Sharing of Operating Experience

on main generator auxiliaries

controls and modifications
carried out for performance
enhancement
Presentation from NPCIL unit: Rajasthan Rawatbhata Site
(Unit#1&2)

Presented by: R.S. Sikarwar, SO/F, CMU

System Engineer: Generator Auxiliaries, Feed Water
& Steam Condensate System

1.

Main Generator

Make
: Canadian General Electric
Serial No.
: 848299
Generator Rating : 244444 KVA
Excitation 375 Volts
Stator Amperes 6720
Field Amperes 2423
Power Factor 0.9

2.

Generator Auxiliaries

(a) Hydrogen Cooling System

(b) Seal Oil System
(c) Stator Water Cooling System

Hydrogen Cooling System

GENERATOR

GAS
DRYER
ADSORBTION

SEP
ARA
TOR

HYDROGEN CYLINDER
SV

GAS DRYER
REACTIVATION

C&I OF HYDROGEN COOLING

SYSTEM
S.N.

MEASURED VARIABLE

C&I USED

1.

HYDROGEN PRESSURE LOW ALARM

MEASURED BY PRESSURE SWITCHES.

MAKE & MODEL MERCOID CONTROLS U.S.,
SET POINT 33 PSIG

2.

HYDROGEN
ALARM

MEASURED BY PRESSURE SWITCHES.

MAKE & MODEL MERCOID CONTROLS U.S.,
SET POINT 50 PSIG

3.

HYDROGEN
CONTROL

4.

HYDROGEN PRESSURE INDICATION

PRESSURE

HIGH

TEMPERATURE

CONTROLLED BY PW CONTROL VALVE

PRESSURE TRANSMITTER & INDICATOR

Modifications Carried Out

S.
N.

MODIFICATIONS

RECTIFICATION MODE
CUM IMPROVEMENT

1.

HYDROGEN
TEMPERATURE CHANGED
FROM
CONTROL SCHEME
PNEUMATIC CONTROL TO
ELECTRONICS/DIGITAL
CONTROL SYSTEMS.

2.

HYDROGEN DRYER CIRCUIT

TEMPERATURE
MEASUREMENT AND FLOW
C&I INSTALLED

Deficiency observed in RAPS-2 Generator H2 dryer

H2 dryer bed surface temperature was maintaining high

and there was less temperature gradient in the dryer
circuit . This was indicating H2 flow was inadequate.

During investigation following observed:

There was inadequate primary and secondary orifices
to developed a driving force for H2 circulation.
The dryer regeneration outlet line found chocked.
The silica gel inside dryer found blackish powder and
was giving resistance to H2 flow.

Generator H2 dew point found sufficiently high, positive.

V - 26

64123-? PG-13338-B
L

V - 41

NEWLY INSTALLED DPG

1.
64123-? PG-13338-A
2.
64123-? PG-13338-B

TO PURGE

TO & FROM
GENERATOR

V-13654
V - 32
V-13652

V - 31

SECON-DARY
ORIFICE
SIZE 5
16"

64123-?PG-13338-A
H

V-13653

GAS
DRYER

GAS
DRYER
V-44

ADSORBING

REACTIVATING

BED-A

ORIFICE SIZE 1 "

16
V - 24

H
E
A
T
E
R

BED-B

MAIN CONTROL

DR - 1

HX 5

S
E
P
A
R
A
T
O
R

SP 1

V-42

H
E
A
T
E
R

DR - 2

LEGEND:RE-GENERATION CYCLE
ADSORBING CYCLE

V -45

CONDENSATE
TANK

SG
DRAIN
V-43

H2ADDITION LINE

R-2 GENERATOR HYDROGEN DRYER CERCUIT

Description of Dryer and Heating /Cooling Cycle Operation:

Hydrogen dryer has been provided in generator hydrogen cooling circuit to

remove the water vapors from the gas. It has two cylinders, each containing a
bed of desiccant (silica gel) and heater of capacity 2.2 kW. The upper and lower
branches of the cylinders are connected at the four way changeover valves.
These valves also form a part of the reactivation circuit that including the cooler
and a flow control orifice in the main inlet pipe.

If this purge flow is stopped for some reason (such as due to choking of
secondary orifice) it will result in overheating of bed the silica gel and its
physical form will change (Granules may become powder). It will then require
replacement of complete charge of silica gel.

On auto control during start of reactivation cycle timer-contact is closed for

one hour and after one hour timer contact opens, to switch off the heater. With
the heater switched off the cylinder is allowed to cool for one hour and so
complete the reactivation cycle,.

In case of timer failure, decomposition of silica gel will make dryer unavailable
and this will cause increase in moisture content of generator hydrogen gas
which is undesirable from equipment health point of view.

Description of Change
Heater Indication Circuit:
Installed and connect two separate indication lamps (parallel to existing field
panel lamps) on the control room panel. Indication lamp will glow when
respective heater M-contactor energizes and heater is ON. At a time, only
one heater ON indication should be there and it will remain ON for one
hour. After next three hour its ON indication will remain OFF (1 hour
cooling and next 2 hours during adsorption cycle). Status of heater and timer
can thus be monitored from control room panel surveillance .

Regeneration gas flow measurement:

Flow monitoring through regeneration bed achieved by measuring differential
pressure across regeneration and adsorption bed. Pressure will be relatively
more in bed which is under regeneration then the bed under adsorption.
Measured Delta P using manometer is 65-70 mm of WC. Thus, Delta P of
range 0-150 mm of WC installed across both the beds. Delta P gauge are
normally maintained in isolated condition and can be valve in for taking
reading during routine.
Two numbers of Delta PG of range 0-150 mm of WC are provided across both
the beds through modification carried out in Dec-2011.

Seal Oil System

B
R
G

SHAFT
SEAL

GENERATOR

SHAFT
SEAL

B
R
G

SEAL DRAIN
ARRANGEMENT

HYDROGEN PRESSURE

SEAL OIL PRESSURE

VACUUM OIL
TANK

C&I of Seal Oil System

S.N.

MEASURED VARIABLE

C&I USED

1.

HYDROGEN
VS
SEAL
DIFFERENTIAL PRESSURE

OIL MEASURED
BY
DIFFERENTIAL
PRESSURE
SWITCHES.
MAKE
&
MODEL MERCOID CONTROLS U.S.,
SET POINT <2.5 PSIG

2.

SEAL OIL PRESSURE

HYDROGEN
VS
SEAL
DIFFERENTIAL PRESSURE

OIL CONTROLLED
BY
DIFFERENTIAL
PRESSURE OPERATED VALVE. MAKE &
MODEL MERCOID CONTROLS U.S.,
SET POINT 4 PSIG

4.

SEAL OIL PRESSURE LOW

FOR STAND BY/EMERGENCY PUMP

OPERATIONS

5.

HYDROGEN
CONTROL SCHEME

CHANGED FROM PNEUMATIC CONTROL TO

ELECTRONICS/DIGITAL
CONTROL
SYSTEMS.

MEASURED
BY
DIFFERENTIAL
PRESSURE SWITCHES & PRESSURE
GAUGES. MAKE & MODEL MERCOID
CONTROLS U.S.,
SET POINT <2.5 PSIG

TEMPERATURE

Stator Water Cooling System

H LS
VH LS

H2

MAKE UP
TANK

-------------------

GENERATOR

HX

PUMP

C&I OF STATOR WATER COOLING SYSTEM

S.N.

MEASURED VARIABLE
WATER

PRESSURE

C&I USED

1.

STATOR
ALARM

LOW

MEASURED BY PRESSURE SWITCHES. MAKE

& MODEL MERCOID CONTROLS U.S.,
SET POINT <5 PSIG

2.

STATOR WATER PRESSURE HIGH

ALARM

MEASURED BY PRESSURE SWITCHES. MAKE

& MODEL MERCOID CONTROLS U.S.,
SET POINT 34 PSIG

3.

STATOR WATER
CONTROL

TEMPERATURE

CONTROLLED BY PW CONTROL VALVE

4.

STATOR
HIGH

WATER

TEMPERATURE

TEMPERATURE SWITCH FOR TURBINE RUN

BACK

5.

STATOR
LOW

WATER

TEMPERATURE

TEMPERATURE SWITCH FOR ALARM

6.

STATOR WATER FLOW LOW

FLOW SWITCH FOR TURBINE RUN BACK

7.

STATOR WATER FLOW LOW

FLOW SWITCH FOR ALARM

8.

STATOR WATER TEMPERATURE

CONTROL SCHEME

CHANGED FROM PNEUMATIC CONTROL TO

ELECTRONICS/DIGITAL
CONTROL
SYSTEMS.

PNEUMATIC CONTROL SYSTEM

PROCESS

PNEUMATIC CONTROLLER

TC

AIR SUPPLY
PW CV

ELECTRONIC CONTROL SYSTEM

BMOS CONTROLLER

PROCESS
TC

RTD

E/A

PW CV

Items for Discussions for Improvement

S.
N.
1.

System

Existing C&I

Improvement
Required in C&I

Differential
Pressure By Mercoid, U.S.
Measurement in Seal oil Pressure Switches
Hydrogen & Stator Water
System

Recommended
Supplier/manufacturer
Make, Model for
replacement
of
existing PS.

THANK
YOU