49

4. HYDROGEN COOLING AND SEAL OIL SYSTEM- STAGE II

4.1 GAS SYSTEM
The gas system consists of the following assemblies:

CO2 distributor

H2 distributor

Gas dryer

Gas unit

4.2 HYDROGEN DISTRIBUTER

The hydrogen for the generator is supplied from the hydrogen
distributor. The hydrogen cylinders are connected to the manifold on the
distributor. Valves on the cylinder and valves on the manifold allow
replacement of individual cylinders during operation. The hydrogen gas
available in the manifold at cylinder pressure is passed to two parallelconnected pressure reducer combinations for expansion to the pressure
required for generator operation. Relief valves on the low-pressure side of
the first pressure reducer are connected to an outlet pipe system through
which excess hydrogen is passed to the atmosphere. The two pressure
reducers are of identical design. The combination of two reducers ensures a
constant pressure even in low or no flow condition. On the other hand, the
arrangement of two combinations allows large quantities of hydrogen to be
reduced in pressure during hydrogen filling procedure.

4.3 CARBON DIOXIDE DISTRIBUTOR

To prevent a potentially explosive mixture being formed, hydrogen and
air must never be allowed to come in contact with each other either during
charging of hydrogen or scavenging of hydrogen from the generator. In both
cases, CO2 is used as an intermediate medium. The CO2 is also supplied in
steel cylinders in liquid state. The arrangement of the CO2 distributor
corresponds to that of hydrogen distributor. The liquid CO2, which is stored
under pressure, is fed to the gas unit via a shut off valve. At the gas unit the
liquid CO2 is evaporated and expanded in a CO2 vaporizer. The heat of
vaporization is supplied to the vaporizer electrically. One relief valves each
on the high pressure and a low-pressure side protects the pipe system
against inadmissible high pressure.

50
For removing the CO2 from the generator, a compressed air supply with
compressed air filter is connected to the instrument air system of the power
plant. Under all conditions of operation except for CO 2 purging, the
compressed air hose between the filter and the generator pipe system
should be disconnected. This visible break is to ensure that no air can be
admitted into hydrogen filled generator.

4.4 GAS UNIT

For measuring and checking the gas pressure in the generator, the gas
unit is provided with pressure transmitter and one pressure gauge for local
measurements. The purity is also measured by a purity meter. This meter
system functions only at rated speed.

4.5 GAS DRIER

A small amount of hydrogen circulating in the generator for cooling is
passed through a gas drier. The gas inlet and gas outlet pipes of the gas
drier are connected at points of the generator with different static heads
(differential fan pressure) so that the gas is forced through the drier due to
the differential pressure only. Drying of hydrogen is ensured by two driers
provided with silica gel, which can be reactivated with the help of built-in
heaters .The drier consists of gas tight cylindrical body with silica gel in a
perforated container at the top. A heater is provided in the central portion of
the drier, which is completely isolated from hydrogen zone. A thermostat is
embedded which cuts off supply to the heater at 120 C, automatically
indicating thereby that the drier is ready for reuse. The colour of silica gel
can be observed through two glass widows provide at the top. A local control
cubicle is provided for electrical control of heaters of both the driers. The
following lamp indications are provided on the cubicle for each drier.

Heater on

Heater off

Regeneration complete.

Normally out of two, one drier is in operation while other is in

reactivation. The continuous circulation of hydrogen through drier is
facilitated by the differential pressure created by fan mounted on the
generator shaft across which the drier is connected .The hydrogen from inlet
connection enters silica gel from bottom and moisture is given up to the

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silica gel while it passes through. The drier hydrogen is led away to outlet
connection from the outer annular space in the drier. Silica gel in drier needs
reactivation as it becomes saturated with moisture. Saturation state of silica
gel can be seen through glass window (at the top) by its colour, which
transforms from blue to pink. When silica gel is saturated, closing inlet valves
isolates the drier and other drier is commissioned by opening the respective
valve. For reactivation of silica gel, heater is switched on and as the
temperature goes up, the moisture evaporates and condenses on inside of
the outer cylinder, which trickles down to the bottom of the drier where there
is a provision for draining off the water collected. When the temperature of
the silica gel reaches 120C the thermostat cuts off the supply to the heater
automatically indicating that the drier is ready for re-use. The supply for the
heater is 220V A.C. single phase, 600Watts.

4.6 TECHNICAL DATA

Rated hydrogen pressure inside the generator
casing
Maximum

hydrogen

pressure

at

which

an

3.5 Kg/cm2 (g)

3.7 Kg/cm2 (g)

annunciation appears
Minimum hydrogen pressure at which an

3.3 Kg/cm2 (g)

annunciation appears
Rated cold gas temperature
Maximum permissible hot gas temperature
Purity of hydrogen

44C
75C
Not less than

Maximum permissible moisture content

97%
15 gm/m3 of H2

4.7 GAS REQUIREMENT

Generator gas volume
56 M3
Amount of hydrogen required filling the generator casing to rated
pressure expressed at NTP
When the machine is stationary
300 M3
When the machine is running
340 M3
Make up hydrogen required per day
15 M3
Amount of CO2 required to remove hydrogen expressed at NTP
When the machine is stationary
120 M3
When the machine is running
168 M3
Amount of CO2 required to remove air expressed at NTP
When the machine is stationary

90 M3

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When the machine is running
Quantity of compressed air differ for purging of

112 M3
150 M3at a pressure

CO2 from the generator

of 0.2 Kg/cm2

4.8 SEAL OIL SYSTEM

Generator shaft seals are supplied with pressurized seal oil to prevent
hydrogen escape at the shaft and the ingress of air in to the generator. As
long as the seal oil pressure in the annular exceeds the gas pressure in the
generator, no hydrogen will escape from the generator hosing. The shaft
seals are supplied with required seal oil from an exclusive closed loop oil
circuit. The oil in the seal oil system is same as that used in the Turbine
/Turbo generator journal bearings and the turbine governing system. During
the normal operation, A.C. seal oil pump draws the seal oil from the seal oil
tank and feeds it to the shaft seals through coolers and filters. The seal oil
supplied to the shaft seals is drained towards hydrogen and airside through
the annular gap between the shaft and the seal ring. The airside seal oil is
returned directly into the seal oil tank through the float valve. The oil drained
on the hydrogen side first flows in to the pre-chambers and flows in to the
intermediate oil tank (I.O.T) before returning into seal oil tank (S.O.T). The
seal oil in the seal oil tank (S.O.T) is kept under vacuum to prevent
deterioration of the hydrogen purity in the generator housing. The gases
entrapped in the oil are thus removed so that the seal oil pumps draw largely
degassed oil only.
For oil circulation three 100% capacity screw type pumps, two A.C.
motors driven and one D.C. motor driven are provided. A vacuum pump is
provided for maintaining vacuum in seal oil tank and is kept in operation
when either of the seal oil pumps is running. Upon failure of normal A.C. seal
oil pumps due to mechanical or electrical fault, the stand by D.C. seal oil
pump automatically takes over supply. Upon failure of all pumps, the seal oil
is taken over by the turbine governing oil system without any interruption.
The seal oil system is self-contained. 1.5 Kg/cm2 keeps the seal oil at a
higher pressure than the gas pressure in the generator. With the seal oil
pumps in operation the seal oil pressure is controlled by differential pressure
regulating valve A. The excess oil is returned to the seal oil tank so that the
required differential seal oil pressure is maintained at the shaft seals. Due to

53
the fact that the gas pressure and the seal oil pressure act in opposite
direction in the valve actuator, the valve stem is moved upwards or
downwards when this pressures are no longer properly balanced. The valve
cone is arranged so that the valve closes further at a downward movement
of the valve stem (occurs at rising gas pressure or falling seal oil pressure).
This oil flow throttling results in a rise of the seal oil pressure at shaft seals.
The differential pressure (set valve) to be maintained by the valve
can be changed by corresponding preloading of the main bellows. The
preloading is applied through a compression spring, the upper end of which
is rigidly connected to valve yoke, while its lower free end is attached to the
valve stem by means of an adjusting unit. The two seal oil coolers each of
100% capacity are provided, one of which is always in operation, while the
other serves as standing by. The seal oil flow can be changed over from one
cooler to another cooler by operation of associated isolating valves. The seal
oil filter arranged directly after the seal oil coolers .It consists of 3 100%
capacity mesh type filters and serves for screening any foreign particle
entrained in the oil and thus preventing any damage to seal babbit and shaft.
By means of change over valve assembly provided at the filters any one filter
can be taken out of service for cleaning without interruption

of oil flow to

the shaft seals.

The oil drains from the shaft seals are in two parts, one towards the
hydrogen side and other towards the airside. The oil drain towards the
hydrogen side is at first passed into the pre-chamber at both the ends. These
pre-chambers serve for defoaming of oil and escape of entrained gas.
Downstream of the pre-chambers the two oil flows combine together and
flow into the intermediate oil tank. The oil from the intermediate tank is
continuously return into the seal oil tank together with the oil drained on the
airside through float valves. One float valve provided on intermediate oil tank
maintains a fixed level in this tank, so that the hydrogen in the drain lines
does not escape into the drain system. The float valve provided in the seal
oil tank does not allow the oil level to go abnormally high. Any surplus oil,
which is not accepted by seal oil tank, is returned to the seal oil storage tank
(S.O.S.T) and finally to main turbine oil tank. In case of any short fall in the
oil level in the seal oil tank the oil flows from the seal oil storage tank

54
automatically and maintains the required constant level. The seal oil tank is
evacuated of gases by a rotary vane vacuum pump is kept in operation by
interlock as long as any of the seal oil pump is working.
When the shaft seal oil supply is obtained from the governing oil
system the pressure is regulated by means of differential pressure regulating
valve B. Except for the valve seat and valve cone this valve is of the same
design as DPR valve A. Due to the different valve cone arrangement the
valve B opens at a downward movement of valve seem (occurs at falling oil
pressure in the seal oil system). The regulated oil further takes the same
path to the shaft seals through the coolers and filters. Since the oil is not
drawn

from the seal oil tank, the float valve of seal oil tank will not open

and the drain oil will flow towards seal oil storage tank, from where it further
flows in to the main turbine oil tank. In this case a slow deterioration of
hydrogen purity take place. The seal oil storage tank is provided with
2100% duty vapour extractors to ensure continuous venting of the tank. An
additional vapour extractor is provided on turbine oil tank to ensure its
continuous venting. To ensure the free floating condition of sealing ring in the
seal body even at high machine gas pressures, the shaft seals are provided
with ring relief oil. The ring relief oil supply is obtained from governing oil
supply line through a filter and is admitted on the side of both shaft seals.

4.9 INTERLOCKS
1. When running pump discharge pressure is less than 4 KSC, other
two reserve pumps start on auto (A.C. seal oil pump through
Auto/Manual selector switch and D.C. seal oil pumps Auto/Manual
switch position independent)
2. When running pump trips the reserve A.C. pump comes on Auto
position of the switch and non-running of regular pump.
3. D.C seal oil pump will come on electrical interlock of both A.C. seal
oil pumps not running together with D.C. seal oil pump Auto/Manual
switch in Auto position. For all the three above, the seal oil tank
should be adequate.

4.10 OPERATION
4.10.1 FILLING AND INITIAL OPERATION

55
Prior to filling the system, all the level switches at the seal oil unit,
seal oil storage tank and pre-chambers are to be set. Prior to filling the
system with oil it should be ensured that all stop and non-return shut off
valves are initially in closed condition.

4.11 NOTE:The procedure for opening the valves are to be followed in the
sequence below.
1. Pressure gauge/Switch isolating valves at the seal oil unit.
2. The pressure transducers isolating valves.
3. a) The isolating valves on impulse lines at seal oil unit.
b) The isolating valves for Differential pressure transducer impulse
lines.
4. Valve V-55 at seal oil storage tank.
5. Valves at seal oil unit for supply of oil to the Generator at slip ring end
as well as turbine end.
6. Opening the corresponding inlet and outlet valves sets one of the seal
oil coolers. Opening the corresponding change over cocks also sets one
of the filters of duplex seal oil filter.
7. The vacuum pumps and bearing vapour extractors are to be checked
for proper working condition. These will be brought in operation later.
The turbine lubricating oil system is to be brought into operation (if not
already working). Valve V-55 being open, the oil flows into the seal oil tank
from the seal oil storage tank. After an interval of time, the level in the
seal oil tank will rise to normal value controlled by float valve V-11. The
A.C. seal oil pumps should be started for filling the system and operation.
4.12 NOTE: 1. In order to avoid chocking of pipe lines due to air locking, the A.C.
seal oil pump should be switched off and on again and again till
the pressure gauges for seal oil pressure at turbine end and
exciter end show constant pressure. After that the seal oil pump
can remain in operation. The quantity of oil that flows towards
hydrogen side of the shaft seals fills the intermediate oil tanks.
When there is no gas pressure at the generator, the oil level rises
above level gauge LG-1.

56
2. In case lubricating oil system cannot be brought in operation,
alternative method of filling the seal oil storage tank and the
system through seal oil storage tank may be adopted.

4.13 VENTING:
a) The DPR-A & DPR B are vented by slackening the screw joints in
the oil impulse lines.
b) The stand by cooler is first filled by opening the inlet and outlet
valves .The vent valves of both the coolers are opened to vent the gases till
the oil comes out of the valves and then they are closed.
c) The stand by filter is first filtered by opening the inlet and outlet
valves. Then both the filters are vented by opening the respective vent
plugs.
d) The following pressure gauges are vented through the venting
screws at respective pressure gauge isolating valves.
PG-1: Pressure gauge at the outlet of A.C. seal oil pump.
PS-1: Pressure switch at the outlet of A.C. seal oil pump.
PG-7: Pressure gauge at outlet of D.C. seal oil pump.
PG-2: Pressure gauge at outlet of Duplex seal oil filter.
PG-3: Pressure gauge for seal oil inlet pressure to shaft seal TE.
PS-2: Pressure switch for seal oil inlet pressure to shaft seal TE.
PS-4: Pressure switch for seal oil inlet pressure to shaft seal TE.
PG-4: Pressure gauge for seal oil inlet pressure to shaft seal EE.
PS-3: Pressure switch for seal oil inlet pressure to shaft seal EE.
PS-5: Pressure switch for seal oil inlet pressure to shaft seal EE.
PG-5: Pressure gauge for ring relief oil pressure to shaft seal TE.
PG-6: Pressure gauge for ring relief oil pressure to shaft seal EE.
PG-9: Pressure gauge for governing oil pressure.

4.14 SETTING OF OIL PRESSURE

a) SETTING OF DPRV A
The check nut at the valve stem is slackened. The adjusting nut is
turned to set DPRV-A for differential pressure of 2.4 Kg/cm 2 so that the seal
oil pressure of 1.5 Kg/cm2 above the gas pressure at the generator shaft
seals is established.

57
Clockwise turning of the adjusting nut increases the seal oil pressure at
shaft seals.
Note: Differential pressure of 2.4 Kg/cm 2 (difference in readings of pressure
gauges PG-3 (PG-4) and PG-8 includes the static hand valve of 0.9 Kg/cm2.)
b) SETTING OF DPRV B
The seal oil filter SF is filled by means of changeover valve V-47/V-48
and the filter is vented by opening the vent plug. The A.C. seal oil pump is
stopped .The DPRV-B is adjusted by adjusting nut for differential pressure of
2.1 Kg/cm2 (difference in readings of pressure gauges PG-3 (PG-4) and PG-8
to obtain seal oil pressure of 1.2 Kg/cm 2 above the gas pressure at generator
shaft seals.)
Normally DPRV-A valve remains in operation and in case of the failure
of pumps and as soon as the differential pressure at generator shaft seals
drops to 1.2 Kg/cm2 and the DPRV-B opens and the oil from governing oil
system flows to the shaft seals.
DPRV- B is set at value less by 0.3 Kg/cm 2 from the actual set valve of
DPRV-A.

4.15 SETTING OF RING RELIEF OIL PRESSURE

The ring relief oil pressure is set by means of valves V-22 and V-23 to a
value of 0.5 Kg/cm2 above seal oil pressure at shaft seals that is operating
value as read on pressure gauges PG-5/PG-6 shall be 6.4Kg/cm 2 with rated
gas pressure of 3.5 Kg/cm2.
All the contacts for the starting of the standard A.C. seal oil pump, DC
seal oil pump, and annunciations are set. The level switches at seal oil unit,
seal oil storage tank and pre-chambers are checked and adjusted. In the seal
oil cooler, the cooling water is regulated for maintaining the seal oil
temperature below 40C. The thermostat TS-I is set for 45C.
The seal oil system is thus commissioned.

4.16 TAKING SEAL OIL SYSTEM INTO SERVICE

Seal oil system is required to be taken into service when the generator is
To be filled with hydrogen or,
To be filled with air for the leakage testing.
The following instructions are to be carried out for starting a system.

58
1) Prior to starting, it should be ensured that all indicating
instruments/devices are ready for operation.
2) Ensure that the seal oil level is observable at the level gauge of
intermediate oil tank and sight glass of seal oil tank. If not fill the seal
oil according to the instructions given for commissioning of the seal oil
system.
3) Check and ensure that the following pressure gauge/Pressure Switch
isolating valves are open.
a) V-46 for pressure gauge at inlet of governing oil.
b) V-37 for pressure gauge after seal oil pump.
c) V-38 for pressure switch at the outlet of A.C. seal oil pump.
d) V-70 for pressure gauge after D.C. seal oil pump.
e) V-35 for vacuum gauge.
f) V-39 for pressure gauge after duplex filter.
g) V-66 &V-67 for differential pressure switch across duplex filter.
h) V-45 for pressure gauge for ring relief oil on TE.
i) V-40 for pressure gauge for ring relief oil at EE.
j) V-43 &V-72 for pressure switches for seal oil pressure at TE.
k) V-44 for pressure gauge for seal oil pressure at TE.
l) V-41for pressure gauge for seal oil pressure at EE.
m) V-42 & V-71 for pressure switches seal oil pressure at EE.
n) V-91 for pressure transducer for seal oil pressure at TE.
o) V-89 for pressure transducer at seal oil pressure at EE.
4) Check and ensure that the following stop valves are open. If not, the
valves are to be opened in the specified sequence.

4.17 AT GENERATOR
a) V-55 in filling pipe.

4.18 AT SEAL OIL UNIT

a) V-3 after IOT.
b) V-15 before SOT.
c) V-1 before A.C. SOP.
d) V-2 before D.C. SOP.
e) V-16 before DPRV - B.
f) V-20 after DPRV - B.

59
g) V-27 before vacuum pump.
h) V-21 after DPRV - A.
i) V-8 after seal oil pumps.
j) V-10 for ring relief oil.
k) V-22 for ring relief oil at TE.
l) V-23 for ring relief oil at EE.
m) V-31 for seal oil supply at TE.
n) V-32 for seal oil supply at TE.
5) Check and ensure whether the following stop valves at seal oil unit, on
the impulse lines are open.
a) V-30 gas impulse to DPRV B.
b) V-25 oil impulse to DPRV B.
c) V-29 gas impulse to DPRV A.
d) V-24 oil impulse to DPRV A.
6) It is to be checked and ensured that the vacuum pump is sufficiently
filled with special oil N62.
7) The A.C. seal oil pump is to be started. In order to avoid the build up of
an excessive pressure in the piping system air cushions/locks in the
piping must be displaced with the oil A.C. seal oil pump should be
started and immediately stopped again until all in cushions have been
positively removed from the piping system. Subsequently the pump is
to be kept in continuous operation. The following pressure gauges are
to be monitored.
i.

PG-1 after A.C. seal oil pump.

ii.

PG-2 after duplex seal oil filter.

iii.

PG-3 for TE seal oil.

iv.

PG-4 for EE seal oil.

8) When the A.C. seal oil pump is started, the vacuum pump and the
vacuum extractor must be started simultaneously.
9) When the oil foam rises above the upper edge of oil sight glass in the
SOT V-27 is to be closed and once again V-27 is to be opened on its
disappearance.
10)

It is to be checked and ensured that all the oil pressure values

are normal.

60
11)

The interlocks for auto starting of the standby A.C. seal oil pump

and the D.C. seal oil pump are to be checked.

12)

The gas tightness of SOT including the connected pipelines and

the valves is to be checked. The value of the vacuum should be

between 3 to 10 torr and this should not change for a period of at least
24 hours.
13)

The seal oil coolers are to be vented by opening the vent valve of

operating cooler until oil emerges. The vent valve is to be closed. The
standby cooler is to be brought into service and the above process is to
be repeated.
14)

Both the seal oil filters are to be brought into operation and the

filters are to be vented by opening the vent plugs. On completion of

venting one of the seal oil filters is to be taken out of service.
15)

The seal oil filters are to be checked for contamination, and if

necessary to be cleaned. (The degree of filter contamination can be

seen at the differential pressure switch DPS-1). In case of red indication
filter cleaning will be required.
16)

The seal oil coolers are to be filled on the waterside and the

coolers are to be vented.

17)

It is to be checked whether the following valves are open.

i.

V-46 pressure gauge for governing oil.

ii.

V-20 after DPRV B valve.

iii.

V-16 Before DPRV B valve.

iv.

V-30 Gas impulse to DPRV B.

v.

V-25 Oil impulse to DPRV B.

vi.

V-19 Governing oil supply.

It is also to be checked that the filter SF is set for operation. By

isolating the electric supply to A.C. and D.C. seal oil pumps, the seal oil
supply must be taken over by the turbine governing system when the
seal oil pressure in the delivery pipe has dropped by 0.3 Kg/cm2.
18)

It is to be checked whether the seal oil supply is at the normal

operating value. (If not, the oil impulse line to DPRV B is to be

vented).

61
19)

The seal oil supply is to be changed over top the main A.C. seal

oil pump.
20)

To bring the ring relief oil into service, the following valv3es are

to be adjusted until the normal operating values are reached.

i.

V-22 for ring relief oil at TE.

ii.

V-23 for ring relief oil at EE.

4.19 NOTE: The final adjustment of pressure for ring relief oil can only be made
when the generator has been filled with H2 at rated pressure and the
machine is running at rated speed.
21)

When the seal oil temperature has reached 30C, the cold water

supply to the service cooler is to be turned on.

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