. If it is possible, rotor winding, radial conducting screw, J conductor connected with magnetic pole and axial conducting screw should be also checked. ) When turbine rotor and collector shaft is uncoupled, leave space on two sides for setting up the dial indicators to measure the axial run-out and circular run-out of the coupling on both sides. Record the measured data for coupling axial and circular run-out, and check rotor air gap and compare with the former records, which was recorded when the generator was assembled. d) The journal should be carefully inspected for evidence of nick, crack, flute, overheating discoloration or other drawbacks. Examine the evidence of excessive attrition or non-circularity on the location where outer oil end shield, bearing bush, sealing bush and labyrinth oil seal ring contact. @) Check axial and radial gaps between blower shroud and rotor blades, between blower hub and stationary blades. Check them also for evidence such as overheating of the blades and the hub, frictional damage on the exircle and end face of the hub, and crack at the root of the rotor blades. The balance weight locating in the hub must be tightened if itis loose. The contact location between the rotor shaft and the hub also need to be checked and cleaned. ) Inspect the rotor wedge to make sure smooth of each vent. In addition, axial displacement between the rotor wedge and the vents of the copper stripe also need to be checked to avoid the reduction of through-flow area of slant vent. 4g) In order to examine the damage after the rotor subjected to a fault condition, nicks that may grow into cracks must to be searched and the distribution of the gap between the rotor body and retaining ring also need to be visually checked. Rotor forging should be carefully inspected, especially for the evidence of mechanical damage or overheating after the generator subjected to negative-sequence current or non-synchronous running. h) Switching on when rotor is static will melt the rotor wedge and may cause the crack on the rotor body due to the high current flowing through the rotor body and the rotor wedge. So, it is necessary to check the rotor wedge carefully for the evidence of burning, attrition or A gel DOCUMENT NO.:TRIYQUA460F572 Page 67 of 102] TiRODA THERMAL POWER PROJECT 1980 JE Hi aS] | TURBINE GENERATOR | aw cexss0 MW PHASE [+ 14660 MV sumenatsizerne | _ INSTRUCTION BOOK Phesell) dislocation. The previous fault current will cause the circulation through the shrink surface between the retaining ring and rotor. For this reason, fiting surface between the retaining ring and rotor must be inspected carefully for the evidence of overheating discoloration and mechanical damage. Industrial endoscope can be used to observe the dislocation or deformation of the end winding under the retaining ring and to determine whether the ‘overhang packing is released. If it is necessary, blower hub ring can be disassembled for a convenient observation by a reflecting mirror. When removing the retaining ring is necessary, insulation tube beneath retaining ring must be examined for the evidence of dislocation and damage. i) In a heavy fault condition, such as non-synchronous running, the coupling will be damaged. For this reason, the coupling must be inspected for the evidence of laxity between the key and the bolt, bolt bending and other damages. X-ray pictures of these parts can be taken ifit is necessary. }) Check the nut, which is used to press the J conductor to the radial conducting screw, and make sure it is not released. When it is necessary to remove the retaining ring for some reasons, ensure that the inner ventilating duct between the J conductor and magnetic pole conductor is unblocked and it is not overheating discolored. No damage and dislocation are present in isolation of end winding including overhang packing, turn isolation and isolation of pole conductor, Isolation of axial conducting screw should not has the evidence such as released, crack, overheating discoloration or damage caused by arc. Be sure that no evidence of dent overheating or jump spark is present on the vertical surface where axial conducting screw is connected with the collector ring conductor. k) Measure the DC resistance of rotor winding referred to Table 6-2-3 in Section 6.2.5.3. Measure the insulating resistance of rotor winding by 500V megger. The insulating resistance may be affected with damp or pollution, if the measured insulating resistance is less than 10MQ. In this case, it need be cleaned up or drying. 1) In major overhaul, rotor can be checked for intertum short circuit by apply 110~120V on. the two sides of the rotor winding to measure the AC impedance. This impedance value is compared with the factory value which should have the same values. m) The electric connection between the rotor field winding of hydrogen-cooled generator and field power supply is implemented by the assembly of radial and axial conductor. The connection of field winding is inside the generator, while the connection of the field power supply is outside the generator. So, hydrogen tightness of radial conductor assembly is essential for a secure service of the generator set. Make sure that the rotor radial conductor assembly does not leak hydrogen in the following situations: 1) The generator is newly assembled. 2) The generator is stopped for maintaining. 3) The generator set is detected having leaking hydrogen. 4) Hydrogen is detected inside the collector enclosure. Feathe DOCUMENT NO.:TRIYQOA460F572 Page 68 of 102Fim eas | TURBINE GENERATOR l TTRODA THERMAL POWER PROTECT Toa i suid czert | INSTRUCTION BOOK Capel teria 5) Radial conductor is incorrectly assembled or disconnected with the field winding. Gas tight test is certificated for the radial conducting screw to ensure that hydrogen will not leak into the collector ring enclosure through the radial conducting screw, otherwise the explosive oxyhydrogen, which consists of 4%~75% hydrogen, will be produced by mixing ‘the hydrogen with the air in the cubic measure. Notes: 4) Before gas tight test, isolation resistance of radial conducting screw assembly should be measured. 2) 1/8" taper-pipe plug screw must be used to seal two ‘small holes drilis on the coupling at the exciter side during the gas tight test. Remember to remove ‘the plug screw after the test, the hole drills must be opened in operation for safety. Air or nitrogen used in the test must be dry. Fluorine F-12 is only recommended for detecting leakage rather than liquid. n) Radial conducting screw should be disassembled according to the assembling process: when it needs to be inspected. Note that pre-inspection for gas tight is needed before the radial conducting sorew is completely disassembled in order to determine whether the radial conducting sorew has to be sent to our company for re-binded the isolation. If a radial conducting screw is detected having leakage, all the conducting screw in the assembly should be disassembled, inspected and repaired if necessary, and then re-assemble the conducting screw using a new rubber seal ring. Radial conducting screw assembly is a maintenance item, so customers should reserve some necessary spare sealing parts. Attention: Correct lubricant should be used when assembling the conducting screw. Silica-base lubricant is recommended for generator without collector ring, while paraffine jubricant is recommended for all conducting screws in the generator with collector ring. This is because silicon steam is harmful to carbon brush contact characteristic. 6.2.7.7 Inspection of bearing, gland seal, bracket assembly Refer to FIG “Bearing, Gland Seal, Bracket Assembly’ and “Installing Process Instruction” a) Inspect radial clearance of oil catch cover, replace the high polymer plastic seal if radial clearance is too large or the high polymer plastic seal is distorted seriously. Inspect tag board and wiring column on the bottom of oil catch cover. Inspect all the insulation wire inside bearing cavity. bb) Record axial position of upper and bottom bearing bracket at horizontal junction, when removing upper bearing bracket. Please inspect, record and check with the technical requirement on the relevant document. ‘Attention: inspect integrality of the seal gasket on gland seal bracket and middle ring carefully.(there is no middle ring at the single gland seal ring generator) ¢) Inspect the bearing carefully, scour the lubricate oil system and filtrate the oll when dusts throw info babbit or babbit surface is scraped. Inspect bearing inlet pipe, outlet pipe, prevent dusts from throwing into bearing. & % a] DOCUMENT NO.:TRYQOA460F572 Page 69 of 102Efi a2 | TURBINE GENERATOR | TRODA THERNAT ROWER PROJECT To0 = samenaercree | INSTRUCTION BOOK nee 4) Inspect clearance of bearing shell, gland seal, gland seal bracket. Inspect radial clearance of oil seal ring, make sure the seal is not distorted, scraped or cracked, change it when necessary. e) Inspect the contact condition between bearing shell and bearing pedestal, make sure bearings are self-aligning and they rise properly in the bearing pedestal. ) Inspect babbit’s change situation on bearing shell, gland seal, oil catch ring .Ultrasonic inspect or liquid penetrant examination is necessary to inspect babbit. Inspect dimension of bearing shell, gland seal, oil catch ring and shaft journal, compare with the recorded dimension, check the abrasion of bearing shell oil seal ring, gland seal, oil catch ring and relative shaft journal. g) Make sure RTDS and wire are good. Make sure insulation pad, insulation pin, insulation tube which on the bottom bearing pedestal, insulation pad on the upper bearing shell are good. Inspect the seal of the jacking oil system, measure the individual insulation resistance to ground. h) Inspect the shape dimension of gland seal, gland seal bracket. Inspect axial clearance and radial clearance between all the oil catch rings and relative shaft journal before removing gland seal bracket. Inspect the non-vertical between gland seal bracket and shaft journal. Inspect the labyrinthic seal clearance for re-installing conveniently. Clean gland seal, gland seal bracket, oil pipe, check the color whether changed of the parts that due to overheat. Inspect installation dimension, compare with the recorded dimension. |) Make sure assembly surface (flange surface, horizontal junction surface) of gland seal bracket, middle ring, bearing bracket, oil catch ring cover are complete. Inspect welding place of these parts carefully. }) All the fixing parts and insulated parts must be good. The pin and pin hole must mate close k) Inspect the distortion of inlet and outlet oil pipes and defoaming tank, Inspect the distortion of pin on the bottom of bearing bracket. Inspect whether the distortion or failure of float ol high level switch on defoaming tank. 1) Measure the insulated resistance between bearing, jacking oil pipe and bearing bracket, middle ring using megger. 6.2.7.8 Check the assembly of blower shroud The blower shroud consists of gas guide shroud and inner end enoloser. It needs to check the gap between gas guide shroud and moving blade. The process of disassembly of shroud and inner end encloser could be inversely to the process of assembly. Check it whether exists the damage and deformation of gas guide shroud and the stationary blade on it. The dismounted non-magnetic brake washer must be replaced with a new one. 6.2.7.9 Check the temperature measuring unit The conventional check mainly includes whether the damage exists in units or leads which connects units to the end of terminal board. ea Jk DOCUMENT NO.:TRIYQOA460F572 Page 70 of 102 Jewaut TIRODA THERMAL POWER PROJECT 1980 E}f 9S | TURBINE GENERATOR | yay (aeso mw PHASE T+ 1860 MW = Suntan eiccrne | INSTRUCTION BOOK Phase ll) During the normal check period, recheck the direct current resistance and measure insulation resistance for the units which measure the temperature between stator winding layers, the hydrogen temperature, and the air temperature in collector ring device and so on. Disconnect the external connected wire and remove the grounding wire from board before measuring. Temperature measuring unit grounding is a very seriously problem. If the insulation resistance of temperature measuring unit in slot is lower than normal under 250V meager, it needs to find the problem and eliminate defect. For confirming measure accuracy of all units on stator winding, it is recommended to measure and record all units data under the condition of non-excitation before shut-down, (detailed refers to Section 5.1.8). The reading accuracy is judged through comparing the temperature between layers and outgoing water temperature with the data of last overhaul or first starting Check the conductivity of thermocouple temperature measuring unit with a multimeter, and re-check the reading accuracy with a potentiometer in cold state. When the above items are tested, the extemal wiring should be disconnected and only the units and their wiring inside frame be tested. Detailed refers to the Fig. GEN. TERMINAL BOARD ARRANGEMENT. 6.2.7.10 Check the lead bushing and current transformer Pay more attention to the safety of disassembly process of lead bushing and current transformer, detailed refers to the Fig. LEAD BUSHING INSTALLATION TOOLS, OUTLINE SUPPLEMENT OF MAIN AND NETURAL LEADS, STATOR MAIN LEAD AND NETURAL ENCLOSER ASSENBLY. Check the gas leakage or water leakage for lead bushing, the flaw, damage or pollution for porcelain bush, bushing flanges and seal washers including the elastic seal rings on bushing, and the smooth of inner-cooled water branch for lead bushing. Check whether excessive heat exists on current transformer, and the looseness on connected wire, lead bushing and assembly fastener piece. 6.2.7.11 Check lead box and neutral encioser Check whether the accumulated water and oil exists inside the outlet lead box and neutral encloser. If exists, clean them after inquiring reason. Check the looseness of fixed equipment for main lead and the pollution of the insulation surface. No foreign matter, accumulated water and oil should be in outlet box and neutral encloser. Check the damage ‘of weld between them, especially when the vibration increasing in this area. Confirm cleanness and good insulation property of insulation washer of outgoing-water flange. Grounding bolt, grounding nut and grounding sheet copper should have a good condition.. Check the insulation and fixed condition for temperature measuring unit on main lead water branch. (Detailed refers to the Figs. OUTLINE SUPPLEMENT OF MAIN AND NETURAL LEADS, STATOR MAIN LEAD ASSEMBLY, NEUTRAL ENCLOSER, STATOR MAIN LEAD AND NETURAL ENCLOSER ASSEMBLY.) 6.2.7.12 Check static excitation system and collector ring Re whe DOCUMENT NO.:TRIYQOA460F572 Page 71 of 102r TIRODA THERMAL POWER PROJECT 1980 EJS} | TURBINE GENERATOR | "IR\Graso wm mnnge Te boat Mn Simenarearcrae | INSTRUCTION BOOK Phasell) Check excitation transformer, thyristor rectifier, magnetic de-excitation and field flashing apparatus, etc in static excitation system, detailed refer to static excitation system guidelines. For collector ting, refers to Section about collector ring devices. 6.2.7.13 Check automatic voltage-regulator Check and correct the voltage regulator according to its guideline during the generator overhauling. Thoroughly check the AVR whether it is cleaning, damage or looseness and foreign matter for the whole regulator. 6.2.8 Rotor vibration and dynamic balance After manufactured, generator rotor and the collector ring shaft have been individually balanced in thermal and cold condition. Before shipped, the rotors are connected together, and are dynamical balanced exactly to eliminate the matter causing unbalance, Generally, unbalance and the matter causing beat all vibrations are following a) Run out of shaft and coupling face. b) Incorrect alignment c) Local heating caused by rubbing d) Hot spots of thermal unbalance due to non-uniform ventilation or electrical fault of the rotor, causing the rotor to bow or bend Rotor Vibration Monitoring Device: There are two holes in the outer catch oil bearing of generator and collector. One is on left, other is on right. The angle between holes and horizontal plane is 45°, and they are vertical to the journal, and the angle between them is 90°. The rotor vibration monitoring device could be set in them. Generally, only a group of device is supplied, and itis set in the hole with larger value of vibration. Each group includes a non-contact sensor (eddying sensors) measuring relative displacement value and an inertial sensors (speed indicator), they combine a pick-up instrument. The relative vibration of journals is measured by eddying vortex sensors, and the absolute vibration of pedestals is measured by inertial sensors. These vibrations are different in phase, so it is necessary to get the absolute vibration of the shaft with vector synthesis. The shaft center orbit could be got with two groups pick-up instruments. Generally, only an amplitude recorded is used to monitor. This pick-up instrument also applies the primary data for shaft balancing. The vibration of all bearing on various load conditions should be measured after scheduled major Inspections while debugging, and save the records so as to compare with the previous ones and the future ones. No matter what kind of reason causes the rotor unbalanced, it is necessary to call in the manufactory engineer to balance this rotor together. 6.2.9 Inspection and maintenance after an accident It is strongly recommended that a detailed examination (water tight test included) be made for stator winding and cooling water connections immediately after the generator is ‘subjected to a heavy fault condition such as a 3-phase of line-to-neutral short circuit, one-phase grounding, or a severe out-of-phase closure. The mechanical forces on the end Lies Seal DOCUMENT NO.:TRIYQOA460F572 Page 72 of 102soli Eeret | INSTRUCTIONBOOK | “2760 WNerRNT T+ tsomw Eig qa | TURBINE GENERATOR |r SOWER PROJECT 1960 winding during these fault conditions can cause many times of normal stress to the windings and their bracing elements. They must be checked immediately and necessary maintenance must be done after an accident so as to avoid a further damage. Generally it is not necessary to pull the rotor out. The inspection result will determine if to pull the rotor out or not. The rotor should be examined for local overheating on the rotor surface and for evidence of overheating at the contact surfaces between the retaining ring and the rotor body if rotor body suffered a heavy negative-sequence current in the accident, Such faults can also generate excessive torque in the shaft and the coupling. These components are designed to withstand the forces caused by a 3-phase short circuit at the generator terminals, while the torque on coupling due to synchronizing out-to-phase can approach many times of the normal value, possibly resulting in a distortion of the coupling keys or bending of the shaft. A check on these parts is therefore needed (Detailed refers to Section 6.2.7.6.). The check and maintaining after shutdown also should provide inspection and maintaining planning and reports (detailed refers to Section 6.2). In addition, the procedure should also be approved. 6.3 Maintenance of hydrogen, seal Oil, cooled water systems and hydrogen coolers 6.3.1 Generator maintenance during shutdown During periods of shutdown, with the generator filled with hydrogen, normal precaution should be taken to avoid condensation within the machine, to assure satisfactory flow of oil to hydrogen seals, to maintain low conductivity in the stator winding water circulation system, and to maintain a non-explosive mixture of hydrogen. 6.3.1.1 Condensation Control of relative humidity will prevent condensation. The relative humidity in the generator during shutdown is dependent upon the temperature around the generator frame. The relative humidity should be checked when the generator is first shutdown and whenever there has been 8K or more change in the outside temperature. To facilitate the maintenance of a relative humidity of approximately 50% or less, the power plant should provide hygrometer or special wet and dry bulb thermometer for measuring the relative humidity. To improve the relative humidity, vent some hydrogen to the atmosphere and add dry hydrogen from the hydrogen supply system. 6.3.1.2 Oil seals The seal oil temperature leaving the seal oil cooler should be maintained between 43 and 49 °C during periods of shutdown. When the vibration of rotor becomes sensitive to load change, we recommend that the seal oil temperature be maintained between 43 and 49 °C. 6.3.1.3 Hydrogen purity The hydrogen purity should be checked regularly and maintained by the addition of fresh hydrogen. The hydrogen purity is normally maintained at 96% or higher when the Ray | DOCUMENT NO.:TRIYQOA460F572 Page 73 of 102bipea TURBINE GENERATOR | TRODA THERMAL POWER PROJECT a INSTRUCTION BOOK | MW @*soune taal 1+ tseonniy hydrogen side seal oil pump is operating, and should be assured at 98% or higher when the generator performance tests are carried out. 6.3.1.4 Water conductivity The water conductivity should be checked regularly and maintained by circulation of stator water through the system demineralizer. The conductivity of the water from demineralizer should be maintained in the range of 0.1 to 0.4 s/cm into the water tank. The normal range of water conductivity of main water circuit should be between 0.6 and 1.5 usiom. 6.3.1.5 General considerations a) The vapor extractor in the generator bearing drain loop seal and in the bearing main oil reservoir should be operated even if during the periods of shutdown so as to remove hydrogen which may escape into the oil drain system. b) The hydrogen alarm system should be in operation. c) During period of cold weather, no special maintenance procedures other than those previously mentioned need to be observed. Any stresses due to temperatures differentials obtained during low temperature conditions will not be sufficient to affect the normal life expectancy of the generator. It should be pointed out that the precautions taken to ensure a non-explosive gas mixture in the generator have some additional significance at the time of ow temperatures, in view of the effect of low temperatures on the ductility of the material forming the hydrogen enclosure. 4) If the unit is filled with air during the shutdown period, only those considerations involving condensation need be observed. It is recommended that hydrogen supply lines be disconnected during this period to prevent an accidental admission of hydrogen to the generator. e) If the generator is to be exposed to below 0°C temperatures while shutdown, the cooling water should be drained from the stator windings and hydrogen cooler to prevent freezing 6.3.2 Hydrogen cooler maintenance The generator coolers are bolted solidly to the generator frame at the water connection ends and are provided with a positioning block,which can be free telescopic,between the cooler and the generator frame at the reverse end. During the maintenance of coolers, the tubes need be bulged tight in the holes of tube sheet, and the tube interior can not be damaged to avoid water leakage for keeping tube interior and exterior cleaning. For the parameters of cooler, please refer to Table 5-1 Operating Parameters of Generator in Section 5. In order to provide for a completely safe procedure, we recommend that the generator be purged of hydrogen whenever the gastight cover is to be removed for any reason, COz and air at atmospheric pressure may be left in the generator frame, but the personnel can not enter the generator frame for safe. Fay: /,q, DOCUMENT NO.:TRIYQOA460F572 Page 74 of 102f a RBI RA TIRODA THERMAL POWER PROJECT 1980 JE SR HAS] | TURBINE GENERATOR | iw (acoso mw PHASE I+ 1660 MW | Banonmeircree | INSTRUCTION BOOK Phasell) The coolers should be cleaned at intervals best determined by experience. If a normal amount of cooling water at the usual temperature does not result in proper cooling of the gas, then cleaning of the coolers is recommended. 6.3.3 Maintenance of stator winding water system, water cooler and filter Refer to ‘Stator Cooled-water System Instruction’. 6.3.4 Maintenance of lubrication oil and seal oil To maintain turbine generators, the following arc recommended especially for the maintenance of lubricant and seal oil and the requirements of oil quality and cleanliness: a) For minimum maintenance and maximum life of the generator, it is important to ensure that the oil in the lubrication system has good characteristics, and be carefully maintained during long-term operation. b) Lubrication oil should be provided in sufficient quantity and cleanliness. Once the lubrication oil is put into the lubricating system, the oil must be constantly monitored for any change from its normal characteristics. Any changes in those characteristics should be corrected as soon as possible. Failure to make such corrections when it is necessary will cause damage to the bearing, crank shaff, seal tile and pump seal of the turbine generator. ©) A clean, well-maintained oil system (reservoir, piping, oll seals, oil coolers and bearing housings) must be provided to ensure the cleanliness of the oil. Any condition that may contaminate the system must be avoided. Preventing contamination of the lubrication oil and seal oil system is much easier and less costly than correcting such a condition once it occurs, and can ensure the quality of cil 4d) The lubrication oil for a turbine generator must be high-quality, refined and uniform viscosity. It must contain the additives to restrain foaming, corrosion and oxidation. ) The lubrication oil can be contaminated by many different sources. Hard particles, such as sand, concrete, glass, metal filings (including welding slag), large grease stain, rust and other substances that can cause damage to lubrication equipment, oil seal system or bearing. This will result in costly repair and downtime. Soft particles such as larger debris of cloth, plastic and paper products will cause the turbine to trip for jamming oil flow, or induce intermittent vibration for oil seal slip, or damage unit for oil flow reduction ) Lubrication oil can also be contaminated by water. Water can cause damage by reducing the lubricating qualities of the oll and contributing to rust formation on steel parts. It also may increase the water amount of the hydrogen gas in the generator and decrease the safety of operation. 9) Water can be introduced by condensation, oil cooler leakage and steam gland leakage, and the water must be removed. It is particularly important that all free water (water not in solution) be removed from the oil. The maximum amount of water in solution depends on the temperature, being about 0.01% at 49°C. Water that may build up in the bottom of the lubrication reservoir should be removed. The amount of water in the oil during operation | + should not be excess 0.05%. Air side seal oil comes directly from lubrication oll system. In the long term of operation, it is unavoidable that a part of the air side seal oil will mix up with Ba he | DOCUMENT NO.:TRIYQOA460F572 Page 75 of 1027S | TURBINE GENERATOR | "RSDATIERNAL PoweR PROWEGT ier JB BA | 'nstrucrionsoox | ™@ Ste asst ae hydrogen side seal oil, resulting in the evaporation of the excess water brought in by that part of lubrication olf free water has not been removed from the oil and finally in raising gas relative humidity in the generator frame. High gas humidity will endanger the insulation, accelerate stress corrosion of rotor retaining ring and at last jeopardize the safety of operation. h) Contamination of the lubrication and seal oil by liquids other than water, such as fuel oil and cleaning solvents, can change the characteristics of the oil, especially the viscosity. Oil purification systems can not remove this kind of contamination. The oil vendor must be consulted to determine if it is necessary to replace oil contaminated by these liquids. i) Oxidation of the lubrication and seal oil over time could cause changes in the oil viscosity and creates sludge. Sludge buildup is an indication of oil deterioration. Sludge buildup can clog pumps, orifices and other oil devices. It can also cause excessive wear and decrease the performance of the lubrication and seal oil system components. So far as seal oil system is concerned, sludge buildup also lowers the gas seal properties, and the high accurate pressure balancing ability of the pressure equalizing valves as well. A bad sludge buildup may cause the seal oil system to lose its gas sealing performance and sometimes result in an accident of mass hydrogen gas leakage. Regularly monitoring and maintaining the recommended oil neutralization can help keep this from happening 6.4 Stator coil water washing and generator backwashing devices a) The water system cleanliness of water-cooled generator is very important. Although water system adopts a series of measures to guarantee the smooth flow of water, it is inevitable that the dirt is accumulated in the comer, bending and necking, etc. With the operating, the accumulated dirt may result in flow reduction or partial obstruction. Hence, in order to maintain safe operation and smooth waterway of generators, the washing must be proceeding during inspection and maintenance. b) Turn on the valves of total inlet & outlet water pipes before washing, expel the accumulated water in coils, and then blow off all residual water using 0.3~05 MPa compressed air. Adopt clean condensation water to wash pipes until the washing water has no yellow impurities, and then blow off the residual water by using compressed air. Water and compressed air are used for washing pipes in tum. Normally, the washing times are Br. c) When individual coil is blocked during operation, the insulation lead water pipes of coil ends and connecting joints of total inlet & outlet pipes should be removed. The compressed air and water are respectively used to wash coil repeatedly. If necessary, high-pressure nitrogen, oxygen and even abstergent acid are used to wash. The flow test should be proceeding for smooth waterway after washing. ) The exterior piping design of water system have equipped with piping connection for backwashing. Its descriptions are as following: Rar, DOCUMENT NO.:TRIYQOA460F572 Page 76 of 102MW (2660 MW PHASE 1 + 1660 MW. ZS | TURBINE GENERATOR | TRODATHERWAL POWER PROJECT 1980 | Hise INSTRUCTION BOOK Phasell) The equipment is made up of four valves, that is, a group and B group. Under normal condition, the cooling water enters through B1 valve, and is discharged from B2 valve. When the stator coil is blocked, the reverse flushing can discharge particles. The operating method is: open a group valve and close B group valve, that is, the inlet & outlet water ends are interchanged. The generator must be shut down when backwashing. To avoid deposition, the backwashing should be carried out periodically. A & B group valves should be restored to the normal operating states after finishing the backwashing, 6.5 Precaution safety items a) Terminal bushings—-replacing gastight gaskets after operating about 10 years b) Radial conductive levers—replacing gastight rubber rings (rotor) after operating about 8 years or repairing for hydrogen leakage ©) Gasket for sealing hydrogen and fluid-—replacing old gaskets with new ones when components are disassembled DOCUMENT NO.:TRIVQOA460F572 Page 77 of 102TURBINE GENERATOR | TRODATHERHAL POWER pROWECT E00 iiaea INSTRUCTION BOOK oe wvonasell) ee Chapter 7 Collector (Static Excitation) Collector is the set whose major function used to produce the stationary current and voltage to the rotor, see FIG 7-1. It consists of collector shaft, brush holders, brush rigging, collector fan, ventilation system and brushes. FIG 7-1 COLLECTOR RING STRUCTURE 7.4 Collector ring Two piece collector ring assemblies are made of an alloy steel forging (40Cr2MoV), shrunk onto an inner bushing after machining and heat treating (HB>300 at surface). The diameter of collector ring is selected by linear velocity of brushes. The width of collector ring Is decided by the exciting current and current density of brushes. There are spirally grooves with the same distance at collector ring surface. These grooves serve three functions: 1) They interrupt the small arcing contacts which carry current between the collector rings and brushes thus assuring even current distribution in the brush face. 2) The grooves furnish additional surface for cooling, Bsa ih | DOCUMENT NO.:TRIYQOA460F572 Page 78 of 102TURBINE GENERATOR | TRODATHERUAL POWER PROTECT iano Hee INSTRUCTION BOOK | MY(Se0 ME TT T¢ Hs Mwy 3) Better contact between the ring and the brush is achieved by allowing the entrapped air to escape. The effect of pneumatic cushion between the brush and collector ring is weakened and contact resistant and temperature rise are lower. The distance of spirally grooves must fit to the axial dimension of single brush alignment, thus contact surface between the ring and the brush can be the same at any time, and the pressure of the constant-force spring at contact surface can be the same and abrasion and current can be even. 7.2 Collector bushing Collector bushing is made of an alloy steel forging (40 Cr2MoV) and it should be heat treated. The collector ring is shrunk onto the collector bushing. The silver-git contact ‘surface makes the contact resistant and the temperature rise lowest. Grooves 45’inclined (the angle is decided by the cooling air and direction of rotation, 45°can exhaust much air) with the axial line are equispaced in circumference. Air inlets of grooves are machined to bugle style to exhaust more air and the grooves furnish additional surface to reduce temperature rise besides exhausting air. Two piece of collector ring contact to the rotor by copper bar, radial and axial lead. Collector bushing is shrunk onto the rotor shaft after collector ring shrunk onto it. There is an insulation ring between collector bushing and rotor shaft. The exciting current is provided through the stationary brush and the surface of the collector ring with high speed. This is the major function of the collector and it will affect the capability of the collector when generator is on line. 7.3 Brush holder and brush rigging The brush holder rigging uses 6 brush holder supports. Each brush holder support includes 2 brush holders, which can install 6 brushes. This style of brush holder allows safe and easy removal of 6 brushes at a time. Removal of the brush holders may be performed while the unit is on line permitting brush changing to be done at a remote location. A removable insulated handle is used for removing and installing the brush holder. 7.4 Collector fan and duct ‘A centrifugal fan is equipped between collector rings. It provides enough cooling air and takes the heat from collector rings and brushes and makes the temperature less than the rated one. The cooling air must be clean, without carbon powder, sand, oil, vapor, solvent and other dirty things. These dirty things will affect the grounding-insulation of collector and damage the surface of the collector rings. 7.5 Brush World famous brand (NCC634, LFC554) material is used for brush. The feature is the friction coefficient and elasticity quantity of the material is suitable. The capability of self-lubricating is powerful. The current density can be higher. The temperature of the collector ring surface is less than 100 'C. Note: Multi-brushes and changing brand are forbidden. Brush from abnormal manufacturer or other brand can not be used to avoid trouble. Ba. a] DOCUMENT NO.:TRIYQOA46OF572 Page 79 of 102 || Gly _E eae | TURBINE GENERATOR | TRODATHERWAL POWER PROJECT THT | ipsa TINSTRUCTION BOOK. | MM 2SS60MMU PASE + reo 7.6 Operation and maintenance of collector (1) Inspect all bolts and lock washers (lock parts), especially rotated parts. Make sure they are all well. (2) The radial center line of brush should be accordance with collector and the brushes are removable up and down but they are not removable righteft and back-front in the magazine (3) Rotated parts should be separated from stationary parts. (4) The best distance from bottom of magazine to surface of collector ring is 3-4 mm, but make sure that there is not any contact with rotated parts. (6) The new brush or collector should run without current until they are smooth, then increase the current to the rated current step by step. (6) Clean the collector rings, insulation, brush rigging, main lead, bareness parts contacting with brush rigging, duct, filter and so on after the collector had run for a jong time when the unit was shutting down. Make sure that the insulation and cooling system can work in good condition. Fea rlal DOCUMENT NO.:TR/YQOA460F572 Page 80 of 102‘MW (2660 MW PHASE I+ 1660 MW Se “E jfmeoe] | TURBINE GENERATOR | "SU UsNuannee osu it INSTRUCTION BOOK eee Phases) Chapter 8 Appendix 8.1 660MW Generator technical data sheet 8.1.1 Basic data Rated capacity Maxim capacity Rated active power Rated stator voltage Rated stator current Rated power factor Rated hydrogen pressure Rated speed Direction of rotation Number of phase Stator winding connection type Rated frequency Short circuit ratio (SCR) Max. negative sequence current (lo! ly) for steady state operation Max. value of (lo! In) t for transient operation Insulation class of stator/rotor winding Efficiency 8.1.2 Excitation data No load field current No load field voltage (75 °C) Rated field current Rated field voltage (90 'C) 8.1.3 Parameters Stator winding resistance (75 °C) 776.5 MVA Match turbine 660 MW 22 kV 20377 A 0.86(lagging) 0.45 MPa (9) 3000 r/min Clockwise viewing from turbine to generator 3 yw 50 Hz 0.518 According to the technical agreement ‘According to the technical agreement Class F According to the technical agreement 1497 A 150V 4669 491V 1.447*10° O/ phase Rotor winding resistance (75 °C) 0.1004. 0. Stator winding capacitance to ground per phase 0.237 uF Rotor winding self-inductance 0.762 X's Direct-axis sub-transient reactance (unsaturated) 22.9 % ('y Direct-axis sub-transient reactance (saturated) 21.0% X'q Quadrature-axis sub-transient reactance (unsaturated)22.4 % Ba She DOCUMENT NO.:TRIYQOA460F572 Page 81 of 102= ties ee GENERATOR | "yy avesot Puase Teneo _ INSTRUCTION BOOK ene ie phasell) X", Quadrature-axis sub-transient reactance (saturated) 20.6 % X'w Direct-axis transient reactance (unsaturated) 30.9% 4 Direct-axis transient reactance (saturated) 272% X'qu Quadrature-axis transient reactance (unsaturated) 45.6% X'q Quadrature-axis transient reactance (saturated) 40.2% X< Direct-axis synchronous reactance 225 % X, Quadrature-axis synchronous reactance 219% Xoy Negative phase-sequence reactance (Unsaturated) 22.6% Xe Negative phase-sequence reactance (Saturated) 20.8% Xo, Zero phase-sequence reactance (Unsaturated) 10.5% Xo Zero phase-sequence reactance (Saturated) 10.0% Teo Direct-axis transient open circuit time constant 875s Tee Quadrature-axis transient open circuit time constant 0972s Tz Direct-axis transient short circuit time constant 1.058 s T’, Quadrature-axis transient short circuit time constant 0.1788 T'uo Direct-axis sub-transient open circuit time constant 0.045 s T'go Quadrature-axis sub-transient open circuit time constant _—_0.068 s T", Direct-axis sub-transient short circuit time constant 0.035 s Ty Quadrature-axis sub-transient short circuit time constant 0.036 s 8.1.4 Characteristic curve See the documentation provided with the generator: SATURATION CURVE VEE CURVE CAPABILITY CURVE 8.1.5 Ventilation parameters Fans Axial fan on each end of rotor shaft Fan total pressure 4508 Pa (equivalent in air) Total volume 40.5 mis Hz inlet temp. <46 'C 8.1.6 Operation performance of H2 cooler One set of cooler on each side located on the top of stator frame, each cooler with two independent parallel water circuits. Rated Hp cooler capacity 5000 kW Water inlet temp. 35°C (or according to technical agreement) H; outlet temp. <46 °C Fa Jha} DOCUMENT NO.-TRIYQOA4G0F572 Page 82 of 102(or according to technical agreement) Hy pressure drop 750 Pa Total volume of cooling water required 900 mh Water pressure drop inside the cooler 55 kPa 213 generator continuous operation capacity at rated He pressure, with 1/4 set of TIRODA THERMAL POWER PROJECT 1980 JE 3B BS | TURBINE GENERATOR | "iy (axes MW PHASE T+ 1660 MW sunt etrcrat | INSTRUCTION BOOK ieee Phaest) 2 coolers (one water circuit) out of service 518 MVA (440 MW) 8.1.7 Stator winding cooling water data Volume of cooling water 116 mh Cooling water pressure drop 0.20~0.23 MPa Max. cooling water inlet temp. 50°C 8.1.8 Other data Weight of the rotor mt Max. transportation weight 365t (Stator including transportation cover and bracket) Weight of generator 502t Generator rotor moment of inertia J 10250 kgm? (Equivalent to rotor flywheel moment) 44 tm Sudden short circuit torque (Absolute value) 2.21x10" Nm Generator rotor critical speed (single span) 4st 734 min 2nd 1906 r/min 8.2 Generator installing/removal tools ia ho SN DWe. No} TOOL DWG. NUMBER AND NAME T6 _ |5D487.394.01 ROTOR INSTALLATION/REMOVAL TOOLS |6x37-65-170-1 -FINISHED-RIGHT LAY GB 1102-74 (prepared by the Customer) '5C048.428 JOURNAL SUPPORT (T.E.) I5B135.313 SLIDING SHOE (ARC) (8B192.2851.01 SKID PLATE \5B557.316.01 STATOR CORE PROTECTOR '5C048.427 ROTOR SUPPORT (58472471 LIFTING_EYE '58472.401 LIFTING_EYE & 68472.402 LIFTING_EYE '58472.404 LIFTING_EYE DOCUMENT NO.:TRIYQOA460F572 Page 83 of 102bipBS [ TURBINE GENERATOR | "Soy ovasou/punse'Trtooco un Buntinieicerne | INSTRUCTION BOOK "__Phasell) SN [DWG. NO| TOOL DWG. NUMBER AND NAME 150467384 GENERATOR BEARING INSTALLATIONIREMOVAL| 2 |) 12 TOOLS 3 T7C = |5B421.606 HEAT_ELEMENT (1.7kW, 220V) «| 14 0487.30 GLAND SEAL BRACKET INSTALLATION/REMOVAL| TOOLS '50487.385 STATOR LEAD BUSHING INSTALLATION/REMOVAL| 5 | To TOOLS 6 | Tig SC#87-405” INSTALLATIONIREMOVAL TOOLS FOR HYDROGEN) [COOLER 7 [115 [ADHESIVE INSTALLING TOOLS 8 [5A440.304 RIPPLE PLATE MEASURE TOOLS: | 9 |AVR TESTING DESK . '5D487.303 ROTOR RETAINING RING INSTALLATION/REMOVAL| 10 TOOLS 1 '5C487.375 RING _KEY REMOVAL TOOLS 2 [5C487.392 END BRACKET LIFTING TOOLS . 15D487.398 INNER END BRACKET & GAS BAFFLE HANDLING| TOOLS 14 [5C487.307 GAS BAFFLE INSTALLATION/REMOVAL TOOLS 8.3 Main tools which prepared by customer (power plant) SN Item Usage Remark 1. for lifting lower E.E bearing bracket 1 [Manual hoist E, ft aesering terminal box and lead) 4 oc of 5t fimin, st) {3. for pulling rotor in axial direction at E.E| 4 Pos of tt 4. for assembling the blower shroud lnydraulic jack Laid on the TS bearing assembly Tool) (S0,0D < 130mm,)when assembling the bearing, to lift roto 2 height <160mm when|S° as to separate from bearing shell at/t Pes fly compressed) journal position, 5 [Laid on the top of the frame to protect tha) 3 [Steel padding plate surface of the seal gasket while|2 pes. lassembling the cooler 2 H. Pad jack bolt while assembling the) 4. 6mm copper padding}bearing shell lb Iplate l2. Protect the rotor shaft where steel-wire|~ P°S rope is put on while lifting the rotor Bay DOCUMENT NO.:TR/YQOA460F572 Page 84 of 102“(Eee | Turse INE GENERATOR | TRODATHERWAL POWER PROJECT 1580 Saaenareuccrae | INSTRUCTION BOOK Phasell ‘MW (2*860 MW PHASE I + 1%650 MW ) ISteel-wire rope IFor lif ing the bearing shell, lower half off tthe bearing pedestal, gland seal ring and} 'blower hub. Ht pes lturning tool on _the| lcoupling (brass stick) [Attach the steel-wire rope to the brass| Istick for tuming while magnetic pole| Vertical centering alignment —_before| installing blower hub, rotor blades and| rotor. IM33 Iifting ring IM27 lifting ring [For fing bearing shell, bearing pedestal land gland seal bracket -ete. For lifting part of the cooler (baffle plate). [2 pos 3 pos: |BWG#11steel-wire rope IFor pulling 96.5 mm nylon rope from EE| to TE through air gap while putting T6L| [protection cover in the stator during rotor| \removal. Specs, 610mm] longer than] |core 196.5 nylon rope [Attached to one end of TL, pull TOL from| EE through air gap and lay in bottom off ithe inner stator. iSpes, 610mm longer than| lcore 10 [Hard Wooden block CT1 |Hard Wooden block CT2 Put between frame and End Bracket to} make a 100mm gap while lowering the| EE End Bracket. Under rotor support tool TSH, _ its Ithickness varying with the actual Icondition. i2pcs. pe "1 (Oiljack — T00t (Oil jack >50t \Adjust stator axial / radial location and] ireduce/add shim. [apes [4pcs Back oil flange and oil baffle cover during oil 'Back oil flange to cover the oil inlet on the| lower bearing shell, oil baffle cover to| i2sets, respectively at surface of insulated parts. 12 Rushing Icheck the oil return condition, or open alEE and TE. \window on the cover to get oil sample 13. forque wrench IFor tightening bolts Ibought by the| [Customer lwinch and sling forLead the rotor into the core 14 |pulling rotor in axial H sot \direction at T.E lcover tool during jas|Used during single gas tight test for stator] 15 lkght test et a ee IR1/8 filing botand _|Close hole EE or ring end and center> acta andl 16 {TE center bore coverjbore in TE shaft end during test. caver: ~ plate IM24 box wrench Tighten M24 bolt to fix the gland seal 17 700mm Long bracket on end bracket. 2 pes M16 220 inner{Tighten the bolts in the coupling off, lhexagon spanner igenerator and collector ring shaft oe |H31-3 air-dry epoxy paint|Glue the insulating shim to the seal LsuBiciené 19 bracket or paint machined & uncovered] lquantity Note: *T6F 6*37-65-170-1 FINISHING-RIGHT LAY GB 1102-74prepared by Customer Ba ike DOCUMENT NO.:TRIYQOA460F572 Page 85 of 102HEI | TURBINE GENERATOR | "RODS THERUIATPowen provECT io AJB BT | 'structionsoox |"? com nasell) 8.4 Additional tools and devices recommended for generator installation (prepared by the customer) SN. Item Type Function |Generator gas tight test (device consists of oblique tiny pressure difference mater land a standard bubble (Check air pressure reduction iduring air tight test. May entrust 'STGC to purchase this device |Check gas fight testing device on 2 [Rotor gas tight testing device Iradial conduct bolt. Made by the |Customer. \Check leak by injecting F-12 into 3. [Halogen leak locator He system, check leak at 10mi/second (Check Hz content in atmosphere 4 |Hp leak locator Jaround and Hz leak location in |generator during operation [Megohm meter 5 (250/500/1000 V) ret insulation resistance lelectric megohm meter 6 (500/1000/2500V) Test insulation resistance IRigh resistance Test insulation resistance Tor evomnetsr Digital display __ [bearing \-shape block ‘Support rotor during maintenance [Check passing condition for stator | 9 [Saspassing test device nding water Inow weve |Check passing condition of stator Cie inding connector and lead pressure-difference type: bushing [Check insulation for bushing and 1 ee ee stator coil connector, check \voltage test device (100 kV) winding DC leak test |Check insulation resistance for stator winding filled with water |(provided by STGC) water filled _ insulation] 12 resistance meter 8.5 Attached figures FIG 8-1 GENERATOR GENERAL ASSEMBLY, FIG 8-2 GENERATOR OUTLINE FIG 8-3 AXIAL AND LATERAL POSITIONING FIG 8-4 BEARING SKETCHATE.E. FIG 8-5 BEARING SKETCHAT TE. FIG 8-6 BEARING AND BEARING PEDESTAL FIG 8-7 DOUBLE-FLOW TYPE OIL SEAL AND BEARING ASSEMBLY Ray, if DOCUMENT NO.:TRIYQOA460F572 Page 86 of 102,fines TURBINE GENERATOR INSTRUCTION BOOK TIRODA THERMAL POWER PROJECT 1980 ‘MW (2660 MW PHASE 1+ 1660 MW Phase) FIG 8-8 BEARING INSULATION TEST GUIDANCE FIG 8-9 PRINCIPLE OF OIL SEAL SYSTEM FIG 8-10 CROSS SECTION OF DOUBLE-FLOW TYPE OIL SEAL FIG 8-11 PRINCIPLE OF OUTER OIL BAFFLE AND VIBRATION MONITOR, FIG 8-12 SKETCH OF BAR CLASP ASSEMBLY ON INSULATED WATER PIPE DOCUMENT NO.:TRIVQOA460F572 Page 87 of 102TURBINE GENERATOR | Tayi ISTRUCTION BOOK PROJECT 1080 T1660 MW aay i en Py = sy ED TO O O 29] wap Taig omy Purp 2098 FIG 8-1 GENERATOR GENERAL ASSEMBLY Beat DOCUMENT NO.:TRIYQOA460F572 i Page 88 of 102Gly fg cj | TURBINE GENERATOR Saavenaeiccrne | INSTRUCTION BOOK TRODA THERMAL POWER PROJECT 1080 ‘MW (2*660 MW PHASE I+ 1660 MW. Phasell) Font, DOCUMENT NO.:TRIYQOA460F572 Page 89 of 102"TIRODA THERMAL POWER PROJECT 1986 ‘MW (2x60 MW PHASE 1+ 1%650 MW. Phasell) TURBINE GENERATOR INSTRUCTION BOOK i | @ hse auyTaseg 4oyewaua9| ‘OOOOT WAIST aOTeTS Fa Fae ‘CaROT weds Bupavag OOF WT aba sae BS a (uoryerteasut wires) 0508T “oaba BUFTTRSOT] 40 w6ua7 3sa3.a0us oui! Page 90 of 102 FIG 8-2 GENERATOR OUTLINE Wa, al DOCUMENT NO.:TRIYQOA460F572TURBINE GENERATOR | PRODATHERNALPOWER PROJECT 1 = LUBE T | instruction sooK [eee ee sy eae LATERAL POSITIONING KEY Gas BOTTOM BOARD YN Mc Ne est Lael Te} E.E. AND TE. OR RINGSIDE SOTTON BROAD BASEBROAD AXIAL ANCHOR BLOCK (BOTH SIDES) FIG 8-3 AXIAL AND LATERAL POSITIONING Ry rt he [ ocumenr NO.:TRIYQOA460F572 Page 91 of 102} TURBINE GENERATOR AJB EB NT | instruction BOOK | | TIRODA THERMAL POWER PROJECT 1980 ‘MW (2*660 MW PHASE I+ 1660 MW Phase i f & FIG 8-4 BEARING SKETCH AT E.E. Page 92 of 102 Bat /,s|_ DOCUMENT NO.:TRIYQOA460F572| TIRODA THERMAL POWER PROJECT 1980 Eimee Ss | TURBINE GENERATOR | Sr Denne Tecan Suntan circree | INSTRUCTION BOOK Phasell) a IN FIG 8-5 BEARING SKETCH AT T.E. Brahe DOCUMENT NO.:TRIYQOA460F572 Page 93 of 102“EJmeBS | TURBINE GENERATOR | TRODATHEIWIAL FoweR pROvECT ato | i MW (2x660 MW PHASE T1660 MW iwantrw eizerne | _ INSTRUCTION BOOK : Phaseil) } EPOXY-GLASS INSULATING BLOCK INSULATING BLOCK 4. 4 ae BEARING HAF AT EE LATS BOLT AND WASHER ¥ (4 POSITIONS) INSULATING BLOCK” aT TT UPPER BEARING BOLT AND WASHER (2 Positions) CLAMPING PLATE “g | Posirion PIN BEARING Lae wkd | Bhai | POSITION PIN. | BEARING ue BEARING SEAT (T-E.) ‘TRIANGLE ort“ BAFFLE key (2 Postrions) CLAMPING PLATE FGR POSITION BIN ——— BEARING 77 SEAT(E.E.) Key (2 Postrions) FIG 8-6 BEARING AND BEARING PEDESTAL Bea Yoo DOCUMENT NO.:TRIYQOA460F572 Page 94 of 102= | TURBINE GENERATOR tae INSTRUCTION BOOK TIRODA THERMAL POWER PROJECT 1980 ‘MW (2660 MW PHASE 1+ 1660 MW ____Phasell) Kate FIG 8-7 DOUBLE-FLOW TYPE OIL SEAL AND BEARING ASSEMBLY DOCUMENT NO.:TRIYQOA460F572 Page 95 of 102TURBINE GENERATOR TIRODA THERMAL POWER PROJECT 1080 INSTRUCTION BOOK | M(s50 MA DHSS I+ to580 Mw ipsa 1, Assembly requirement: Break and remove test wire before removing any part of gland seal bracket and — bearing bracket at E.E. Provided washer or equivalent components must be used to brake the bolt fixing the wire clip (see \ view A), when Cr ae ai, assembling the test wire. FIG.1—CLBLE INSULATED BEARING.) 2. Series number explanation: 001 end bracket 002 bearing insulated pad 003 bearing pedestal 004 oil baffle 005 gland seal bracket 008 middle ring 007 cable terminal 008 bearing shell insulated gasket 009 bearing shell pad 010 inlet oil pipe 3. Connecting wire of grounding monitor BGE1— middle ring BGE2— bearing shell pad — bearing shell fixed pin BGE4-— bearing shell insulated gasket — bearing shell insulated gasket (right side) BGE6~- cil baffle — double insulated inlet oil pipe 4, Bearing insulation test Refer to assembly drawing of gland seal bracket, bearing and end bracket and Fig.1--double insulated bearing at E.E. Before or after the rotor shaft and turbine coupled together, check insulation resistance of the following junctions by 500V Meg-ohmmeter when assembling. Test relative cable terminal: (1) gland seal bracket and middle ring (item 006) to frame—-BGE1 (2) 2) left insulated bearing shell gasket (item 008) to frame--BGE4 b) left insulated bearing shell gasket (item 008)to bearing shell pad (item 009) (3) a) right insulated bearing shell gasket (item 008) to frame—-BGES b) right insulated bearing shell gasket(item 008)to bearing shell pad(item 009) (4) bearing shell fixed pin to frame—-BGES (5) lower gland seal bracket (item 005) to middle ring (item 006) (6) when gland seal bracket in its position, upper gland seal bracket (item 005) to middle Fing (item 006) (7) insulated shell pad (item 002) to frame-—-BGE2 (8) a) outside oil baffle (item 004) to frame---BGE6 Fea DOCUMENT NO.:TRIVQ0A460F572 Page 96 of 102“Ej 2 | TURBINE GENERATOR | THODATIERAL rowER PROJECT a0 sexi crt | INSTRUCTION BOOK lel coaatans or HE aed ) outside oil baffle (item 004) to rotor shaft (9) double insulated inlet oil pipe (item 010) to frame-—-BGE7 Expected value of insulation resistance—-100 mega ohm ‘After bearing assembly and before coupled with turbine rotor, connect gland seal & oil baffle with the rotor to make oil seal short-circuit, and measure insulation resistance of rotor to end bracket. At this time, expected insulation resistance of the bearing, gland seal to ground is >10 mega ohm. This value will be 21 mega ohm after filing lubricating oil. 5. Assemble bearing bracket and testing cable terminal (BGE1 to BGE7), measure insulation resistance of all cable terminals insulation to ground after the rotor shaft and turbine rotor coupled together: Testing BGE1 to BGE7 alternately by 500V Meg-ohm meter grounding, and record the data for reference. Above insulation resistance should be measured again after passing lubricating oft 6. During operation: refer to Chapter of "Generator Operation" in this instruction book. C 2. Series number explanation: 001. end bracket 002 bearing insulated pad = 003 bearing pedestal 004 _oil baffle 005 gland seal bracket 006 bearing shell pad 007 inlet oil pipe 4, Bearing insulation test Refer to assembly drawing at T.E. and Fig.2. Before the rotor and the turbine coupled together, YY check the insulation resistance of the following junctions : by 500V Meg-ohmmeter when assembling parts. (1) insulated bearing shell pad (item 008) to frame FIG.2 SINGLE INSULATED BEARING(T (2) upper gland seal bracket (item 005) to frame (8) lower gland seal bracket (item 005) to frame (4) outside oil baffle (item 004) to rotor (8) inlet oil pipe (item 007) to frame Expected value of insulation resistance—-100 mega ohm Before the rotor shaft and turbine coupled together, for the rotor to frame, expected value of insulation resistance is >10 mega ohm. This value will be>1 mega ohm after filing lubricating oi FIG 8-8 BEARING INSULATION TEST GUIDANCE Bay, DOCUMENT NO.:TRIYQOA460F572 Page 97 of 102"TIRODA THERMAL POWER PROJECT 1080 ‘MW (2*660 MW PHASE 1+ 1660 MW Phasell « 2 é G 2 a o w z 2 2 INSTRUCTION BOOK meagan seinen oe po —— | umd go gt Sa oe ee onan mr — Teieclt = | afeeeal | 1). co san SE a wor SEE = Tees at eed | | pete, US ae I J wep pope poesured ya) som nde EE wm tmeg en ED ey nt oe ee TT ve opr tenes a FIG 8-9 PRINCIPLE OF OIL SEAL SYSTEM Page 98 of 102 IENT NO.:TRIYQOA460F572 Fea Fe DocuMtTURBINE GENERATOR | "RODATHERIAL POWER PROVES 0 AGJEAE S| ‘instruction sox. | Mere mnpuats 1+ maou 001- BEARING 002- OIL SEAL RING 003- SEAL OIL OIL. 004- AIR SIDE SEAL OIL. 005- He SIDE SEAL OIL 006- OIL SEAL SEAT 007- LABYRINTH OIL BAFFLE 008-H) SIDE BACK SEAL OIL 009- H: SIDE RING TANK O10-AIR SIDE RING TANK 01 1-AIR SIDE SEAL OIL AND BEARING BACK OIL FIG 8-10 CROSS SECTION OF DOUBLE-FLOW TYPE OIL SEAL Frayfo| Document NO.:TRIYQUA460F572 Page 99 of 102