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Turbogenerators
Table of Contents
Introduction
Technical Customer Documentation
Operating and Maintenance Manual
Product Technical Documentation
Introduction Tab 1
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0--0010--12580/1--6 0212E

0114E
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0--0030--0001 0808E
0114E
Introduction of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0--0040--0041 0511E
0114E
Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0--0050--0001 0808E
0114E
KKS - Power Plant Identification System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0--0060--0001/1-2 0808E
0114E
Symbols for Supervisory Circuits and Supervisory Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0--0070--0001/1-2 0708E
0114E
.
All Rights Reserved
.
.
.
Safety Instruction Tab 2
.
.
e Siemens AG 2011 --
General Safety Information for Hydrogen-Cooled Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0--0100--0003/1-2 0810E

0114E
Safety Equipment for Hydrogen Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8310--0004 0908E
0114E
.
.
Technical Data Tab 3 .
Copyright
.
Design Data Tab 3.1 .
Rating Plate Data for Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1605--12580 0811E

0114E
General and Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1607--12580 0114E
0811E
Reactive Capability Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1611--12580 0114E
0811E
Permissible Loading at Rated P.F. -- During Voltage and Frequency Deviations . . . . . . . . . . . . . 2.1--1612--0002 0114E
0203E
Unbalanced Load-Time Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1614--0062 0114E
0411E
Current Overload Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1615--0002 0114E
1205E
Permissible Synchronizing Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1617--0001 0114E
1205E
Limited Duration of Open-Circuit with Overvoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1618--12580 0114E
0811E
Hydrogen Cooler Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1620--12580 0114E
0811E
.
Limit and Setting Values Tab 3.2 .
General........................................................................................................................................2.1-1630-0006
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1630--0006
0114E
1008E
1008E
Limit & Setting
Measuring PointValues-Generator
List . . . . . . . . . . . Supervisory
. . . . . . . . . . . Equipment..........................................................2.1-1632-1638
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1635--12580/1-6
0114E
0811E
0811E
Measuring Point List....................................................................................................................2.1-1635-12580/1-6
Power Consuming Device List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1637--12580/1-2
0114E
0811E
0811E
Power Consuming Device List............................................................................................... .....2.1-1637-12580/1-2 0811E
0114E
.
Specifications Tab 3.3 .
Distribution: UNRESTRICTED
PrimaryWater
Primary WaterSpecification..........................................................................................................2.1-1639-0002/1
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1639--0002/1
0114E
0106E
0106E
Specification
Gas of Ion Exchange Resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1639--0002/2
Specification..........................................................................................................................2.1-1640-0002 0114E
0106E
0898E
Turbine
AdditiveOil Specification...............................................................................................................2.1-1680-0001
Specification for Alkalizer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1639--0002/3
0114E
0710E
1101E
Approved
Gas Specification Oils..................................................................................................................2.1-1681-0001/1-2
Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1640--0002
0114E
0109E
0898E
Turbine Oil Specificaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1680--0001 0710E
Approved Turbine Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1681--0001/1-2 0109E
Siemens AG
BHEL,Haridwar MK &MAB 2.0--0010--12580 / 1
Energy Sector 0212E
0114E
Dimensions and Weights Tab 3.4
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1670--12580 0114E
0212E
Generator Outline Drawing, Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--3102--160533 Index-A
Index A
.
.
Description of Components and Auxiliary Systems Tab 4 .
.
.
MK - Abstract Tab 4.1 ..
Design and Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1100--0051/1--2 0901E
0114E
Generator Cooling Gas Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1150--0012 0212E
0114E
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1210--0020 1008E
0114E
Stator Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1230--0012 1008E
0114E
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1300--0030 0901E
0114E
Hydrogen Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1440--0026 1008E
0114E
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1450--0001 1010E
0114E
Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1460--0011 1008E
0114E
.
MKA06, MKA07 - Shaft Seal Tab 4.2 .
Description of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--6000--0008 1008E
0114E
Shaft Seal -- Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--6001--0013 0901E
0114E
Insulation and Sealing of Seal Ring Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--6005--0002 1008E
0114E
.
..
MKA10 ... MKA37 - Stator Tab 4.3 .
.
Stator Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2100--0036 0111E
0114E
Outer Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2110--0014 0911E
0114E
Core and Winding Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2130--0016 1208E
0114E
Stator Bearing Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2150--0021/1--2 1008E
0114E
Hydraulic Testing and Anchoring of Stator Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2190--0017 1008E
0114E
Stator Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2200--0024/1-2 1008E
0114E
Mounting of Stator Core and Winding Assembly in Stator Casing . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2201--0038 0911E
0114E
Stator Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2300--0030 1208E
0114E
Connection Diagram of Stator Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2301--0080 0110E
0114E
Stator Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2303--0075 0901E
0114E
Micalastic High Voltage Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2320--0014/1-4 1008E
0114E
Construction of High-Voltage Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2321--0011 1208E
0114E
Stator Winding -- Corona Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2330--0004 1008E
0114E
Coil and End Winding Support System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2340--0018 1008E
0114E
Stator End Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2341--0113 0106E
0114E
Electrical Connection of Bars and Phase Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2350--0024 0701E
0114E
Electrical Bar Connections and Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2351--0010 1208E
0114E
Terminal Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2370--0030 1008E
0114E
Cooling of Terminal Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2371--0035 0210E
0114E
Water Cooliing System -- Ststor Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--2380--0006 1008E
0114E
.
..
MKA40 - Rotor Tab 4.4 .
.
Rotor Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3000--0033 1008E
0114E
Cooling of Rotor Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3100--0020 1008E
0114E
D-Cooling System for Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3101--0034 1008DE
0114E
Rotor Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3300--0015 1008E
0114E
Rotor Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3301--0037 0210E
0114E
Rotor End Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3310--0075 0901E
0114E
Arrangement of Damper Bar in Rotor Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3333--0013 0210E
0114E
Rotor Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3350--0003 1008E
0114E
Field Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3370--0016 1010E
0114E
Mechanical and Electrical Connection of EE Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3373--0021 0210E
0114E
Radial Blower .(Rotor
. . . . . .Fan)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3600--0001 0210E
0114E
Rotor Fan and Fan Baffle Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--3603--0021 0210E
0114E
..
MKA70 - Cooler Tab 4.5 ..
..
0114E
Siemens AG
BHEL,Haridwar 2.0--0010--12580 / 2
Energy Sector 0212E
0114E
MKD - Bearing Tab 4.6
Generator Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--5000--0024/1-2 1008E
0114E
Generator Bearing -- Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--5001--0036 1008E
0114E
Measuring of Bearing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--5003--0013 1008E
0114E
Generator Bearing Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--5005--0018 1008E
0114E
Generator Bearing -- Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--5007--0012 1008E
0114E
.
MKW -- Seal Oil System Tab 4.7 .
Seal Oil Diagram -- Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--7111--12580/1--2 0811E
0114E
Seal Oil Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--2603--148221 Index DD
Index
.
..
MKG -- Gas System Tab 4.8
..
Gas Diagram -- Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--7211--12580/1--2 0811E
0114E
Gas Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--2604--148222/001 Index DD
Index
Gas Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--2604--148222/004 Index CC
Index
.
MKF -- Primary Water System Tab 4.9 .
Primary Water Diagram -- Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--7311--12580 0811E
0114E
Primary Water Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--2605--148223 Index CD
Index
.
MKQ -- Waste Gas System Tab 4.10 .
Waste Gas Diagram -- Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8311--12580 0811E
0114E
Waste Gas Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--2604--148222/002 Index CC
Index
.
MKY - Protection and Monitoring Devices Tab 4.11

..
.
Generator Measuring Points -- Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8421--12580/1--2 0811E
0114E
Generator Measuring Points -- Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--2601--148219/001 Index BB
Index
Generator Measuring Points -- Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24--2601--148219/002 IndexCC
Index
Cooling Gas Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8010--0002/1-2 1008E
0114E
Generator Mechanical Equipment Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8320--0029 1298E
0114E
Electrical Generator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8330--0008/1-2 1008E
0114E
Arrangement of Brush Holders for Rotor Grounding System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8351--0011 0103E
0114E
Measuring Devices and Supervisory Equipment -- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8400--0002 1010E
0114E
Resistance Temperature Detectors and Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8410--0004/1-2 1010E
0114E
Supervision of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8420--0034/1-2 0711E
0114E
Supervision of Bearing Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8440--0001 1008E
0114E
Supervision of Seal Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8450--0016 0309E
0114E
Supervision of Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8460--0028 0106E
0114E
Gas Analyzer for the Detection of Hydrogen Leakages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8469--0001 1008E
0114E
Supervision of Primary Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--8470--0008 0708E
0114E
.
..
.
.
BHEL,Haridwar
Siemens AG 2.0--0010--12580 / 3
0212E
0114E
Contract Drawings Tab 7
Generator Cross Section --- Longitudinal Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ---0090---160441 Index A
Index A
Generator Cross Section --- Lateral Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24---0090---160642 Index A
Index A
Generator Cooling Gas Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ---0090---160443 Index A
Index A
Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24---0128---148718 Index A
Index A
Generator Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24---3102---160533 Index A
Index A
Operation Tab 9 .
.
Turning and Running Up Tab 9.1
.
Preparations for Starting --- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 ---5000---0002 0806E
0114E
Hints for Cooler Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---5003---0006/1-2 0210E
0114E
Turning Gear Operation and Runup of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 ---8010---0012 0210E
0114E
Simplified Generator Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---8011--- 0027 0210E
0114E
Startup, Voltage Regulation With Automatic Control --- Static Excitation System . . . . . . . . . . . . . 2.3---8030---0021 0806E
0114E
Operation Under Load Tab 9.2 .
On-Load Running, Voltage Regulation With Automatic Control --- Static Excitation System . . . . 2.3---8130---0026 0209E
0114E
On-Load Running, Changeover of Automatic Voltage Regulator from Automatic to Manual --- .
Static Excitation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---8150---0021 0709E
0114E
On-Load Running, Changeover of Automatic Voltage Regulator from Manual to Automatic --- .
0114E
Generator Load Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---8170---0050 0210E
0114E
.
Shutdown Tab 9.3 .
Shutdown of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 ---8310---0012 0610E
0114E
Generator Shutdown Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---8311---0025 0709E
0114E
Unloading and Shutdown, Voltage Regulation With Automatic Control --- ..
0114E
.
Standstill Tab 9.4 .
Supervision of Generator During Standstill --- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 ---8400---0030 0709E
0114E
Supervision of Generator During Standstill --- Slipring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---8900---0020 0901E
0114E
.
Trouble-Shooting Tab 10 .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---9000---0001 0808E
0114E
.
MKA10 ... MKA37 --- Stator .
Stator and Generator Supervisory Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 ---9200---0031/1-3 0710E
0114E
MKA40 --- Rotor .
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---9310---0001 1208E
0114E
MKA70 --- Cooler .
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 ---9440---0030/1-2 0511E
0114E
MKD --- Bearings .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3---9450---0001 ..
0710E
0114E
.
Maintenance Tab 11 ..
.
..
.
Maintenance in Operation Tab 11.1
Maintenance and Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 ---4200---0001 0710E
0114E
Survey on Maintenance and Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 ---4205---12580 0212E
0114E
MKA10 ... MKA37 --- Stator .
.
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4---4210---0061/1-2 0210E
0114E
.
MKA40 --- Rotor .
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4---4310---0003 0710E
0114E
.
MKA70 --- Cooler .

.
Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4---4240---0007 0806E
0114E
.
MKD - Bearings ..
Maintenance and Supervision --- Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 ---4250---0004 0114E

.0109E
Siemens AG
BHEL,Haridwar 2.0 --0010 --12580 / 4
Energy Sector 0114E
0114E
Maintenance at Generator Standstill Tab 11.2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0010--0008 0909E
0114E
.
MK - Abstract .
Determination of Dewpoint Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0019--0001 0109E
0114E
Packing, Transport and Storage of Generator Rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0030--0003/1-4 0710E
0114E
Checking Desiccant in Packing of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0032--0001 0109E
0114E
Insulation Resistance Measurements on Rotor Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0033--0002 0909E
0114E
Preparation of Machinery Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0200--0001 0210E
0114E
Checking the Insulation for Protection From Shaft Currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0300--0002/1-3 0210E
0114E
Flushing the Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--0320--0001/1-2 0310E
0114E
Measures to prevent Corrosion During Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1003--0021 0504E
0114E
Preventive Measures to Avoid Moisture Condensation -- Survey . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1005--0003 0109E
0114E
Inspection Schedule -- Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1010--0005/1-2 1110E
0114E
Inspection Schedule -- Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1020--0022 0302E
0114E
Inspection Schedule -- Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1030--0025 0408E
0114E
Inspection Schedule -- Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1040--0016 0109E
0114E
Inspection Schedule -- Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1050--0005 0109E
0114E
Inspection Schedule -- Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1060--0002 0109E
0114E
Inspection Schedule -- Generator Supervisory Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1080--0005 0109E
0114E
Measures for Preservation of Generator During Standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--1100--0025 0109E
0114E
MKA06, MKA07 - Shaft Seal .
Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--6000--0005 0114E
0109E
Insulation and Sealing of Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--6110--0002/1-2 0114E
1010E
.
MKA10 ... MKA37 -- Stator .
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2000--0016 0114E
0409E
Check List for Works on Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2001--0001 0109E
0114E
Cementing the Joints of Profiled Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2120--0001 0109E
0114E
Generator Drying System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2155--0002 0109E
0114E
Mounting of Inner Labyrinth Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2162--0004/1-2 0109E
0114E
Fitting New Seal Strips to Labyrinth Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2163--0001/1-3 0710E
0114E
Insulation Resistance Measurements on Stator Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2300--0004/1-2 1194E
0114E
Drying the Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2310--0014 0806E
0114E
Electrical Tests on Stator Winding With vacuum Impregnated MICALASTIC .
High-Voltage Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2320--0001/1-3 0409E
0114E
Treatment of Bolted Contact Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--2350--0001 0109E
0114E
.
MKA40 -- Rotor 0114E
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--3000--0016 0310E
0114E
Insulation Resistance Measurements on Rotor Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--3300--0004 0310E
..
MKA70 -- Cooler 0114E
..
MKD - Bearings
0114E
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5--5000--0009 0109E
Siemens AG
BHEL,Haridwar 2.0--0010--12580 / 6
Energy Sector 0212E
0114E
Exciter Table of Contents
General

1 General
Table of Contents.............................................................................................. ELR-1.0-0001-0209/14 (
Preface.............................................................................................................. ELR-1.1-0001-0001 (
Addresses ......................................................................................................... ELR-1.2-0001-0001 (
General safety instructions ............................................................................... ELR-1.3-0001-0001/14 (
2 Technical Data
2.1 Identification
Identification Data ............................................................................................. ELR-2.1-0001-0209 (
Rating Plate Data .............................................................................................. ELR-2.1-0002-0209/12 (

2.2 Mechanical Data

Copyright Siemens AG 2011 - All Rights Reserved
Dimensional Drawing ........................................................................................ 0-7902-509914b (

Dimensions and Weights .................................................................................. ELR-2.2-0001-0209 (
Materials............................................................................................................ ELR-2.2-0002-0209 (

2.3 Electrical Data

Design Data ...................................................................................................... ELR-2.3-0001-0209/12 (
Curves and Data ............................................................................................... ELR-2.3-0002-0209/13 (
2.4 Operating and Setting Values

Operating and Setting Values ........................................................................... ELR-2.4-0001-0209 (
2.5 Measuring Instruments, Connection points and Consumers

List of Measuring Instruments, Connection points and Consumers ................. ELR-2.5-0001-0209 (

Siemens AG
BHEL,Haridwar ELR-1.0-0001-0209 / 1
Energy Sector 11(
General
3 Components and Purchased Parts
3.1 General
General Technical Description.......................................................................... ELR-3.1-0001-0209/14 1(
3.2 Cooler
Cooler Technical Description......................................................................... ELR-3.2-0001-0209 (

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4 Operation and Supervision

Turning and Running up ................................................................................... ELR-4.1-0001-0209 (
Operation under Load ....................................................................................... ELR-4.2-0001-0209 (
Shutdown .......................................................................................................... ELR-4.3-0001-0209 (
Standstill ........................................................................................................... ELR-4.4-0001-0209 (
5 Troubleshooting
General ............................................................................................................. ELR-5.1-0001-0209 (
Ground Fault Detection..................................................................................... ELR-5.2-0001-0209 (
Exciter Temperatures........................................................................................ ELR-5.3-0001-0209 (
Cooler................................................................................................................ ELR-5.4-0001-0209/12 (
Fuses on the Exciter ......................................................................................... ELR-5.5-0001-0209/13 (
Stroboscope ...................................................................................................... ELR-5.6-0001-0209/12 (
Dryer ................................................................................................................. ELR-5.7-0001-0209 (
BHEL,Haridwar
Siemens AG ELR-1.0-0001-0209 / 2
Energy Sector (
General
6 Maintenance
6.1 General
General ............................................................................................................. ELR-6.1-0001-0209 (
Standstill during Maintenance, Long-term Storage .......................................... ELR-6.1-0002-0209 (
6.2 Maintenance during Operation

Maintenance Intervals....................................................................................... ELR-6.2-0001-0209 (
Cooler and Leakage Water Indication .............................................................. ELR-6.2-0002-0209/12 (
Bearing.............................................................................................................. ELR-6.2-0003-0209 (
Air filter and Dryer ............................................................................................. ELR-6.2-0004-0209/12 (
Ground Fault Detection..................................................................................... ELR-6.2-0005-0209/12 (
Fuses on Rectifier Wheel.................................................................................. ELR-6.2-0006-0209/12 (
6.3 Maintenance at Standstill / Inspection

General ............................................................................................................. ELR-6.3-0001-0209 (
Inspection Intervals ........................................................................................... ELR-6.3-0002-0209 (
Cooler................................................................................................................ ELR-6.3-0003-0209 (
Bearing.............................................................................................................. ELR-6.3-0004-0209 (
Ground Fault Detection..................................................................................... ELR-6.3-0005-0209 (

Leakage Air Filter.............................................................................................. ELR-6.3-0006-0209 (
Checking the Insulation Resistance RR-Wheels .............................................. ELR-6.3-0007-0209 (
Measurement of the insulation resistance on the rotor, stator
and exciter set windings ................................................................................... ELR-6.3-0008-0209 (
Insulation Test Report ...................................................................................... ELR-6.3-0009-0209 (
Checking the Insulation for Protection from Shaft Currents ............................ ELR-6.3-0010-0209 (
6SHFLDO$VVHPEO\,QVWUXFWLRQV011
6SHFLDO$VVHPEO\,QVWUXFWLRQV(/5(n Ex
Pilot Exciter Housing......................................................................................... ELR-8.4-0001-0209/12 1011
Main Pole Coil .................................................................................................. ELR-8.5-0001-0209/12 1011
Terminals and Line Connections Main and Pilot Exciter .................................. ELR-8.6-0001-0209/14 1011
End Shield (DE and NDE)................................................................................. ELR-8.7-0001-0209/12 1011
Seal........................................................................... ELR-8.8-0001-0209/12 1011
Sealing (NDE) ........................................................................................... ELR-8.9-0001-0209/12 1011
Cover (Main Exciter Air Guide) ......................................................................... ELR-8.10-0001-0209/12 1011
RR Air Guide Cover .......................................................................................... ELR-8.11-0001-0209/12 1011
Temperature Measuring Point Bearing............................................................. ELR-8.13-0001-0209/12 1011
Ground Fault Detection..................................................................................... ELR-8.14-0001-0209/12 1011
Stroboscope ...................................................................................................... ELR-8.15-0001-0209 1011
Fuse Monitoring 1 (Stroboscope) ..................................................................... ELR-8.16-0001-0209/12 1011
Coupling bolt ..................................................................................................... ELR-8.17-0001-0209/12 1011
RR Heat Sink ................................................................................................... ELR-8.18-0001-0209/12 1011
RR Wheel (Assembly)....................................................................................... ELR-8.19-0001-0209/12 1011
Siemens AG
Energy Sector (
Turbogenerators
Preface
Introduction
This manual contains information on the operation and

maintenance of the turbogenerator. The information has been
prepared on the assumption that the operating and
maintenance personnel have a basic knowledge of power
plant engineering and operation.
It is an essential prerequisite for satisfactory operation and
maintenance of the turbogenerator that the operating and
maintenance personnel are fully familiar with the design of the
turbogenerator plant and receive thorough training in
operating and maintaining the unit.
-- All Rights Reserved
e Siemens AG 2008
Copyright
Siemens AG
BHEL,Haridwar MK &MAA 2.0--0030--0001
Energy Sector 0E
Turbogenerators Notes on the Use of the
Introduction Technical Documentation
The Operating and Maintenance Manual comprises Each section contains a number of separate documents.
several folders containing the following sections: Please check your manual against the Table of Contents,
and notify (see 2.0--0050) if you should identify any
1 Introduction mismatches or have any other queries regarding your manual.
2 Safety Instruction
Identification Number
3 Technical Data
This identification number is sufficient reference for locating
3.1 Design Data
a particular document within the manual. However, when
3.2 Limit and Setting Values
ordering documents, the complete document identification
3.3 Specifications
code must be quoted.
3.4 Dimensions and Weights
4 Description of Components and Auxiliary Systems Document Number
4.1 Abstract The document number comprises the identification number
4.2 Shaft Seal detailed above, a variant number, a page number and a date
4.3 Stator reference number complete with language code.
4.4 Rotor The page number is omitted from single-sided documents.
4.5 Cooler
4.6 Bearing
4.7 Seal Oil System Identification number
4.8 Gas System
Variant number
4.9 Primary Water Sytem
4.10 Waste Gas System Page number
All Rights Reserved
4.11 Protection and Monitoring Devices

5 Tools 2.0--0040--0041 / 1
6 Spart Parts 0511E
7 Contract Drawings
8 Purchased Parts Language symbol
e Siemens AG 2011--
9 Operation
Date
9.1 Turning and Running Up
9.2 Operation under Load
9.3 Shutdown Supplements
9.4 Standstill The contents of this manual are subject to a continual
Copyright
10 Trouble-Shooting review and revision process, and you should receive

11 Maintenance supplements consisting of copies of new or revised
11.1 Maintenance in Operation documents for inclusion in your manual. Please ensure that
11.2 Maintenance at Generator Standstill you include these in your manual, and that you remove any
superseded or obsolete documents.
The supplements are numbered consecutively in
ascending order starting with 1, and you should file the
documents included in each supplement delivery in your
manual to enable you to check whether you have received all
supplements.
Spare Parts
The part numbers indicated in the documents contained in
this manual are not suitable for ordering spare parts. Please
order your spare parts in line with the instruction detailed in the
Spare Parts section of this manual.
Siemens AG
Energy Sector 0511E
0114E
Turbogenerators
Addresses
Introduction
1 Generator Documentation For carload shipments:

The documentation for the turbogenerator is published by
the Technischen Redaktion. In the warranty period, this
department is also responsible for the issuance of revised Siemens AG
pages and for ensuring that the manual will always contain the Energy Sector
latest, up-to-date information. After the warranty period, our Standort Muelheim, Technopark
service division will be responsible for further revisions and 45473 Muelheim a.d. Ruhr
updating. Germany
All comments or questions about this documentation,
proposals for improvement and requests for supplementary Muelheim (Ruhr) -Styrum, Anschlussgleis
information should be forwarded direct to:
or:
Siemens AG
Energy Sector Siemens AG
Standort Muelheim Energy Sector
Generator-Dokumentation Standort Muelheim, Hafen
Postfach: 10 17 55 45473 Muelheim a.d. Ruhr
45466 Muelheim a.d. Ruhr Germany
All Rights Reserved
Germany
Muelheim (Ruhr) -Speldorf, Anschlussgleis
Telefon: +49 208 456-5118
Telefax: +49 208 456-2021
E-Mail: Generator.Doku@siemens.com If you have any queries regarding the correct address or
method of shipment, please contact Siemens AG in

Muelheim, Germany.
All parts returned should carry the following information:
2 Product Service J Name of consignor

Copyright
Siemens AG maintains representatives in all major cities in Company, department and name of individual in charge.
Germany and in nearly every part of the world. For spare parts
and the services of personnel, as weIl as technical questions, In addition, the following information should be included in
contact our local representatives. the shipment:
J Reason for return of parts.

3 Returning Parts J Siemens AG department already attending to the matter.
When returning parts to the manufacturers works, be sure J Sl. No. of unit to which the returned part belongs.
to choose the right address and mode of shipment and to
include the necessary supplementary information in the 4 Zip Code
shipment, enabling prompt action to be taken. Postal addresses
Return shipments should be sent to the following
addresses: for letters up to 1.000 g:
Postfach 10 17 55
For LCL shipments and railway express:
45466 Muelheim a.d. Ruhr
Germany
Siemens AG
Energy Sector
for packages and parcels:
Standort Muelheim, Hafen
Rheinstrae 100 Rheinstrae 100
45478 Muelheim a.d. Ruhr 45478 Muelheim a.d. Ruhr
Germany Germany
Siemens AG
Energy Sector 0E
Turbogenerators KKS
Introduction Power Plant Identification System
1 Introduction D: (Function Key 3)

This letter identifies the area of the generator with which the
component or system is associated. The D used in the above
KKS is the abbreviation of the German term Kraftwerk-
example stands for the bearing system.
Kennzeichen-Systems which translates as Power Plant
Depending on the actual generator model, following letters
Identification System, and is used to identify power plant
are used:
systems and components. The KKS was originally developed
by German power plant operators and suppliers, and applies
A Generator casing, including stator, rotor and cooling
to all types of power plants.
systems
This description only addresses those sections of the KKS
C Excitation system
relevant to the generators and its auxiliary systems.
D Bearing
F Stator and rotor water cooling system including coolant
supply and treatment
2 Identifier Structure G Stator and rotor hydrogen cooling system including
coolant supply
In order to ensure that the KKS is clear and easy to under- Q Waste gas system
stand, the alphanumerical identifier is made up of 4 main cate- W Seal oil system including supply and treatment
gories as follows: X Waste fluid system
Y Generator I&C and protection systems
Category 0 identifies the entire power plant
All Rights Reserved
Category 1 identifies the function

Category 2 identifies the equipment unit 11: (Function Key 4)
Category 3 identifies the component. This two-digit number is used to identify the system section.
As a rule, the system sections are numbered consecutively in
the direction of flow. The number 11 used in the example
Please note that Category 3 is not normally used for gene-
above indicates the TE generator bearing.
rators and their auxiliary systems.

The identifier used as an example below is that used for a
temperature measuring point at the generator unit 3 of a power C: (Equipment Unit Keys 1)
plant. This letter is used to identify the function of the correspond-
ing component. The following letters are used:
Copyright
Category 0
A Equipment units
B Components (such as vessels or pipe)
Category 1
(broken down into 4 function keys) C Direct measuring circuits
Category 2
(broken down into 3 equipment T: (Equipment Unit Keys 2)
units keys) This letter is used to identify Equipment Unit Key 1.
As a rule the following combinations of letters are used:
3MKD11 CT014A
AA Valves (including actuators)
AC Heat exchangers
3: (Category 0)
AN Compressors and fans
This number identifies the actual unit in power plants com-
AP Pumps
prising more than one unit. This identifier is not used for single-
AT Cleaning and drying equipment as well as filters, strainers
unit power plants, and is not required for system diagrams, lists
and separators
and descriptions.
BB Tank
It is not defined by the KKS but can be selected freely, e.g.
BP Orifices
in line with the actual unit designation.
BR Piping and tubing
CF Flowmeters
M: (Function Key 1) CL Level measuring instruments
This letter identifies the main machine set. CM Humidity and moisture measuring instruments
CP Pressure gauges and transducers
MK: (Function Key 1 + 2) CQ Instruments used for measuring the quality of a fluid
This letter code identifies the generator. All generator com- (e.g. gas purity meters)
ponents and auxiliary systems use this identifiers for Function CT Temperature measuring instruments
Keys 1 and 2. CY Vibration measuring instruments
Siemens AG
BHEL,Haridwar MK &MAA 2.0--0060--0001 / 1
Energy Sector 0E
014: (Equipment Unit Keys n) A: (Equipment Unit Key 3)
This 3-digit number is a serial number used to distinguish In cases where measuring units are equipped with several
components with identical Function Keys (1 through 4) and sensors, the individual sensors are distinguished by means of
Equipment Unit Keys (1 and 2). It is possible to allocate specific this letter.
number ranges to specific functions.
Number
Valves: AA ... Pipes: BR ... Measuring Circuits: C. ...
consecutively
001 - 050
Valves, general
051 - 100
Main pipes
101 - 150 Binary and analog measuring
Valves in main pipes Control valves
151 - 190 circuits
Supply and vent lines for

191 - 199 Safety valves
safety valves
201 - 250 Check valves
Spare For automatic testing system
251 - 299 Manually-operated valves
301 - 399 Shutoff valves for measurements Pressure lines Spare
Drains, purging connections and
401 - 499 Valves in drain pipes and purging lines Acceptance test measurements
relief lines
501 - 599 Valves in vent pipes Vents lines Local measuring circuits
Sampling line connections and
601 - 699 Valves in sampling lines and metering lines Spare
metering lines
701 - 799 Valves for internal controls Internal control line
Blocked
801 - 899
Spare Spare
901 - 999 Combined measuring circuits
Table 1 KKS Numbering System for Valves, Pipes and Measuring Circuits
Siemens AG
BHEL,Haridwar 2.0--0060--0001 / 2
Energy Sector 0E
Turbogenerators Symbols for Supply Circuits
Introduction and Supervisory Equipment
M Control valve,
Piping motor-operated
Shutoff valve,
Liquid
solenoid-operated
Air Control valve, piston-operated
Control valve,
Combustible gas
hydraulically or pneumatically operated
Non-combustible gas Pressure relief valve, spring-loaded
Waste gas Pressure relief valve,

(combustible/non-combustible gas) spring-loaded, safety function
Process flow line, signal line Level control valve
Lines, crossing Ceck valve
Lines, joining Restricting orifice
Tee branch Sight glass

All Rights Reserved
U-Loop Mixing section
Flexible line Orifice plate

Drain funnel Heat Exchangers and Tanks

Generator cooler
Drain trough (hydrogen/air)
Electric heater,
Exhaust to atmosphere above roof CO2 flash evaporator
Copyright
Reduction of the line Shell-and-tube heat exchanger
Liquid tank
Valves and Fittings
Gas bottle
Shutoff valve
Control valve Machines
Multi-way valve M Electric motor
Check valve Centrifugal pump
Check valve, lockable Diaphragm pump
Pressure reducing valve,

Screw pump
safety function
Gate valve Exhauster and vacuum pump
Three-way cock Coupling, general
Siemens AG
BHEL,Haridwar MK &MDB 2.0--0070--0001 / 1
Energy Sector 0E
Treatment Systems Meanings of Identification Letters and
Symbols to DIN 19 227, Part 1
Separator, general E Electrical
Filter, general F Flow rate
Air or gas filter, general L Level
Liquid filter, general M Moisture
Tubular element filter P Pressure
Q Quality variables
Mixed-bed filter
(e.g. O2 or conductivity)
Ion exchange filter T Temperature
.... Gas dryer Y Vibration
Measurement and Control Framing for valve and fitting identification
Flow measurement Framing for measuring point identification
Controller, general Terminal Points in Supply Circuits
Flow guide for volumetric flow meter System limit
Limit of supply
Component limit
Siemens AG
BHEL,Haridwar 2.0--0070--0001 / 2
Energy Sector 0E
Generator General Safety Information
Safety Information for SGen5 Generators
1 General 3 Safety Notices and Warnings

Four different signal words are used in this documentation
Generators are designed and manufactured to
to identify information which is of particular importance for
state-of-the-art technology and comply with the applicable
safety: DANGER, WARNING, CAUTION and NOTICE.
safety standards.
All safety notices are introduced by a corresponding signal
Despite the implementation of best possible safety meas-
word. Theses signal serve to emphasize the severity of the
ures, hazards which could result in personal injury or death or
hazard.
damage to the generator or other property cannot be ruled out
The use of these signal words is explained below:
completely when working on, in or in the area of the generator.
This technical product documentation has been prepared to
minimize these hazards and to ensure smooth and cost-effect-
ive operation.
This technical product documentation applies to all persons
who perform work on a generator during assembly, operation,
DANGER
maintenance or removal. DANGER is used for high-risk hazards which, if not
The information given in this documentation is import- avoided, will cause death or severe personal injury.
ant for safety. Failure to comply with the instructions set
forth in this documentation can result in severe or even
WARNING
fatal injuries during the work or in subsequent operation.
The information and instructions shall therefore be ob-
served and implemented exactly as described.
All Rights Reserved
WARNING is used for medium-risk hazards which, if not

avoided, can cause death or severe personal injury.
2 Normal Generator Operation
CAUTION
A generator has the following functions,
-- To convert rotating mechanical energy to electrical energy .

(generator operation), CAUTION is used for low-risk hazards which, if not avoided,
-- To supply or absorb reactive power (phase shift operation), can cause slight or moderate personal injury.
-- To act as a start up motor for gas turbine start up (motor op-
Copyright
eration). NOTICE is used if damage to equipment can occur if the

safety notice is ignored or not fully complied with.
Use of the generator for any other purpose is considered to
be outside normal or intended operation. Siemens AG does The safety notices may be combined with a corresponding
not accept any liability for any damage which may result from pictorial symbol (pictogram) to highlight the nature of the haz-
such use. ard.
Siemens AG
BHEL,Haridwar MKA 2.0--0100--0003 / 1
Energy Sector MKC 01E
The use of these pictograms is explained below:
DANGER
Observe instructions!
Electrical shock hazard All of the information given in this documentation is import-
ant for safety, including information which is not explicitly iden-
tified through signal words and symbols. Examples of informa-
tion which is not explicitly identified include information on
technical limits or approved consumables. This information
which is not explicitly identified must be also observed and im-
plemented exactly as described. Failure to comply with these
instructions can lead to severe or even fatal injuries during the
work or in subsequent operation.
Explosion hazard
4 Organizational Notices
Shift procedures shall be prepared based on this documenta-

tion and containing additional information on the following:
Rotating machinery
risk of entrapment
-- Responsibilities,
-- Work organization,
-- Work sequences,
-- Special operational aspects.
In addition to this documentation, the general legal provi-
sions and other regulations for the prevention of accidents and
the protection of the environment must be observed.
The safety data sheets for any hazardous materials used
Hot surface shall be observed.
This documentation shall be kept readily accessible at the
work location at all times.
Warning signs shall be placed in the operating areas, at
entrances and near the generator in compliance with the
general legal provisions and other regulations for the preven-
tion of accidents. Compliance with these signs must be en-
sured.
Hazard due to overhead load Any personnel in the operating areas shall wear personal
protective equipment in compliance with the general legal
provisions and other regulations for the prevention of acci-
dents.
The operator shall ensure that sufficient quantities of the re-
quired protective equipment are provided and that such pro-
tective equipment is in good condition.
Any damage or deviations from the information described
Crushing hazard in this documentation detected on the generator or its auxiliar-
ies shall be reported immediately to the responsible personnel
and the generator shut down if necessary.
Siemens AG
BHEL,Haridwar 2.0--0100--0003 / 2
Energy Sector 01E
Turbogenerators
Safety Equipment for Hydrogen Operation
Safety Instructions
1 General J During normal operation practically no hydrogen can enter

The use of hydrogen as coolant in generators requires spe- the turbine system via the loop seal together with the
cial safety equipment to effectively prevent the occurrence of drained seal oil because the hydrogen is degassed from the
hazardous operating conditions which could pose a danger to seal oil in the seal oil storage tank.
the operating personnel and the plant. J In the event of loss of the seal oil supply system, the loop
This section details the safety precautions for generators. seal prevents the hydrogen from flowing into the partially
The required measuring and alarm systems are detailed in a filled oil drain pipes and thus from entering the turbine sy-
different section (see Section 2.1--8400 Measuring and stem. To limit the hazard caused by such a fault in terms of
Supervisory Equipment). time, the fast hydrogen depressurization system (if pro-
vided) is tripped automatically or the fire protection valve
2 Uncontrolled Hydrogen Losses must be opened manually.
The small leaks which can develop during operation can
result in a continuous escape of hydrogen. Provided the total 4 Permanent Ventilation of Seal Oil Storage Tank
hydrogen losses due to such leaks do not exceed 18 m3 (at The seal oil storage tank is designed as a permanently
standard temperature (0_C) and pressure (1.013 bar) as per ventilated vessel and is connected to the bearing vapor
DIN 1343) over a 24-hour period, it is not necessary to exhauster. The exhauster creates a slight vacuum in the seal
implement restrictions in terms of generator operation. See oil storage tank so that the hydrogen can degas from the seal
also DIN EN 60034, Part 3. oil. After a specified holding time, the degassed oil is routed to
If the gas losses should be so high that the rated hydrogen the turbine oil tank (which also receives the bearing oil) via a
pressure cannot be maintained, the so-called fire protection loop seal.
valve and, if installed, the fast hydrogen depressurization The permanent ventilation of the seal oil storage tank pre-
Siemens AG 2008 -- All Rights Reserved
system should be tripped (cf. Section 2.3--9640 Gas Pressure vents the formation of explosive hydrogen-air mixtures even
and Volume Flow Rates). The turbine trip is activated upon under faulted conditions when hydrogen degasses from the
tripping of the fire protection valve and/or the fast hydrogen de- oil.
pressurization system. 5 Hydrogen Bottle Supply
Following activation of the fast depressurization system To avoid any undue hazard to the plant by the hydrogen
(comprising two solenoid valves in the vent gas system plus supplies, the volume of hydrogen that can be stored inside the
the fire protection valve) the generator hydrogen pressure is turbine buildings is limited to 80 m3 (s.t.p.). Only two hydrogen
reduced to near-atmospheric pressure within 5 to 10 minutes. bottles may be opened at any one time during normal opera-
Depressurization via the fire protection valve alone is slightly tion (this does not apply to gas filling).
e
slower.
Copyright
6 Prevention of Formation of Explosive

3 Removal of Hydrogen Pockets Loop Seal Gas Mixtures in Turbine Building
Downstream of Seal Oil Storage Tank Care should be taken to ensure that a sufficient air change
Special precautions are taken with regard to faults affecting rate is maintained at locations of potential hydrogen leaks. This
the seal oil supply. Because the shaft sealing effect breaks includes the hydrogen unit, the gas dryer, the vent gas system
down in the event of a loss of the seal oil system hydrogen can and the area underneath the generator and the foundation
flow into the bearing compartments. This hydrogen is plate. In these areas, it must be ensured that the air movement
extracted from the compartment by exhausters and vented to is perceivable (i.e. air velocities of > 0.1 m/s) in order to reliably
the environs. Under normal operating conditions, the prevent the formation of explosive hydrogen / air mixture and
exhauster creates a slight vacuum which prevents oil vapor to achieve the specified air change rate.
from escaping from the bearing compartments along the shaft. The air velocity should be measured with an anemometer.
Exhauster operation is monitored by a pressure transmitter, In cases where the specified air velocity cannot be
and if one exhauster should fail, a standby exhauster is achieved in critical locations, special ventilation measures
automatically started up. must be implemented or fans installed to ensure reliable
To prevent any hydrogen which enters the bearing mixing of the air (cf. DIN EN 60034, Part 3).
compartment from escaping via the oil drain pipes, the oil is
7 Generator Safety Zone
returned to the turbine oil tank via the seal oil storage tank and
A safety zone must be specified around the generator.
a loop seal. The loop seal is permanently filled with oil to
Within this safety zone, the performance of spark-inducing
prevent the escape of gas. The loop is designed to withstand

activities or use of naked lights is prohibited. The safety zone
transient pressure surges.
should be clearly marked with barriers (color code on floor,
The above measures have the following effects:
signs or tape). The safety zone should be 3 to 5 meters in
J The bearing compartments and oil drain pipes are perma- width. The same applies for the hydrogen unit, the hydrogen
nently ventilated and are thus not rated as explosive spaces bottle rack, the liquid level detector rack, the gas dryer and the
during normal operation. vent gas lines on the turbine building roof.
BHEL,Haridwar MKG
Siemens AG MKQ &MDB 2.1--8310--0004
Energy Sector MKW 0E
Technical Data
Stator manufacturers serial no.: 12580
Generator 12580 2011

2014
SGEN5--3000W 50 s-1 right
3a YY U1V1W1 50 Hz
27000 V r 5 % 20122 A S1
941000 kVA cos = 0.85
Rot. Exciter (brushless) 407 V 5549 A
Thermal class: F IM1106 IP64
H2: pe = 5 bar / H2O 44 _C / 49 _C
Stator transport weight: 443 Mg VDE / IEC
Rotor transport weight: 88 Mg
Siemens AG Energy Sector
BHEL,Haridwar MK &MDA
0114E
Turbogenerators
General and Electrical Data
Technical Data
General
Job name 2 x 800 Yeramarus Therminal Power Station
Generator type Sgen5--3000W (125/67)
Year of manufacture 2011
2014
Stator serial no.
12580
Rotor serial no.
Shaft identification no. 9U938
Rated Data and Outputs

Apparent power 941 MVA
Active power 660 MW
800 MW
Current 20.122 A
Voltage 27 kV r 5%
Speed 50 s-1
Frequency 50 Hz
Power factor 0.85

Inner connection of stator winding / slots YY
H2 pressure 5 bar
Cont. perm. unbalanced load 5%
e Siemens AG 2011
Rated field current for rated output 5549 A

Rated field voltage 407 V
The machines are designed in conformity with IEC 34 and should be operated according to these specifications.
The field current is no criterion of the load carrying capacity of the turbogenerator.
Copyright
Siemens AG
BHEL,Haridwar MK &MDA 2.1--1607--12580
Energy Sector 0811E
0114E
Turbogenerators Technical Data
Technical Data Reactive Capability Curve
Generator Type: SGen5--3000W

Rated A
Apparent Output S 941.000 MVA 988.000 MVA
Armature Voltage U 27.000 kV
Armature Current I 20.122 kA 22.127 kA
Frequency f 50.00 Hz
Power Factor P.F 0.85 0.85
Rated H2 Pressure PE 5.00 bar 5.00 bar
Cold Gas Temperature TK 44.00 _C 44.00 _C
e Siemens AG 2011 -- All Rights Reserved
Copyright
Siemens AG
BHEL,Haridwar MK &MEC 2.1--1611--12580
0811E
0114E
Energy Sector
Design Data
Turbogenerators
Permissible Loading at Rated P.F.
Technical Data
During Voltage and Frequency Deviations
+5%
Voltage deviation
1 2 5 10 min Duration at rated MVA
-- 10 % -- 5 % Frequency deviation 0 Frequency deviation + 5 %
Voltage deviation
90 95 97 100 % MVA continuously

-- 5 %
P.F. = Rated P.F.
e Siemens AG 2003
Copyright
Permissible operating ranges of generator:

Continuous operation with rated MVA.
Short time operation with rated MVA* but

continuous operation is not permissible
even at reduced load.
Continuous operation with reduced load or

short time operation at rated load.
* During the two hours following a fault, generator may be operated only in range permissible for continuous operation with rated MVA.
Siemens AG
Energy Sector 0203E
0114E
Distribution: UNRESTRICTED Copyright e Siemens AG 2011 -- All Rights Reserved
Energy Sector
BHEL,Haridwar
Technical Data
Turbogenerators
101
Siemens AG
8
6
4
3
i22 t = 8 s
100
Per unit negative-sequence current

8
MK
6
&MDA
3
2
Design Data
10-1
i2 = 0.08 continuous
8
6
Unbalanced Load-Time Curve
4
3
3 4 6 8 100 2 3 4 6 8 101 2 3 4 6 8 102 2 3 4 6 8 103
Time t in s
0114E
2.1--1614--0062
0411E
Energy Sector
l 6.5
Technical Data
l rated
BHEL,Haridwar
Turbogenerators
Siemens AG
6
5.5
related stator current

4.5
MKA
3.5
&MDA
3
2.5
2
Current Overload Capability
1.5
1
0 20 40 60 80 100 120
time in sec
0114E
2.1.--1615--0002
1205E
Turbogenerators Design Data
Technical Data Permissible Synchronizing Criteria
Generator Generator
+10 _
Angular error in
leading, subsynchronous _ leading, supersynchronous
+7
+5
All Rights Reserved
Voltage difference in % Voltage difference in %
--15 --10 --5 +5 +10 +15

0
--0.7 --0.5 --0.3 --0.1 +0.1 +0.3 +0.5 +0.7
Speed deviation in % Speed deviation in %

Copyright
--5
_
Angular error in
Generator Generator
lagging, subsynchronous lagging, supersynchronous
--10
permissible speed deviation 0.5 % max.

Example: Angular error +7_ ^ permissible voltage difference 10 % max.
BHEL,Haridwar
Siemens AG MK &MDA 2.1--1617--0001
Energy Sector 1205E
0114E
Energy Sector
U . frated
Technical Data
Urated f
Turbogenerators
BHEL,Haridwar
Siemens AG
1.5
1.4
1.3
MKA
1.2
&MDA
1.1
SGen5--3000W
with Overvoltage
1.0
0 10 20 30 sec.
0.5 1 2 3 4 5 min.
Limited Duration of Open-Circuit
5 10 20 30 min.
After an overfluxing operation with U/Urated . frated/f >1.1 there must be a phase of at least 15 min. with
U/Urated . frated/f < 1.1 before a further no load operation is conducted with U/Urated . frated/f >1.1 .
0811E
0114E
2.1--1618--12580
Turbogenerators
Cooler Data
Technical Data
Design Data for the H2 Cooler

Data for
2 x Type: 4315 / 748 / 14 / 2 -- NSV -- S201 --34N200 Units Materials and Pressures
100%
(2 identity elements 50% each)
Materials
Fins Cu
Gas flow 33 m3/s
Tubes 1.4404
Heat dissipating capacity 6395 kW Tubesheets 1.4404
Cold gas temperature 44 _C Water
channels 1.4404 (Steel/
Hot gas temperature 79,8 _C
TE)
Gas pressure drop 1081 Pa
Cooling water flow 516 m3/h
Maximum water inlet temperature 39 _C
Water outlet temperature 49,9 _C
Water velocity in tubes 1,78 m/s
Terminal temperature difference at rated operation 5 K
Copyright
Siemens AG
Energy Sector 0114E
0811E
Turbogenerators Operating and Setting Values
Technical Data General
Strict observance of the operating and setting values is a the specific site conditions, such as static head in case of pres-
prerequisite for reliable operation of the turbogenerator. sure measuring points or thermal characteristics in case of
Separate tables are provided for the various design groups temperature measuring points. These calculated values are
of the generator and its auxiliaries. They show the transmitters intended as guiding values for making the preliminary settings
activating the controls and alarms as well as the transmitters during initial commissioning of the unit.
acting on the generator protection circuits. These settings require certain corrections to account for
The Remark column contains additional information on the actual conditions. The final settings obtained after startup
controls, temperatures and pressures. and initial load operation, if not coincident with the table values,
All operating and setting values refer to rated output of gen- are to be promptly submitted to SIEMENS AG Energy Sector
erator and maximum cooling water temperatures under (address, see 2.0--0050) for revision.
steady-state conditions. Revised pages will then be sent to the holder of the
The operating and setting values initially specified in this Technical Documentation Generator (instruction manual)
manual are based on experience under due consideration of as updates.
All Rights Reserved
Copyright
Siemens AG
Energy Sector 1008E
0114E
BHEL,Haridwar 2.1-1632-12580/1
0114E
0114E
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Turbogenerators Lists
Technical Data Measuring Point List
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Technical Data Power Consuming Device List
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Technical Data Power Consuming Device List
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Turbogenerators Specifications
Technical Data Primary Water Specification
The water used must not contain any contaminants that H Ammonia : Minimum; test with Nesslers solution
might have a harmful effect on the materials used in the as a reagent must not cause a
primary water system. For this reason, the water shall meet the change in color
following quality criteria:
H Cu, dissolved : Less than 20 ppb
H Fe, dissolved : Less than 20 ppb
H Conductivity : $10mmoh/cm, preferably 0.5mmho/cm
H Dissolved solids : The water must not contain chemi-
H pH : 6 -- 8 cals from treatment processes, such
as hydrazine, morpholine, levoxine,
H Dissolved O2 : Minimum, preferably less than 100ppb phosphates, etc.
H Dissolved CO2 : Minimum; downstream of a strongly If the water to be used does not meet these quality criteria,
H Chlorides : acidic cation exchanger, a conductiv- Siemens AG / PG -P261 -- Werk Mlheim * shall be notified for
H Others anions : ity of 0.2 mmho/cm is permissible their evaluation and approval.
e Siemens AG 2006
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* Address: Siemens AG
Power Generation
Postfach 10 17 55
D -- 45466 Mlheim a.d. Ruhr
Siemens AG
BHEL,Haridwar MKF &MEC 2.1--1639--0002 / 1
Energy Sector 0106E
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Turbogenerators
Gas Specification
Technical Data
1 Compressed Air 2 Carbon Dioxide (CO2)

The compressed air shall be free of corrosive contaminants Carbon dioxide shall be made available with a purity
and hazardous gases, flammable or toxic. 99.9 Vol-%. The remaining 0.1 Vol-% shall be free of
The maximum total oil or hydrocarbon content, exclusive of corrosive contaminants; traces of ammonia (NH3) and sulphur
noncondensables, shall be as close to zero (0) as possible, dioxide (SO2) shall not be detectable by analysis. [2]
and under no circumstances shall it exceed one (1) vpm*
under normal operating conditions. 3 Hydrogen (H2)
The compressed air shall be practically free of dust. The The hydrogen gas shall be made available with a purity
maximum particle size in the air stream shall be five (5) mm. 99.9 Vol-%. The remaining 0.1 Vol-% shall be free of
The oxygen content of the expanded air shall be between corrosive contaminants; traces of ammonia (NH3) and sulphur
20 and 21 Vol-%. dioxide (SO2) shall not be detectable by analysis. [2]
The dew point at line pressure shall be at least 15 K below
the minimum possible generator temperature. In no case 4 Nitrogen (N2)
should the dew point at line pressure exceed 10 _C. [1] The nitrogen gas shall be made available with a purity
99.99 Vol-%.
Contaminants (O2, H2O): not applicable
The remaining 0.01 Vol-% shall be free of corrosive
contaminants; traces of ammonia (NH3) and sulphur dioxide
(SO2) shall not be detectable by analysis.
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Also refer to the following information

[1] For gauge pressure and volumetric flow rate of compressed air
see gas supply diagram.
* vpm = 0.0001 Vol-%. [2] In case of systems being fed from the central supply system, the
** s.t.p = standard temperature and pressure, 0 _C and 1.013 bar, required pressures and volume flows of CO2 and H2 are noted
to DIN 1343. on the gas supply diagram.
EG3-010998
Siemens AG
BHEL,Haridwar MKG &MDA 2.1--1640--0002
Energy Sector 0898E
0114E
Turbogenerators
Turbine Oil Specification
Technical Data
Introduction Requirements
This specification covers the requirements to be met by the In conformity with DIN 51519, oils of the ISO viscosity
turbine oils used for SIEMENS turbine-generator units. classes ISO VG 32 and ISO VG 46 shall be used.
The turbine oil shall contain no additives having an adverse
effect on the materials used in the oil system. In addition, the
WARNING additives shall be free from metal-containing organic com-
Health hazard. Turbine oil can damage your health. Avoid any pounds (e.g. zinc-containing organic compounds).
direct contact with turbine oil and thoroughly wash off any tur- The turbine oil shall give satisfactory performance without
bine oil after contact with bare skin. undergoing any adverse changes at bearing temperatures of
130 _C (266 _F) max. and oil tank temperatures of 80 _C
Dependent on the turbine speed, only turbine oils of grades
(176 _F) max.
TD 32 and TD 46 acc. to DIN 51515, Part 1 shall be used.
The turbine oil shall be suitable for being blended with rem-
These are paraffin-base mineral oils containing additives for
nants (4 vol. %, max.) of an equal-base turbine oil of a different
improved corrosion protection and resistance to deterioration.
brand. This shall not result in any harmful change in the oil
Turbine oils having a higher or lower viscosity must not be
properties.
used without the approval of SIEMENS.
Provided that the necessary hygiene precautions are taken
Special requirements must be observed in the case of
the turbine oil shall not cause a hazard to the health of the
turbine-generator units incorporating gears.
personnel handling the oil.
A list of the turbine oils permissible for the above applica-
tions is available from SIEMENS.
Requirements for As-Delivered Condition of Oil

Test criteria Recommended value Unit Test to DIN Test to ASTM
Air release at 50 _C (122 _F) max. 4 min 51 381 D 3427
e Siemens AG 2010
Neutralization number max. 0.20 mgKOH/g 51 558 D 9740

Water content max. 0.01 % w/w 51 777 D 1744
Foaming characteristics at 25 _C (77 _F)
Foaming max. 400 (62) cm3 (sq.in.)
-- D 8920
0 cm3
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Foam stability max. 450 s

Steam emulsion test max. 300 s 51 589 --
Kinematic viscosity at 40 _C (104 _F)
a) ISO VG 32 min. 28.8
max. 35.2 mm2/s
(cSt) 53 018 D 4450
b) ISO VG 46 min. 41.4
max. 50.6
Density at 15 _C (59 _F) max. 0.900 g/cm3 51 757 D 1298
Flash point
a) ISO VG 32 min. 160 (320)
_C (_F) ISO 2592 D 9200
b) ISO VG 46 min. 185 (365)
Pour point, equivalent to or less than -- 6 (21.2) _C (_F) ISO 3016 D 9700
Cleanliness to ISO 4406 min. 17/14 Code ISO 4406 --
Demulsibility max. 20 min 51 599 D 1401
Color max. 2 -- ISO 2049 D 1500
Copper corrosion max. 2-100A3 -- 51 759 D 1300
Rust prevention (steel) max. O-B -- 51 585 D 6650

Oxidation test,
max. 2.0 mgKOH/g 51 587 D 9430
increase in neutralization number after 2 500 h
Siemens AG
Energy Sector 0710E
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Turbogenerators
Approved Turbine Oils
Technical Data
Lube-oils for turbine-generator sets must be selected rately in the third column of the tables below. The oils for
taking into account the specified viscosity grade. For geared geared turbines are listed in Table 2. Note that oils for geared
turbine-generator sets it is necessary to select an oil specifi- turbines can also be used in turbine-generator sets without
cally designed for geared turbines. gearing. In such cases we recommend that Siemens AG PG,
In most cases, the ISO viscosity grade is indicated in the be consulted.
product designation. For a better overview, it is shown sepa-
Table 1: Approved Turbine Oils (January 2002)
Manufacturer/ Product Viscosity Manufacturer/ Product Viscosity

Supplier Designation Grade Supplier Designation Grade
TL 32 32 Gulf Oil International Gulf Crest 46 46
Addinol
TL 46 46 HPC (Hindustian Turbinol 32 32
Turbine Oil E 32 32 Petroleum Corp.) Turbinol 46 46
Adnoc
Turbine Oil E 46 46 Oil 1893 32
Imperial Oil
OTE 32 32 Oil 2062 46
Agip
OTE 46 46 Indian Oil Corp. Servoprime 32 32
Turbinol 32 32 (IOC) Servoprime 46 46
Turbinol 46 46 Q 8 van Gogh 32 32
BP Kuwait Petroleum
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Turbinol X 32 32 Q 8 van Gogh 46 46

Turbinol X 46 46 Mobil DTE 797 32
Regal R&O 32 32 Mobil Mobil DTE 798 46
Caltex
Regal R&O 46 46 by ExxonMobil Mobil Turbine Oil 32 32
Perfecto T 32 32 Mobil Turbine Oil 46 46

Perfecto T 46 46 MOL Turbokomol 46 KS 46
Perfecto HPT 32 32 Nippon
FBK Turbine 32 32
Castrol Perfecto HPT 46 46 Mitsubishi Oil
Turbine Oil 32 32 Novo Ufimskij TP-22B 32
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Perfecto XPT 32 32 OMV turb TD 32 32

OMV
Perfecto XPT 46 46 OMV turb TD 46 46
Chevron GST Oil Marbrax TR-32 32
32 Petrobras
ISO 32 Marbrax TR-46 46
Chevron
Chevron GST Oil Petrogal Galp Turbinoil 46 46
46
ISO 46
Prista TP 32 32
Chinese Turbine Oil SR32 32 Prista Oil
Prista TP 46 46
Petroleum Corp. Turbine Oil SR46 46 Repsol Turboaries
Teresso 32 / 32
ISO-32
32 Repsol
Terestic 32
Repsol Turboaries
Teresso 46 / 46
ISO-46
46
Terestic 46
Wintershall Wiolan
Turbinenl 46 LP 46 32
Schmierstoff- DW 32
Esso / Exxon
by ExxonMobil Teresso GT 32 / raffinerie Salzbergen Wintershall Wiolan
32 46
Terestic GT 32 DW 46
Teresso GT 46 / Turbo Oil T 32 32
46
Terestic GT 46 Shell Turbo Oil T 46 46
Teresso GTC 32 / Turbo Oil GT 32 32

32
Terestic GTC 32
Turbina R 32 32
Fergananef- YPF
TP-22S 32 Turbina R 46 46
Teorgsintez (LMZ)
Yukong
Renolin DT 2 Yukong Limited 32
Fuchs DEA 46 Turbine Oil 32
Renolin TDL 46
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Table 2: Approved Oils for Geared Turbines ( January 2002)
Manufacturer/ Product Viscosity Manufacturer/ Product Viscosity
Supplier Designation Grade Supplier Designation Grade
TP 32 32 Mobil DTE AW 32 32
Addinol
TP 46 46 Mobil Mobil DTE AW 46 46
Power Turbo 32 32 by ExxonMobil Mobil DTE 832 32
Apar Industries Ltd.
Power Turbo 46 46 Mobil DTE 846 46
Kosmol TF 32 32 OMV turb HTU-SI 32 32
Aral OMV
Kosmol TF 46 46 OMV turb HTU-SI 46 46
Turbinol 32 EP 32 QALCO Turbine Oil T 46 46
Turbinol 46 EP 46 Aries Turbogas
BP 32
Turbinol X EP 32 32 ISO 32
Repsol
Turbinol X EP 46 46 Aries Turbogas
46
Regal EP 46 46 ISO 46
Regal Premium Savita Chemicals Daphne Super
32 46
Caltex EP 32 Ltd. Turbine Fluid AW 46
Regal Premium Wintershall Wiolan
46 32
EP 46 DW-G 32
Perfecto AWT 32 32 Wintershall Wiolan
46
Schmierstoff- DW-G 46
Perfecto AWT 46 46
raffinerie Salzbergen Wintershall Wiolan
Castrol Perfecto IP105 32 32
DWP 32
Perfecto XPG 32 32
Wintershall Wiolan
Perfecto XPG 46 46 46
DWP 46
Turbinas EP 32 32
Cepsa Turbo Oil CC 32 32
Turbinas EP 46 46
Turbo Oil CC 46 46
Teresso EP 32 32 Shell Turbo Oil S 32 32
Teresso EP 46 46
Turbo Oil S 46 46
Esso / Exxon Teresso GT EP 32 /
32 Turbo Oil GT-EP 32
by ExxonMobil Terestic GT EP 32
Regal EP 32 32
Teresso GT EP 46 /
46 Regal EP 46 46
Terestic GT EP 46
Texaco Regal Premium
Renolin TGD 32 32 32
Fuchs DEA EP 32
Renolin TGD 46 46
Regal Premium
HPC (Hindustian Turbinol XT 32 32 46
EP 46
Petroleum Corp.) Turbinol XT 46 46
Preslia 32 32
Indian Oil Corp. Servoprime 32T 32
TotalFinaElf Preslia 46 46
(IOC) Servoprime 46T 46 (Lubrifiants S.A.) Preslia GT 32 32
Preslia GT 46 46
YPF Turbina EP 32 32
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BHEL,Haridwar 2.1--1681--0001 / 2
Energy Sector 0109E
0114E
Turbogenerators Technical Data
Technical Data Weights
Assembly component Weight Units

Rotor 88 Mg
Stator complete (with cooler) 520 Mg
Stator shipping weight (with cooler) 443 Mg
Cooler 3,2 Mg
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NOTE:
The weights specified above were calculated. The tolerance of the weights amounts to therefore 10%.
Siemens AG
Energy Sector 0212E
0114E
Turbogenerators General Design Features
Description Design and Cooling System
1 General 3 Hydrogen Cooling System
The two-pole generator uses direct water cooling for the The hydrogen is circulated through the generator interior in
stator winding, and direct hydrogen cooling for the rotor a closed system by means of a single multi-stage axial-flow fan
winding, phase connectors and bushings. The losses in the which is arranged at the TE rotor end. The fan draws the hot
other generator components, such as core losses, friction and gas from the air gap and the core and delivers it to the coolers.
windage losses as well as stray losses are dissipated to the Downstream of each cooler, the gas is divided into several flow
hydrogen. paths as follows:
The generator frame is pressure--resistant and gastight and
equipped with end shields at the turbine end as well as the Flow path I routes the cold gas through ducts in the stator
exciter end. The hydrogen coolers are arranged vertically frame to the EE end-winding space where the cold gas flows
inside of the cooler section at the turbine end. along the clamping fingers before entering the axial bores in
The generator comprises the following components: the core. For this purpose, the clamping fingers and pressure
plate are designed as gas ducts to enable the cold gas to be
J Stator routed between clamping fingers and end lamination into the
Outer Casing stator core. Along its path through the stator core from the EE
Stator core and winding assembly to the TE, the gas absorbs the heat given off by the stator core
Cooler section before exiting the core at the turbine end via the ducts along
Hydrogen coolers the clamping fingers and entering the stator end--winding
End shields space from where it is returned to the coolers by the axial flow
fans.
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J Rotor
Flow path II routes the cold gas under the hub of the fan into
Rotor shaft
the rotor end--winding space for direct cooling of the TE half of
Rotor winding
the rotor winding. The rotor winding is symmetrical relative to
Rotor retaining rings
the generator center and the rotor axis.

Field connections
Each winding is divided into eight cooling zones. The first
cooling zone includes the slot portion from the end to the center
J Bearings
of the rotor body, and the second cooling zone extends across
J Shaft seals half of the end winding. These two cooling zones are repeated
four times in a symmetrical arrangement around the rotor.
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The following auxiliary equipment is required for generator The cooling gas for the slot portion enters the hollow
operation: conductors through openings in the end winding and flows
through these conductors to the center of the rotor body. The
J Oil system hot gas is then discharged into the air gap between the rotor
body and the stator through radial openings in the conductors
J Gas system and the rotor slot wedges. The cooling gas holes are arranged
J Primary water system at different levels in the conductor assembly to give each
hollow conductor its own cooling gas outlet.The cooling gas for
J Excitation system the end winding is admitted through the end face and flows
through the conductors up to approximately the pole center,
where it passes into a collection compartment and is then
discharged into the air gap via slots in the end of the rotor body.
2 Cooling System
Flow path III routes the hydrogen to the EE rotor end-winding
The heat losses generated in the generator interior are space for direct cooling of the exciter-end half of the rotor
dissipated to the secondary coolant (such as raw water or winding. Because of the symmetrical configuration of the
condensate) via the hydrogen and primary water. cooling gas flow, the cooling is performed in the same manner
The generator is exclusively cooled by direct cooling where as for the turbine-end half of the rotor winding. The hot gas also
the heat is dissipated directly to the coolant. This means that flows to the center of the rotor before being discharged to the
hot spots and large temperature differentials between adjacent air gap.
components which could lead to different thermal expansion
are largely eliminated thus minimizing mechanical stresses Flow path IV routes the cold gas through the flux shield and
particularly with regard to the copper conductors, insulation, the inner rim of the flux shield in the TE stator end-winding
rotor and the stator core. space.
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Flow path V routes the cold gas through the flux shield in the the secondary coolant (raw water, or condensate). The pri-
TE stator end-winding space. mary water is circulated in a closed system and dissipates the
absorbed heat to the secondary cooling water. The pump is
Flow path VI routes the cold gas radially into the TE core end. supplied with cold primary water from the primary water cool-
This flow is required since the gas for axial core cooling flows ers, and delivers the water to the generator via the filter. Up-
from the exciter end to the turbine end which means that it has stream of the generator, the cooling water flow is divided into
already absorbed heat when it exits the core at the turbine end. the two following paths:
Flow path VII routes cold gas into the phase connectors and This flow path routes the water to the manifold at the exciter
terminal bushings and, via the terminal box, to the TE suction end and from there to the stator bars via insulating hoses. Each
space. stator bar is connected to the manifold by a separate hose. The
cooling water flows through the cooling ducts towards the tur-
Following heat absorption, the six flows are mixed before bine end of the generator. After exiting the stator bars, the wa-
being returned to the coolers by means of the axial flow fan. ter flows through insulating hoses to a water manifold from
where it is rerouted back to the coolers. The water flows
3.1 Coolant Temperature Control through the stator bars in one direction only, the temperature
The cooling water flow through the hydrogen coolers is rise of the coolant (and thus of the bars) is minimized which,
automatically controlled to maintain a uniform temperature in turn, means that the relative movements between the top
level for all loads and cold water temperatures. The cold gas and bottom bars due to different thermal expansions are also
temperature is used as reference variable. minimized.
4 Primary Cooling Water System The secondary water flow through the primary water cooler
is automatically controlled to ensure that the generator
The treated water used for cooling the stator winding is re- temperature is maintained at a constant level under different
ferred to as primary water system in order to distinguish it from load conditions.
Siemens
BHEL,Haridwar AG 2.1--1100--0051 / 2
Energy Sector 0901E
0114E
Turbogeneratoren Generator Khlgas-Schema
Beschreibung SGen5--3000W
Turbogenerators Generator Cooling Gas Circuit
Description SGen5--3000W
Ansicht Y Ansicht X
View Y View X
A--A B--B
Y B D A
X
C C
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Warmgas-Khlkanal versetzt gezeichnet D--D A
B
Hot gas cooling channel show displaced
C--C
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D
Warmgas / Hot gas
Kaltgas / Cold gas
Ursprung/Source: 24--0090--131027
Handhabung: OFFEN
Siemens AG MK &MDB 2.1--1150--0012
Energy Sector 0212DE
Description Stator
1 Stator 3 Stator Frame (Inner Frame)
The stator comprises a stator frame as well as the stator The inner frame of the stator comprises the core and the
core and winding assembly. winding. The supporting rings form part of the inner cage which
Manufacture of the stator frame is performed independently is suspended in the outer frame by a large number of flat
of the stator core and winding assembly production, and prior springs distributed over the entire core length. The flat springs
to installation of the winding, the core is linked to the stator are tangentially arranged over the circumference in sets of
frame by means of flat springs. three springs each, i.e. a vertical supporting spring on either
side of the core and a single horizontal stabilizing spring below
the core. As an alternative, the springs below the core can be
omitted. The springs are so arranged and tuned that forced
2 Stator Frame (Outer Frame) vibration resulting from the magnetic field will not be
transmitted to the frame and foundation.
The stator frame is a gastight and pressure-resistant
welded construction and houses the stator core, the stator 3.1 Stator Core
winding and the hydrogen coolers which are arranged The stator core is stacked from insulated electrical
vertically in a separate cooling header at the turbine end. sheet-steel laminations with a low loss coefficient and mounted
A cage of circular and axial ribs on the inside of the outer in supporting rings over insulated dovetailed guide bars. Axial
frame ensures the rigidity of the shell. End shields containing compression of the stator core is obtained by clamping fingers,
the shaft seal and bearing components are bolted to the stator pressure plates and non-magnetic through-type clamping
All Rights Reserved
frame. A high-viscosity sealant is injected in sealing grooves bolts which are insulated from the core.
to ensure that the flanged joints are sealed airtight. The pressure plates and end zones of the stator core are
The core portion of the stator frame is divided into effectively shielded against stray magnetic fields by means of
compartments which house the springs for suspending the cooled flux shields.
stator core. The cold gas for cooling the stator core and the
exciter-end rotor winding flows through gas ducts welded to the 3.2 Stator Winding
inside surface of the shell. The stator winding is fractional pitch two-layer type winding
Feet are welded to the stator frame to support the stator on which is made up of individual bars. The bars are located in
steel beams embedded in the foundation. The stator is firmly rectangular slots uniformly distributed over the entire
anchored to the beams with anchor bolts through the feet. circumference of the stator core.
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Siemens AG
BHEL,Haridwar MKA10 &MDB 2.1--1210--0020
Energy Sector 1008E
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Description Stator Winding
1 Design voltage insulation which is characterized by excellent

Stator bars, phase connectors and bushings are designed electrical, mechanical and thermal properties in addition to
for direct water cooling. In order to minimize the stray losses, being fully waterproof and oil-resistant. To minimize corona
the bars are composed of separately insulated strands which discharges between the insulation and the slot walls, a final
are transposed by 540q in the slot portion and consolidated coat of semiconducting varnish is applied to the surface of the
with epoxy resin in heated molds. After bending, the end turns slot portion of all bars. In addition, all bars are provided with
are consolidated with baked synthetic resin fillers. end corona protection to control the electric field at the
The bars comprise hollow and solid strands distributed over transition point from the slot portion of the bar to the end
the entire bar cross section to ensure good heat dissipation. At winding section and to prevent arcing.
the bar ends, the solid strands are brazed to a connecting
sleeve and the hollow strands to a water box which is linked to 3 Bar Support System
the water manifold by an insulating hose made of To protect the stator winding against the effects of
polytetrafluoroethylene (PTFE). The electrical connection load-induced magnetic forces and to ensure permanent firm
between the top and bottom bars is made by bolted seating of the bars in the slots during operation, the bars are
connections at the connecting sleeve. provided with a side ripple spring, a slot bottom equalizing strip
The water manifolds are insulated from the stator frame so and a top ripple spring located under the slot wedge. The gaps
that the electric resistance of the winding can be measured between the bars in the stator end windings are filled with
without having to remove the water. During operation, the insulating material and cured following installation. The ends
water manifolds are grounded. of the bars thus form a cone-shaped end winding. For radial
support, the end windings are clamped to a rigid support ring
2 Micalastic High-Voltage Insulation made of insulating material which is fully supported by the
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The proven MicalasticE system is used for the stator frame.

high-voltage insulation of the stator bars. With this system, Curable filler material is arranged between the stator bars
several layers of half-overlapping mica tape are applied to the and the support ring to ensure firm support of each individual
bars. The mica tape is composed of a thin high-strength bar by the support ring. The bars are clamped to the support
backing material to which the mica is bonded by a small ring with pressure plates held by bolts made from high-strength
amount of epoxy resin. The number of layers and insulating material. The stator end winding and support ring
consequently the thickness of the insulation depends on the thus form a rigid short-circuit-proof structure which does not
generator voltage. Following application of the mica tape, the restrict movements of the winding due to thermal expansion
bars are dried under vacuum and impregnated with epoxy because the support ring is allowed to move axially within the
stator frame.
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resin which exhibits very good penetration properties due to its

low viscosity. The stator winding connections are routed to six bushings
During next stage of this impregnation process the bars are located in a compartment of welded non-magnetic steel below
pressurized with nitrogen to complete the vacuum-pressure the generator at the exciter end. Current transformers for
impregnation (VPI) process. The impregnated bars are then metering and relaying purposes can be mounted on the
formed to the required shape in molds and cured in an oven at bushings.
high temperature. This ensures a virtually void-free high
Distribution:UNRESTRICTED
Siemens AG
Energy Sector 1008E
0114E
Description Rotor
1 Rotor Shaft The individual turns of the coils are insulated against each
The rotor shaft is a single-piece solid forging manufactured other by interlayers. L-shaped strips of laminated epoxy glass
from a vacuum casting. Slots for insertion of the field winding fiber fabric with Nomex filler are used for slot insulation. The
are milled into the rotor body. The longitudinal slots are slot wedges are made of high-conductivity material and
distributed over the circumference so that two solid poles are extend below the shrink seat of the retaining ring. The seat of
obtained. the retaining ring is silver-plated to ensure a good electrical
The rotor poles are designed with transverse slots to contact between the slot wedges and rotor retaining ring. This
reduce twice system frequency rotor vibrations at rated speed. system has long proved to be a good damper winding.
To ensure that only high-quality forgings are used, strength
tests, material analyses, and ultrasonic tests are performed 3 Rotor Retaining Rings
during manufacture of the rotor. The centrifugal forces of the rotor end windings are
After completion, the rotor is balanced in various planes at contained by single-piece rotor retaining rings. The retaining
different speeds and then subjected to an overspeed test at rings are made of non-magnetic high-strength steel in order to
120 % of rated speed for two minutes. reduce stray losses. Each retaining ring with its shrink-fitted
insert ring is shrunk onto the rotor body in an overhung
position. The retaining ring is secured in the axial position by
a snap ring.
2 Rotor Winding
The rotor winding consists of several coils which are 4 Field Current Lead
inserted into the slots and series-connected such that two coil The field current is supplied to the rotor winding via radial
groups form one pole. Each coil consists of several bolts and two semicircular conductors located in the hollow
2001-- All Rights Reserved
series-connected turns, each of which consists of two bores of the exciter- and generator shafts.
longitudinal and transverse turns which are connected by The field current leads are connected to the exciter leads
brazing in the end section. at the exciter- and generator shaft coupling with
The rotor winding consists of silver-bearing de-oxidized Multi-Contact plug-in contacts which allow for unobstructed
copper hollow conductors with cooling ducts. thermal expansion of the field current leads.
e Siemens AG
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Fig. 1 SGen5 rotor shaft during mechanical machining
Siemens AG
Energy Sector 0901E
0114E
Description Hydrogen Cooler
The hydrogen cooler is a shell and tube type heat line. This control valve is activated by temperature transmitters
exchanger which cools the hydrogen gas in the generator. The located upstream and downstream of the cooler sections.
heat removed from the hydrogen is dissipated through the
cooling water. The cooling water flows through the tubes, whiIe
the hydrogen is passed around the finned tubes.
The hydrogen cooler is subdivided into sections which are
vertically mounted in the cooler assembly. The cooler sections
are solidly bolted in position at their upper ends and freely
movable at the lower ends.
The cooler sections are parallel-connected on their water
sides. Shutoff valves are installed in the lines upstream of the
cooler sections. All parallel-connected water paths must have
equal flow resistances to ensure a uniform cooling water supply
to the cooler sections and equal cold gas temperatures
downstream of the individual sections. The required cooling water
volume flow is adjusted by control valves on the hot water side.
Controlling the cooling water volume flow on the outlet side
ensures an uninterrupted water flow through the cooler sections 1 2 3
so that proper cooler performance will not be impaired. 1 Stator frame
To maintain the cold gas temperature at an approximately 2 Cooler
3 Cooler assembly
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constant level under all operating conditions, a motor-operated

control valve is arranged, in the common cooling water outlet Fig. 1 Arrangement of Hydrogen Cooler
Copyright
Siemens AG
Energy Sector 1008E
0114E
Description Bearings
1 Bearings
The sleeve bearings are provided with hydraulic shaft lift oil
during startup and turning gear operation. To eliminate shaft
currents, all bearings are insulated from the bearing cover,
respectively. The temperature of the bearings is monitored with
thermocouples embedded in the lower bearing sleeve so that
the measuring points are located directly below the babbitt.
Measurement and any required recording of the temperatures
are performed in conjunction with the turbine supervision. The
bearings have provisions for fitting vibration pickups to monitor
bearing vibrations.
2 Bearing Oil System

Both bearings of the generator and the bearing of the exciter
unit or slip ring shaft are connected to the turbine lube oil
supply. 1 2 3
1 Connection for shaft lift oil

2 Thermocouple
3 Bearing sleeve
Fig. 1 Bearing
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Copyright
Siemens AG
BHEL,Haridwar MKD &MDB 2.1--1450--0001
Energy Sector 1010E
0114E
Description Shaft Seals
The points where the rotor shaft passes through the stator
H2 side Air side
casing are provided with a radial seal ring. The seal ring is
guided in the seal ring carrier which is bolted to the seal ring
carrier flange and insulated to prevent the flow of shaft 16
currents. The seal ring carrier is split along its axis. The design 1
facilitates installation and ensures reliable measurement of
15 2
clearances and dielectric resistance. The seal ring is lined with
babbitt on the shaft journal side. The gap between the seal ring 3
14
and the shaft is sealed with seal oil. The seal oil is supplied to
the sealing gap from the seal ring chamber of the sealring 13 4
carrier via radial bores and an annular groove in the seal ring.
To ensure effective sealing, the seal oil pressure in the annular
gap is maintained at a higher level than the gas pressure with
in the generator casing. The oil drained on the hydrogen and
air sides of the seal rings is returned to the seal oil system 12 11 10 9 8 7 6 5
through drains in the stator end shields. ln the seal oil system
the oil is regenerated by a vacuum treatment, recooled, filtered
1 Seal ring holder (air side) 09 Seal ring
and then returned to the shaft seals. 2 Seal ring holder (H2 side) 10 Secondary seal
On the air side, pressure oil is supplied laterally to the seal 3 Seal ring chamber 11 Seal strip
4 Oil wiper ring (air side) 12 Rotor shaft
ring via an annular groove. This ensures always free 5 Groove for seal ring relief 13 Inner labyrinth ring
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movement of the seal ring in the radial direction in case of 6 Babbitt 14 Seal
7 Annular groove for seal oil 15 Insulation
higher housing hydrogen pressures. 8 Seal oil inlet bore 16 End shield
On the gas side, a secondary seal in the seal ring serves to
Fig. 1 Shaft Seal
reduce the hydrogen-side axial oil flow and to stabilize
hydrogen purity.
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MKA06
Siemens AG
Energy Sector 1008E
0114E
Turbogenerators
Shaft Seal
Description
The rotor shaft ends are brought out of the gastight of the seal ring carrier at the end shield. The seal oil is admitted
enclosure through shaft seals as shown on the attached into the annular groove of the seal ring via passages in the seal
drawing (see also 2.1--6001, Shaft Seal). ring carrier and seal ring. A continuous film of oil is maintained
With this type of shaft seal, the escape of hydrogen between the shaft and the seal ring. The clearance between
between the rotating shaft and the housing is prevented by shaft and seal ring is such that friction losses are minimized
maintaining a continuous film of oil between the shaft and a and an oil film of sufficient thickness is maintained without an
non-rotating floating seal ring. To accomplish this, seal oil is unnecessarily large oil flow. Temperature rise of the seal oil is
fed to the seal ring in a closed circuit at a pressure which is therefore small which contributes to reliable sealing. The
slightly higher than the hydrogen pressure. In addition, the air babbitt lining of the seal ring ensures high reliability even in the
side seal ring is supplied with jacking oil to assure free axial event of mixed friction.
movement. On the gas side, a secondary seal in the seal ring The seal oil pump delivers the oil at a pressure maintained
serves to reduce the hydrogen-side axial oil flow and to 0.7 to 1.0 bar above the generator hydrogen gas pressure at
stabilize hydrogen purity. the shaft seal by means of a differential pressure valve.
The shaft seal is characterized by its short axial length, its Higher pressure oil for ring relief is fed to the annular groove
independence from the respective axial and radial position of in the air side seal ring carrier and forced between the seal ring
the shaft and an oil supply circuit with facilities for continuous and the seal ring carrier. In this way the oil and gas pressures
vacuum treatment of the oil. More details are given in a acting on the seal ring are balanced, and the friction between
separate description (see also 2.1--7100, Seal Oil System). seal ring and seal ring carrier is reduced. The seal ring is thus
The two halves of the babbitted seal ring float on the shaft free to adjust its radial position, which is important during the
journal with a small clearance and are guided in axial direction starting period. The seal ring will adjust its position according
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by a divided seal ring carrier resistant to distortion and to the shaft position as dictated by the oil film thickness and the
bending. The seal ring is relatively free to move in the radial vibratory condition.
direction, but is restrained from rotating by use of a pin. The The seal ring need not follow the axial movement of the
seal ring carrier, bolted to the end shield, is insulated to generator shaft, which is primarily caused by the turbine
prevent the flow of shaft currents. The oil is supplied to the expansion. The design permits the shaft to slide through the
shaft seal at two different pressures (seal oil pressure and seal ring without impairing the sealing effect.
higher pressure oil for ring relief) through the mounting flange
Copyright
Siemens AG
BHEL,Haridwar MKA &MDB 2.1--6000--0008
Energy Sector 1008E
0114E
Turbogenerators
Shaft Seal
Description
Drawing
H2 --side
16 Air side
1
15
2
14
3
13
4
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12 11 10 9 8 7 6 5
1 Seal ring holder (air side) 10 Secondary seal

2 Seal ring holder (H2 --side) 11 Seal strip Air
3 Seal ring chamber 12 Rotor shaft
4 Oil wiper ring (air side) 13 Inner labyrinth ring
5 Groove for seal ring relief 14 Seal Hydrogen
6 Babbitt 15 Insulation
7 Annular groove for seal oil 16 End shield Seal oil
8 Seal oil inlet bore
9 Seal ring
Pressure oil for
seal ring relief
MKA06
BHEL,Haridwar
Siemens AG MKA07 &MDC 2.1--6001--0013
Energy Sector 0901E
0114E
Turbogenerators Shaft Seal
Description Insulation and Sealing of Seal Ring Carrier
5
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6
7
Copyright
1 End shield bearing (top section)

2 Shaft seal insulation
3 Seal ring
4 Antirotation device
5 Joint
6 Thrust bolt for seal
7 Seal ring carrier (bottom section)
8 Rotor shaft
9 Bearing shell support
Siemens AG
BHEL,Haridwar MKA &MDC 2.1--6005--0002
Energy Sector 1008E
0114E
Turbogenerators Stator
Despcription Stator Frame
To facilitate manufacture, erection and transport, the stator The welded stator frame consists of the cylindrical frame
consists of the following main components: housing, two flanged rings and axial and radial ribs. The cool-
ing header at the turbine end encloses the entire end-winding
J Stator frame portion of the stator up to the end wall of the slot portion. The
J Cooling header cooling header is used for routing the cold gas into the cooling
J End shields gas ducts to the exciter end.
J Terminal box The arrangement and dimensioning of the ribs are deter-
mined by the cooling gas passages and the required mechani-
The stator frame with spring-mounted core support, core cal strength and stiffness. Dimensioning is also dictated by
and stator winding is the heaviest component of the entire gen- vibrational considerations, resulting partly in greater wall
erator. A rigid frame is required due to the forces and torques thickness than required from the point of view of mechanical
arising during operation. In addition, the use of hydrogen for strength.
the generator cooling requires the frame to be pressure-resis- Two lateral supports for the spring-mounted core support
tant up to an internal pressure of approximately 10 bar (130 in the frame are located directly adjacent to the points where
psig). the frame is supported on the foundation. Due to the rigid de-
sign of the supports and foot portion the forces due to weight
and short-circuits will not result in any over-stressing of the
frame.
Manifolds are arranged inside the stator frame at the bot-
tom and top for filling the generator with argon and H2. The
connections of the manifolds are located side by side in the
All Rights Reserved
lower part of the frame housing.

Additional openings in the casing which are sealed gastight
by pressure-resistant covers allow access to the pressure
plates of the spring-mounted core support and also permit the
lower portion of the core to be inspected. Access to the end-

winding compartments is possible via manholes in the TE
cooling header and the EE end shield.
In the lower part of the frame at the exciter end an opening
is provided for bringing out the winding ends. The terminal box
is flanged to this opening. The terminal box is made of non-
Copyright
magnetic steel.
The cooling header is located at the turbine end of the sta-
tor frame. It accommodates the baffle ring, the baffle ring car-
rier and the hydrogen cooler sections. The cooler sections are
installed in vertical cooler wells. Ribs in the cooler assembly
interior serve for improved cooling gas passage and contrib-
ute towards mechanical strength and stiffness.
Fig.1 Stator frame (Similar Design)

Handhabung: OFFEN
Siemens
BHEL,Haridwar AG MKA10 &MDB 2.1--2100--0036
Energy Sector 0111E
0114E
Description Outer Casing
1 General The welded casing is internally reinforced by radial and

To facilitate manufacturing and assembly, the stator axial ribs. The arrangement and dimensioning of the ribs are
consists of the following main components: determined by the cooling gas passages and the required
mechanical strength and stiffness. Dimensioning of the ribs
J Outer casing considers vibration specific features as well, resulting in
J Core and winding assembly sometimes larger wall thicknesses than required by strength.
J Plate springs In addition, the use of the hydrogen for the generator
J End shield bearing incl. shaft seal cooling requires the frame to be pressure-resistant up to an
J Hydrogen cooler internal pressure of approximately 10 bar (130 psig).
Manifolds are arranged inside the stator casing at the top
and bottom for filling the generator with H2 and argon or CO2.
2 Outer casing The connections of the manifolds are located side by side in
The welded outer casing is fabricated from structural steel. the lower part of the generator lagging.
The stator inner casing with the electrical active components At the exciter end of the outer casing openings are provided
is elastically supported in the outer casing by plate springs. for bringing out the winding ends or to receive the terminal
A rigid casing is required due to forces and torques arising in bushings.
operation. They are transferred to the foundation via the The front side casing walls are seated by bolted on end
welded-on stator feet. shields.
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5
Copyright
4
6
1 Cooler well 4 Manifold

2 Frame rib 5 Flange for end shield
3 Stacking beam 6 Stator front
Fig. 1 Outer Casing
Siemens AG
BHEL,Haridwar MKA10 &MDC 2.1--2110--0014
Energy Sector 0911E
0114E
Description Core and Winding Assembly
After stacking of the stator core, the insulated guide bars The supporting rings of the ends are welded to each other
are installed in the respective slots. The required stiffness is to form a skeleton frames each. They transmit the mechanical
obtained by welding supporting rings and the pressure plates forces to the outer casing via welded springs.
to the guide bars.
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Copyright
1 2 3 4 5 6 7 8 9
1 Supporting ring
2 Mounting location for spring
3 Stator core
4 Building bar
5 Pressure palte
6 Support ring
7 Insulating cap
8 Water connection box

9 Stator end winding
Fig. 1 Core and Winding Assembly of a THDF-Generator
Note: The photograph shows a typical equipment which may not correspond in all details to the specific equipment described.
BHEL,Haridwar
Siemens AG MKA20 &MDB 2.1--2130--0016
Energy Sector 1208E
0114E
Description Stator End Shields
Pressure-resistant end shields are provided to seal the

cooling header at the turbine end and the stator frame at the
exciter end. The end shields contain the generator bearings
and shaft seals (see also 2.1--5001, Generator Bearing).
1 2 3
1 End shield flange
2 Seal oil supply line
3 Seal oil drain
Fig. 2 EE End Shield (View from Generator Interior)

All Rights Reserved
The bearing oil is supplied to the lubricating gap via ducts

in the bearing shell support and in the lower bearing
sleeve.
Copyright
1 2 3 4 5
1 Bearing oil outlet

Fig. 1 TE Cooler Assembly (View from Generator Interior) 2 Hydraulic shaft lifting equipment
3 Bearing oil inlet
4 Connection for fast reduction of H2 casing pressure
5 Terminal box
Fig. 3 Bottom Section of End Shield

All bearing and seal oil inlet and outlet pipes are perma- (View from Generator Exterior
nently installed in the end shield.
The horizontally-split end shields are of hollow box type The bearing compartment is sealed on the air side with
construction. Radial and axial ribs together with the end walls labyrinth rings. On the hydrogen side the bearing compartment
provide for the necessary stiffness of the end shields. is closed by the shaft seal and labyrinth rings. The oil for the
The lower half end shields accommodate the insulated shaft seal is admitted via integrally welded pipes. The seal oil
bearing shell supports. The insulation prevents any short-cir- drained towards the air side is drained together with the
cuiting of shaft currents across the bearings. The bearing shell bearing oil. The seal oil drained towards the hydrogen side is
supports accommodate the spherical bearing shell and due to first collected in a gas and oiltight prechamber below the
their shape ensure self-alignment of the bearing with respect bearing compartment for defoaming and then passed to the
to the rotor axis. seal oil supply system.
BHEL,Haridwar
Siemens AG MKA &MDB 2.1--2150--0021 / 1
Energy Sector 1008E
0114E
The EE end shield is covered with a tapered copper shield
to prevent stray fields between stator winding and frame.
Fig. 4 Copper shield
Siemens
BHEL,Haridwar AG 2.1--2150--0021 / 2
Energy Sector 1008E
0114E
Description Hydraulic Testing of Stator Frame
1 Hydraulic Testing of Stator Frame 2 Sealing the Bolted Flange Joints

Following manufacturing, the empty stator frame with The bolted flange joints which must be gastight (e.g., end
attached cooler header, end shields and terminal box is shields) are sealed with a plastic sealing compound. On
subjected to a hydraulic test at 10 bar to ensure that it will be completion of the assembly of each component, the sealing
capable of withstanding maximum explosion pressures. The compound is injected into the respective grooves.
water pressure is increased in steps, with the pressure being Round flanges (e.g., manhole covers, bushings, terminal
reduced to atmospheric pressure after each step to allow for box) are sealed with O-ring packings.
measurement of any permanent deformations. Gastight sealing of the flanged connection between the
This test also checks for leakage at the weld seams. In cooler assembly/stator frame and terminal box/stator frame is
addition, the welded structure is subjected to an air pressure achieved by field welding.
test to check its gastightness.
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Copyright
Siemens AG
Energy Sector 1008E
0114E
Description Stator Core
1 Stator Core The core is built up by stacking the lamination in layers on

In order to minimize the hysteresis and eddy-current losses the pressure plate with its welded clamping fingers. The
induced by the rotating magnetic flux traversing the core, this individual layers are staggered to ensure a uniform per-
is built up of successive layers of thin, segmented laminations. meability to the magnetic flux. Stacking mandrels and bolts
inserted into the slots and bores during the stacking process
make for smooth slot walls.
To ensure maximum compression and to prevent undue
compaction of the core during operation, the laminations are
hydraulically compressed at frequent intervals during the
stacking process, and at specified stages, the core is also
heated to ensure further consolidation. The complete stack is
kept under pressure by means of clamping bolts and pressure
plates.
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1 2
1 Holes for clamping bolts

2 Cooling gas holes
Fig. 1 Insulated Lamination

The segments are punched from 0.5-mm thick electrical

steel laminations with a high silicon content, carefully deburred
and then coated with insulating varnish on both sides.
Copyright
Fig. 3 Stacked Core Complete with Ring Sets
The clamping bolts running through the core are made of

non-magnetic steel, and are insulated from the core and the
pressure plates.
Clamping fingers are used to transmit the pressure from the
pressure plates to the core. The clamping fingers extend up to
the ends of the teeth and thus ensure a firm compression even
in this area.
The stepped and glued arrangement of the laminations at
the core ends provides for an efficient support of the tooth
portions and also contributes to a reduction in eddy-current
losses and local heating in this area. The clamping fingers are
Handhabung: OFFEN
Fig. 2 Core During Stacking

made of non-magnetic steel to prevent eddy-current losses.
Siemens AG
BHEL,Haridwar MKA30 &MDB 2.1--2200--0024 / 1
Energy Sector 1008E
0114E
After compression and clamping of the core, guide bars are core, a copper rope is inserted into the groove of one of the
inserted into the slots provided in the outside surface of the bars.
core and welded to the pressure plates.
1
2
3
4
Point of contact
1 2 3 4 5
1 Guide bar 3 Lamination

1 Stator slot 4 Clamping finger 2 Insulation 4 Copper rope
2 Bolt for flux shield 5 Pressure plate
3 Clamping bolt Fig. 5 Insulation and Grounding of Stator Core
Fig. 4 Compacted Stator Core

In order to ensure sufficient heat removal, the axial holes
run through the entire core to allow the cold gas to travel from
The guide bars are insulated from the core as shown in the cold gas compartment at the exciter end to the hot gas
Figure 5. In order to ensure sufficient grounding of the entire compartment at the turbine end.
Siemens
BHEL,Haridwar AG 2.1--2200--0024 / 2
Energy Sector 1008E
0114E
Fasting of Stator Core and Framework
Turbogenerators
in Stator Frame
Description
THDF Series
2
3
4
5
6
7
8 A -- A
9 2
3
5
8
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1 Stator frame
2 Tension lock
10
3 Carrier ring
4 Shield ring
5 Dovetail support beam
6 Pressure plate
7 Pressing finger
8 Isolated clamp bolt
9 Stator core
10 Flat spring
9
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Fig. 1 Stator frame with flat springs
10
Fig. 2 Flat spring Fig. 3 Stator frame
Siemens AG
Energy Sector 0911E
0114E
Stator Winding
Turbogenerators
Conductor Construction and
Description
High-Voltage Insulation
1 General, Connection The transposition provides for a mutual neutralization of the

The three-phase stator winding is a fractional-pitch two voltages induced in the individual strands due to the slot
Iayer type consisting of individual bars. Each stator slot crossfield and end winding flux leakage and ensures that
accommodates two bars. minimum circulating currents exist. The current flowing
Up through the conductor is thus uniformly distributed over the
entire bar cross-section so that the current-dependent losses
are reduced.
All Rights Reserved
1
Up = pole pitch
1 Strand
Fig. 1 Lape Type Winding
Fig. 1 Stator Bar
The slot bottom bars and top bars are displaced from each
other by one winding pitch and connected at their ends to form To ensure that the strands are firmly bonded together and
coil groups. to give dimensional stability in the slot portion, the bars are
The coil groups are connected together with phase cured in an electrically heated press. Prior to applying the bar
connectors inside the stator frame as shown in the connection insulation, the bar ends are bent with a special device which
diagram. shapes the involutes over a cone shell. This ensures a uniform
Copyright
This arrangement and the shape of the bars at the ends spacing of the bars over the entire length of the end turns after
result in a cone-shaped winding having particularly favorable installation.
characteristics both in respect of its electrical properties and In the course of manufacture, the bars are subjected to
resistance to magnetically induced forces. The bars afford numerous electrical tests for quality control.
maximum operating reliability, since each coil consists of only
one turn. This makes the turn insulation and the main insulation 3 High-Voltage lnsulation
identical. The high-voltage insulation is provided according to the
proven Micalastic system. With this insulation system, several
2 Conductor Construction half-overlapped continuous layers of dry mica/glass fabric tape
The bar consists of a large number of separately insulated are applied from end to end on the stator bars. The tape is a
strands which are transposed to reduce the skin effect losses. composite tape built up from a thin, high-strength backing
The strands of small rectangular cross-section are provided material to which the mica is bonded by a small amount of
with a braided glass fiber insulation and arranged side by side epoxy as an adhesive for further processing.
over the slot width. The individual layers are insulated from The bent bar ends are then provided with a final protective
each other by a vertical separator. In the straight slot portion the wrapping of highly flexible glass fabric tapes in order to obtain
strands are transposed by 540_. a smooth surface.
Siemens AG
Energy Sector 1208E
0114E
Turbogenerators Connection Diagram of Stator Winding
Description SGen5-3000W
Direction of rotation
Main discharge pipe
(in generator)
TE
All Rights Reserved
EE
Main supply pipe
(in generator)
VI VI
V V
IV IV
Copyright
III III
II II
I I
Casing C
L bottom
rear
front W2 V2 U2
W1 V1 U1
Ring-circuits H2 cooled 2-Layer lap winding

Hose line made of insulating material 3 Phases, 2 Poles, 42 Slots
Chord 17/21
(7 Slots per pole and phase)
Short = Bottom bar Connection: YY

Source: 24--0420--126136
Slot 1 --42
Long = Top bar
BHEL,Haridwar
Energy Sector 0110E
0114E
Turbogenerators Stator Slot
3
4
5
6
7
8
9
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10
11
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12
1 Stator core
2 Slot wedge
13 3 Slide strip
4 Top ripple spring
5 Fill strip
14
6 Top strip
7 Cooling duct
8 Solid strand
9 Lateral intermediate strip
10 Top bar
11 Intermediate strip
12 Bottom bar
13 Micalastic-insulation
14 Low conductive side ripple strip
15 Low conductive equalizing strip
Handhabung: OFFEN
15
Siemens AG
Energy Sector 0901E
0114E
Turbogenerators
Micalastic High Voltage Insulation
Description
High-quality mica, selected epoxy resins and a matching indirect cooled generators built by Siemens AG since then
vacuum impregnation process are the characteristic features have been provided with this type of insulation, i.e. 262 turbo-
of the Micalastic insulation for large turbogenerators. A generators with a total rating of more than 90 000 MVA. Since
consistent development has led to a high quality insulation 1960 this insulation has been registered under the trade-mark
system, the reliability of which is ensured by continuous quality Micalastic by Siemens AG.
control. The stator windings of the worlds largest single-shaft
The first 10.5 kV winding of a turbogenerator to be impreg- generators with an output rating of 1640 MVA and a rated
nated under vacuum with a solventless thermosetting voltage of 27 kV were also provided with the Micalastic in-
synthetic resin was completed in 1958. All direct cooled and sulations.
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Copyright
Fig.1 Water-cooled Stator Winding of a 789 MVA Turbogenerator with Micalastic Insulation for a Rated Voltage of 21 kV.
Siemens AG
Energy Sector 1008E
0114E
Fig. 2 Construction of a Stator Bar With Internal Gas Cooling Fig. 3 Construction of a Stator Bar With Water Cooling
Method of Insulation and Impregnation the wall of the slot, the insulation in the slot section is then
For insulation with Micalastic, the conductor strands (with provided with a coat of conductive varnish.
internal gas cooling, the ventilating ducts as well) are arranged At voltages above 6 kV, a semiconductive coating is also
together to form a compact assembly and set to the required added on the slot-end sections to control the electric field and
shape. This assembly is then baked with epoxy resin to give prevent the formation of creepage sparks during high-voltage
it the mechanical strength required for further processing tests.
(Fig. 2, Fig. 3). After application of the end corona protection, the bars are
Following this, several layers of mica tape are applied ready for installation in the slots.
continuously and half-overlapped to the end-turn and slot
portions of the bar. The mica tape consists of a thin high-
strength backing material to which the mica is bonded by Tests
synthetic resin. The number of layers, i.e., the thickness of After insulation and curing, the insulation of each stator bar
insulation, is determined by the voltage of the machine. The is subjected to a high-voltage test at 150 % Up of the winding
taped bars are then dried under vacuum and impregnated with test voltage (Up = 2 x UN + 1 kV) for quality control. For as-
synthetic resin which, by reason of its low viscosity penetrates sessment of the quality of the slot insulation, the dielectric dis-
the insulation thoroughly and eliminates all voids. After resin sipation factor tan E is measured as a function of the voltage.
impregnation under vacuum conditions, the bars are pres- The dielectric dissipation factor/test voltage curve of a typical
surized in a nitrogen atmosphere. The impregnated bars with stator bar with MICALASTIC insulation is shown in Fig. 4.
direct conductor cooling are then brought to the required di- Fig. 4 shows the fluctuations due to manufacturing of the
mensions in molds and cured in an oven at high temperature. maximum increase in the dielectric dissipation factor up to
To minimize corona discharges between the insulation and rated voltage for the bars of a 21 kV winding.
Siemens AG
BHEL,Haridwar 2.1--2320--0014 / 2
Energy Sector 1008E
0114E
manner it is possible to insulate windings for voltages of over
30 30 kV efficiently and reliably.
x 10 - 3 Micalastic has a long electrical life as determined on
tan E 20 hundreds of experimental bars and substantiated on numer-
ous full-size bars (Fig. 6).
10 30
kV
0 mm
0.2 0.4 0.6 0.8 1.0 1.2 1.4
Rated voltage 20
E
Fig. 4 Dielectric Dissipation Factor of a Stator Bar With
Micalastic Insulation for 21 kV as a Function
of the Voltage 1.5 E p
10
The method of impregnation, which is exactly matched to Ep
the insulation, and the use of a special impregnating resin en- max. operating stress
able the maximum increase in dielectric dissipation factor to be
reduced considerably below the limits specified in section 33 0
1 10 102 103 104 105 106 107 108 min
of VDE 0530, Appendix X.
During insertion of the stator bars, high-voltage tests of one 1 10 100 years
minute duration are performed as follows: Time
115 % Up after installation and blocking of bottom bars Fig. 6 Electrical Life of MICALASTIC Insulation
110 % Up after installation and blocking of top bars

105 % Up after completion of winding
Micalasticis a good conductor of heat by reason of the
100 % Up after trial run of generator.
high mica content and the voidfree synthetic resin. Efficient
99.8 heat transfer is particularly important in machines that require
a thick insulation because of the high voltages, especially if
99 these machines are not designed with direct conductor
98 cooling.
Micalastic is highly resistant to high temperatures and
95 temperature changes. The composition of the insulation and
in %
90 synthetic resin impregnation permits the machine to be

operated continuously under conditions corresponding to
80 those for insulation class F.
60
60 x 10 - 3
40
tan E
40
20
20
10 0 20 40 60 80 100 120 140 _C
5 Temperature
Fig. 7 Dielectric Dissipation Factor of 27 kV MICALASTIC

1 Insulation as a Function of the Temperature
0.1 0.2 0.4 0.6 1 2 4
' tan E / ' Umax
Fig. 5 Cumulative Frequency of Maximum Increase in Dielectric Micalastic insulation shows only an insignificant increase
Dissipation Factor of Bars in a 21 kV Winding With in the dielectric dissipation factor with increasing temperature
Micalastic Insulation (Fig. 7).
The Properties of Micalastic The elasticity of Micalastic enables it to accommodate
Micalastic is an extremely dependable winding insulation thermo-mechanical stresses. Studies on models have
system developed for high-voltage turbogenerators. The provided information on the performance of Micalastic in-
insulation is applied from end to end on the stator bars provid- sulation under the effect of alternating thermal stresses. Heat
ing effective protection against overvoltages arising during cycles with large differences in temperature are generated by
normal operation and against the high stresses that may occur the alternate application of heating and cooling. The result:
at the slot ends when high test voltages are applied. In this there is no displacement between the Micalastic insulation
Siemens AG
BHEL,Haridwar 2.1--2320--0014 / 3
Energy Sector 1008E
0114E
and the copper conductor, even after 5000 heat cycles, with Micalastic is highly resistant to chemical action. Corro-
1000 cycles between 40 _C and 160 _C. sive gases, vapors, lubricating oil and weak acids or alkalis, to
Micalastic owes its insensitivity to high temperatures and which the windings of air-cooled machines may be exposed
temperature changes to the cured synthetic resin. This favor- under unfavorable conditions, do not attack the insulation; the
able performance under thermal stress is particularly advanta- impregnating resin behaves neutrally towards chemicals.
geous for machines subject to frequent load changes, e.g., Micalastic retains its outstanding properties, even after
generators driven by gas turbines or peak-load generators in years of operation. Evidence of its unchanging quality has
steam power plants. been provided by repeated tests carried out on machines over
Micalastic does not burn. The flammability is so low that an operating period of several years. Throughout the service
even on arcing it does not continue to burn once the arc is history of the first turbogenerator equipped with this insulation
extinguished. Fire extinguishing systems, such as CO2 system in 1958 there has never been a service failure originat-
systems, are therefore not necessary for machines insulated ing within the insulation system. Meanwhile 262 turbogenera-
with Micalastic. tors using the Micalastic insulation system have been
Micalastic provides protection against moisture due to its placed in operation, with an accumulated 2880 machine years
impregnation with synthetic resin which seals the winding of successful service experience.
completely.
Siemens AG
BHEL,Haridwar 2.1--2320--0014 / 4
Energy Sector 1008E
0114E
Turbogenerators Construction of High-Voltage Insulation
Description Micalastic Insulation
1 2
4
All Rights Reserved
5
Copyright
8 7 6
Item No. Component Insulant, semiconductive material

1 Crossover filler Micanite
2 Profile strip Micanite
3 Cooling channel Austenite
4 Strand bonding Epoxy resin
5 Micalastic insulation Mica tape, vacuum impregnated with epoxy resin
6 Outer corona protection Conductive polyester mat tape

7 Inner potential control Semi-conductor tape
8 Strand insulation Braided glass fiber insulation
Registered trade-mark
Note: The number of conductors shown does not necessarily correspond to the number of conductors of the generator described.
Siemens AG
Energy Sector 1208E
0114E
Turbogenerators Stator Winding
Description Corona Protection
To prevent potential differences and possible corona

1 2 3 4 5 6 7
discharges between the insulation and the slot wall, the slot
section of the bars are provided with an outer corona
protection. This protection consists of a wear-resistant, highly
elastic coating of conductive varnish containing graphite to
which an outer sleeve of semi-conductive polyester mat is
bonded.
At the transition from the slot to the end winding portion of
1 Semi-conductive polyester mat
the stator bars, several layers of a conductive coating are 2 Stator bar (slot end)
applied in varying lengths. This assures equal electric poten- 3 High-voltage insulation
4 Outer corona protection
tial distribution and prevents corona discharges during opera- 5 End corona protection
tion and during performance of high-voltage tests. 6 Glass-tape-epoxy protective layer
7 Stator bar (end winding)
A final wrapping of glass fabric tapes impregnated with poly-
ester resin serves as surface protection outside the slot section. Fig. 1 Typical Buildup of Corona Protection
All Rights Reserved
Copyright
Fig. 2 Applying a Protective Sleeve of Semi-Conductive Fig. 3 Application of Graded End Corona Protection
Polyester Mat
BHEL,Haridwar
Energy Sector 1008E
0114E
Turbogenerators Stator Winding
Description Coil and End Winding Support System
The stator windings are placed in rectangular slots which With the windings placed in the slot, the bar ends form a
are uniformly distributed around the circumference of the stator cone-shaped end winding. In order to minimize stray losses,
core. The location of the bars in the slots is detailed in Section the cone is design with as small a taper angle as possible. The
2.1--2303, Stator Slot. design of the end windings is detailed in Section 2.1--2341,
The bar is inserted in the slot. Semi-conducting side ripple Stator End Winding.
springs ensure that the bar is securely positioned in the slot, Any gaps in the end winding due to the design or manufac-
and that good contact is established between the outer corona turing are filled with curable plastic fillers, ensuring solid sup-
protection of the bar and slot wall. port of the cone-shaped top and bottom layers.
Radial positioning of the bar is done with slot wedges. Be- Clamping bolts made of high-strength fiberglass fabric as
low the longitudinally divided slot wedges a top ripple spring of well as pressure plates and spacers are used to brace the
high-strength fiber glass fabric is arranged between the filler winding bars against a rigid, tapered support ring made of fiber-
and slide strip which presses the bar against the slot bottom glass fabric. Tight seating is ensured through the use of plastic
with a specific preloading. An equalizing strip is inserted at the fillers on both sides of the bars. The fillers are cured on comple-
slot bottom to compensate any unevenness in the bar shape tion of the end winding assembly.
and slot bottom surface during bar insertion. These measures Each end winding thus forms a compact, self-supporting
prevent vibrations. The slot wedges are installed with a speci- arch of high rigidity which prevents bar vibrations during opera-
fied preload which is checked following installation. tion and can withstand short-circuit forces.
In addition, the end winding covering provides good protec-
tion against external damage. The supporting rings are posi-
tioned on brackets in such a manner that axial movement due
All Rights Reserved
to thermal expansion and contraction of the winding is allowed.

Copyright
1 2 3
1 2
1 Slot wedge
1 Slot wedge 2 End-winding cover
2 End-winding cover 3 Clamping bolt
Fig. 1 Stator with Complete Stator Winding Fig. 2 End-winding Cover and Support System
Siemens AG
Energy Sector 1008E
0114E
Turbogenerators Stator End Winding
1 2 3
All Rights Reserved
Copyright
4 5 6 7 8 9 10 11 12 13
1 Bottom bar 8 Flux trap

2 Top Bar 9 Gas cooled ring circuit
3 Pressure plate for stator bars 10 Support ring
4 Stator core 11 Water manifold
5 Clamping finger 12 Insulating sleeve
6 Pressure plate for stator core 13 Insulating hose

7 Insulated tension bolt
Siemens AG
Energy Sector 0106E
0114E
Stator Winding
Turbogenerators
Electrical Connection of Bars, Water Supply
Description
and Phase Connectors
1 Electrical Connection of Bars Each water box is fitted with a nozzle for connecting the
The electrical connection between the top and bottom bars hoses.
is made by means of a bolted contact surface. The exciter-end water boxes serve for water admission and
distribute the cooling water uniformly to the cooling channels
of the bar. The hot water is collected on leaving the cooling
channels in the turbine-end water boxes. The cooling water is
then discharged from the generator via the hoses and the
manifold.
During manufacturing of the stator bars, various checks are
performed to insure water tightness and unobstructed water
passages.
To ensure better accessibility, this test is performed before
the top section of the TE water boxes are welded into place.
After welding of the upper sections, all welded joints are
leaktested with helium.
The tangential air clearance between the water boxes and
bar connections within a coil group and the axial clearance
relative to the frame, end shield bearing and cooling header
which are at ground potential, is so dimensioned that additional
Fig. 1 Electrical Bar Connections and Water Supply insulation is not required. For the spaces between the individ-
ual phases insulting caps, which enclosure both the connect-
All Rights Reserved
At their ends, the strands are brazed to a connecting ing sleeve and the water boxes, are connected to the stator
sleeve, the strand rows being fanned out by means of a spacer. bars.
The contact surfaces of the connecting sleeve for the top and
bottom bars are pressed against each other by non-magnetic 3 Phase Connectors
clamping bolts. Special care is taken to obtain a flat and paral-
The phase connectors link the beginnings and ends of the

lel contact surface. In order to prevent any reduction in contact winding to the bushings. They consist of copper tubes, the
pressure or any plastic deformations due to excessive contact cross-section of which results in a low specific current loading.
pressure, belleville washers are arranged on the clamping The cooling gas flows through the copper tubes for direct
bolts which ensure a uniform and constant contact pressure. cooling of the phase connectors.
The phase connectors are wrapped with resin-rich mica
Copyright
2 Water Supply tapes half-overlapped, which contain the full quantity of a

The bar ends are designed such that the welded joints at the synthetic resin with very good penetration properties.
water connection are not subjected to unallowable loads Following this, a wrapper of shrinking tapes is applied.
during assembly. The insulation of the phase connectors is then cured at a
While the solid strands of the stator bars terminate in the specified temperature. This ensures that the shrink tape
connecting sleeve, the cooling channels are welded into the contracts to form a voidfree insulation.
water boxes. Each water box comprises two sections, i.e. the The connections between the phase connectors and the
lower section into which the cooling channels are welded and stator winding are designed as bolted connections.
the cover-type upper section.
Siemens AG
Energy Sector 0701E
0114E
Electrical Bar Connections
Turbogenerators
and Water Supply
Description
THDF, THFF Series
:
8
1
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Copyright
2 3 4 5 6 7
9 10
1 Teflon hose 5 Water box 09 Spring washer

2 Crimping sleeve 6 Connecting sleeve 10 O-ring
3 Cap nut 7 Bottom bar
Class.: UNRESTRICTED
4 Pipe connection 8 Top bar : Contact surface
Note: Clamping plates and clamping bolts are not shown.
Siemens AG
BHEL,Haridwar 2.1--2351--0010
Energy Sector MKA20 &MDB 1208E
0114E
BHEL,Haridwar
0114E
BHEL,Haridwar
0114E
Description Water Cooling System -- Stator Winding
1 General
Two separate water cooling systems are used for the stator
winding as well as the phase connectors and the terminal
bushings (see also 2.1--1100, Design and Cooling System;
2.1--7300, Primary Water Supply).
The interconnections between live components as well as
the connections between live components and the grounded
cooling system manifolds are designed as insulated and
pressure-resistant PTFE hoses. The locknuts are secured by
means of O-rings made of Viton and Belleville washers. The
fittings are made of non-magnetic stainless steel.
2 Winding Cooling System

The primary water manifolds are arranged around the end
windings, and are connected to the stator bars by means of
hoses. The primary water manifolds are insulated from the
frame, and connected to the primary water supply pipe by
means of an insulating and pressure-resistant PTFE
expansion joint which is located outside of the stator frame and
serves to accommodate the thermal expansion of the stator
All Rights Reserved
frame and the primary water tank.

The primary water flows through the stator bars from the
exciter end to the turbine end. The bars are hydraulically
connected in parallel in order to maximize the cooling effect
Fig 1. Water Manifold and Hoses at Stator End Winding
while minimizing the flow rate and pressure loss. This design
also ensures a uniform thermal expansion of all stator bars.

The hoses in the terminal box are grounded at one end, and
are furthermore provided with a metallic section for applying
3 Phase Connector Cooling System the voltage for measuring the insulation resistance of the
The primary water supply pipes for the phase connectors water-filled stator winding.
Copyright
and terminal bushings are arranged on the outside of the The primary water is admitted to three terminal bushings
stator frame near the terminal box. The supply pipes are linked via a water manifold, flows through the connected phase
to the primary water inlets and outlets by means of PTFE connectors and is then discharged to the outlet manifold via
hoses which are also used to route the primary water past the the opposite terminal bushings.
flexible connectors, and for linking series-connected sections The water flow through the two cooling systems is
of the phase connectors. monitored by metering the flow rate through the three phases.
Siemens
BHEL,Haridwar AG MKA &MDB 2.1--2380--0006
Energy Sector 1008E
0114E
Turbogenerators
Rotor Shaft
Description
The high mechanical stresses resulting from the centrifugal selected so that the two solid poles are displaced by 180_.
forces and short-circuit torques call for a high-quality heat- Due to the non-uniform slot distribution on the circumfer-
treated steel. Therefore, the rotor shaft is forged from a vacuum ence, different moments of inertia are obtained in the main
cast steel ingot. Comprehensive tests ensure a adherence to axes of the rotor. This in turn causes oscillating shaft deflec-
the specified mechanical and magnetic properties as well as tions at twice the system frequency. To reduce these vibra-
a homogeneous forging. tions, the deflections in the direction of the pole axis and the
The rotor shaft consists of an electrically active portion, the neutral axis are compensated by transverse slotting of the
so-called rotor body, and the two shaft journals. Integrally poles.
forged flange couplings to connect the rotor to the turbine and The solid poles are also provided with additional longitu-
exciter are located outboard of the bearings. Approximately dinal slots to hold the copper bars of the damper winding. The
two-thirds of the rotor body circumference is provided with rotor wedges act as a damper winding in the area of the
longitudinal slots which hold the field winding. Slot pitch is winding slots.
1 2 3 4 5 6
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Copyright
1 Rotor slot 4 Pole

2 Rotor tooth 5 Slot for damper winding
3 Transverse slot in pole 6 EE shaft journal
Fig. 1 Rotor Shaft

Siemens AG
Energy Sector 1008E
0114E
Turbogenerators Rotor
Description Cooling of the Rotor Winding
Each winding is divided into eight cooling zones. The first body and the stator through radial openings in the conductors
cooling zone includes the slot portion from the end to the center and the rotor slot wedges. The cooling gas holes are arranged
of the rotor body, and the second cooling zone extends across at different levels in the conductor assembly to give each
half of the end winding. These two cooling zones are repeated hollow conductor its own cooling gas outlet.
four times in a symmetrical arrangement around the rotor. The cooling gas for the end winding is admitted through the
The cooling gas for the slot area enters the hollow end face and flows through the conductors up to approximately
conductors through openings in the end winding and flows the pole center, where it passes into a collection compartment
through these conductors to the center of the rotor body. The and is then discharged into the air gap via slots in the end of the
hot gas is then discharged into the air gap between the rotor rotor body.
1 1 2 3
All Rights Reserved
1 Rotor body
1 Gas inlet (slot portion) 2 Gas outlet in rotor wedge (cooling gas flow from left)
2 Gas inlet (end winding) 3 Gas outlet in rotor wedge (cooling gas flow from right)
Copyright
Fig. 1 End Winding Gas Inlets Fig. 2: Gas Outlets at Rotor Center
Siemens AG
Energy Sector 1008E
0114E
Turbogeneratoren D-Khlsystem fr Lufer
Turbogenerators D-Cooling System for Rotor
All Rights Reserved
Gasaustritt
gas outlet
Copyright
Handhabung: OFFEN
Siemens
BHEL,Haridwar AG MKA40 &MDC 2.1--3101--0034
Energy Sector 1008DE
0114E
Description Rotor Winding
1 Rotor Winding 2.2 End Winding Bracing

The spaces between the individual coils in the end winding
1.1 Construction are filled with insulating members which prevent coil
The rotor winding consists of several coils inserted into the movement. Fig. 1 shows a typical rotor end winding with
longitudinal slots of the rotor body. The coils are wound so that inserted fillers.
two poles are obtained.
The half turns are combined to turns after having been
inserted in the rotor slots. The turns connected in series in one
slot pair constitute a coil. The individual coils of the rotor
winding are electrically connected in series forming a north and
south pole.
1.2 Conductor Material

The conductors are made of copper with a silver content of
approximately 0.1 %. As compared to electrolytic copper,
silver-alloyed copper features high strength properties at
higher temperatures so that coil deformations due to thermal
stresses are minimized.
1.3 Insulation
All Rights Reserved
The insulation between the individual turns is made of

layers of glass fiber laminate. The coils are insulated from the
rotor body with L-shaped strips of glass fiber laminate with
Nomex filler.
To obtain the required creepage paths between the coil and
the frame, thick top strips of glass fiber laminate are inserted
below the slot wedges.
2 Location of Parts in the Rotor Winding

Copyright
6
2.1 Rotor Slot Wedges 6 6
To protect the winding against the effects of the centrifugal
force, the winding is secured in the slots with wedges. The slot
wedges are made from a copper-nickel-silicon alloy featuring 1 2 3 4 5
high strength and good electrical conductivity, and are used as
damper winding bars. The slot wedges extend below the shrink
1 Rotor body 4 Filler
seats of the retaining rings. The rings act as short-circuit rings 2 Slot wedge 5 Gas outlet, transverse conductor
to induced currents in the damper windings. In addition, slots 3 Gas inlets, longitudinal conductor
are milled in the pole area to receive the damper wedges. Fig. 1 Rotor End Winding
Siemens AG
Energy Sector 1008E
0114E
Turbogenerators
Rotor Slot
Description
1 2 3 4
6
All Rights Reserved
7
8
Copyright
1 Cooling gas bore 6 Hollow condcutor

2 Radial cooling gas outlet 7 Cooling gas duct
3 Rotor shaft 8 Winding insulation

4 Rotor wedge 9 Slot liner
5 Top strip
Note: The number of conductors shown does not necessarily correspond to the number of conductors of
the generator described.
BHEL,Haridwar
Energy Sector 0210E
0114E
BHEL,Haridwar
Energy Sector
1 2 3 4 5 6 7 8
Description
Turbogenerators
Siemens AG
MKA41
&MDB
Rotor
Rotor End Winding
1 Snap ring 5 Filler

2 Rotor shaft 6 Retaining ring
Similar Design 3 Terminal lug 7 End ring
4 Rotor winding 8 Nut for balancing weights
0114E
0901E
2.1--3310--0075
Note: The number of conductors shown does not necessarily correspond to the number of conductors of the generator described.
Turbogenerators Arrangement of Damper Bars in Rotor Body
Description SGen5--3000W Series
All Rights Reserved
Copyright
Siemens AG
Energy Sector 0114E
0210E
Turbogenerators
Rotor Retaining Ring
Description
The rotor retaining rings contain the centrifugal forces due

to the end windings. One end of each ring is shrunk on the rotor
body, while the other end of the ring overhangs the end
windings without contacting the shaft. This ensures an un-
obstructed shaft deflection at the end windings.
The shrunk on end ring at the free end of the retaining ring
serves to reinforce the retaining ring and secures the end
winding in the axial direction at the same time.
A snap ring is provided for additional protection against
axial displacement of the retaining ring.
To reduce the stray losses and retain strength, the rings are
made of non-magnetic, cold-worked material.
Comprehensive tests, such as ultrasonic examination and
liquid penetrant examination, ensure adherence to the
specified mechanical properties.
The retaining ring shrink-fit areas act as short-circuit rings
to induced currents in the damper system. To ensure low
contact resistance, the shrink seats of the retaining rings are
coated with nickel, aluminium and silver by a three-step flame
spraying process.
All Rights Reserved
Fig. 1 Ultrasonic Examination of Retaining Ring

before Shrink On Only
Copyright
Siemens
BHEL,Haridwar AG MKA &MDB 2.1--3350--0003
Energy Sector 1008E
0114E
Description Field Connections
The field current connection comprises several fluorocarbon-elastomer O-rings placed next to each other
components, which are detailed below, and provides the along the axis of the radial bolt. The sealing effect is achieved
electrical connection between the rotor winding and the by the clamping action of a threaded ring and fiberboard. The
exciter. seal can be checked via two holes machined radially into the
shaft end near the O-rings.
1 J-strap Lead
The J-strap lead consists of a copper conductor. One end
of the J-strap lead is brazed to the rotor winding, while the other
end is screwed to the radial bolt. 3 Field Current Lead in Shaft Bore
The leads are run in the axial direction from the radial bolt
2 Radial Bolt to the EE coupling. They consist of two semi-circular
The radial bolts are screwed into the semicircular field conductors insulated from each other through a plate and from
current leads, and are connected to the rotor coils by means the shaft by a tube. The field current leads in the generator
of J-strap leads. The radial bolts are subjected to extreme shaft are connected to the field current leads in the exciter
centrifugal forces, and are made from hight-strenght copper. shaft/slipring shaft at the coupling with Multi-Contakt plug-in
The seal between the air and hydrogen spaces is located contacts which allow for unobstructed thermal expansion of
at the exciter end of the shaft, and comprises two the field current leads.
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2
3
Copyright
4
1
3
1 Retaining ring 4 Radial bolt 1 J-strap lead

2 Rotor winding 5 Rotor 2 Rotor
3 J-strap lead 6 Field current lead 3 Radial bolt
Fig. 1 Radial Bolt (Similar Design) Fig. 2 J-strap Lead (Similar Design)
Siemens AG
Energy Sector 1010E
0114E
Description Mechanical and Electrical Connection of EE Coupling
1 2 3
4
All Rights Reserved
5
6
7
8
Copyright
11 2 10
1 Gernerator rotor 6 Plug-in socket strip

2 H2-seal between half coupling 7 Plug-in bolt MULTI-CONTACT
3 Coupling bolt 8 Field current lead in exciter rotor shaft

4 Insulation 9 Insulation
5 Insulation 10 Threaded ring
11 Fiberboard
Note: The sketch must not in agreement with all design details of the actual generator.
Siemens AG
Energy Sector 0114E
0210E
Turbogenerators
Rotor Fan
Description
The generator cooling gas is circulated by one axial-flow The moving blades of the fan are inserted into T-shaped
fan located on the turbine-end shaft journal. To augment the grooves in the fan hubs. The fan hubs are shrink-fitted to the
cooling of the rotor winding, the pressure established by the shaft journal spider.
fan works in conjunction with the gas expelled from the
discharge ports along the rotor.
1 2 3 4 5 6
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Copyright
1 Shaft journal 4 Fan hub

2 Cooling gas inlet (rotor cooling) 5 Moving blades
3 Balancing slot 6 Rotor retaining ring
Fig. 1 Rotor Fan
Note: Depending on the relevant generator size, the rotor fan has 3 to 6 stages.
Siemens AG
Energy Sector 0210E
0114E
Turbogenerators
Rotor Fan and Fan Baffle Ring
Description
1 2
All Rights Reserved
Copyright
6 6 5 4 3
1 5 3 2
1 Baffle ring carrier

2 Baffle ring
3 Guide vane
4 Fan hub
5 Blade
6 Gas inlet, rotor
6 4
Note: Depending on generator size the rotor fan is of the three-to-six-stage type.
Siemens AG
Energy Sector 0210E
0114E
Turbogenerators
H2 Cooler
Description
The hydrogen cooler is a surface-type heat exchanger. The cooling water flow through the cooler elements and thus proper
heat removed from the hydrogen is dissipated through the cooler performance.
cooling water. The water flows through the finned tubes while
the hydrogen flows around them.
The vertical arrangement enables the heat exchanger to be
installed without having to increase the overall axial length of
the generator or the cross-sectional area of the stator frame.
The cooler comprises a pair of separate cooling elements
each of which consists of two tube bundles, the two
tubesheets, two return water channels as well as the inlet and
outlet water channels. The water inlet and outlet lines which
route the cooling water to and from the cooler are connected
to inlet and outlet channels which are situated above the cooler
elements. The tube bundles are interconnected by the shared
upper tubesheet. The end compartment is located below the
cooling elements. The gaps between the stator frame and the
end compartment as well as between the stator frame and the
upper tubesheet are sealed with O-rings.
The side walls of the cooling elements are made of
structural steel and serve to brace the cooler and direct the
hydrogen flow. Close the rubber profiles attached to the cooler
All Rights Reserved
well and to prevent uncooled hydrogen from flowing past the

cooler.
The upper tubesheets are bolted to the stator frame.
Fiberboard strips at the lower tubesheets guide the cooler
elements, thus allowing the tube bundles to vertically expand

and contract freely inside of the cooler well.
The hydrogen flows horizontally through the cooler, while
the cold water flows downward to the return water channel
where and flows upward again the water outlet channel.
The water sides of the cooler elements are connected in
Copyright
parallel. Shutoff valves are installed in the lines upstream and

downstream of the cooler elements. The requisite flow of
cooling water depends on the generator output and is
regulated by a water-side control valve. Outlet-side regulation
of the flow of cooling water effectively ensures uninterrupted Fig. 1 Removal of an H2 cooler element
BHEL,Haridwar
Energy Sector 1008E
0114E
Turbogeneratoren
Generator Bearings
Description
1 2 3 4 5 6
All Rights Reserved
Copyright
1 Flange for wiper mounting 3 Stop 5 Bearing insulation

2 Upper bearing sleeve 4 Bearing saddle 6 Lower half of stator end shield
Fig. 1 Exciter-End Generator Bearing
The rotor shaft is supported in sleeve bearings having of 0.2 mm between the bearing sleeve and the insulation of the
forced-oil lubrication. The bearings are located in the stator radial locator.
end shields The oil required for bearing lubrication and cooling A stop is provided at the bearing sleeve joint to prevent the
is obtained from the turbine oil supply system and supplied to bearing from turning in the saddle.
the lubricating gap via pipes permanently installed inside the The inner surface of the cast bearing sleeve body is
lower half of the stator end shield and via grooves in the provided with spiral dovetail grooves which firmly hold the
bearing saddle and lower bearing sleeve. babbitt liner to the bearing sleeve body. The lower bearing
The lower bearing sleeve with its self-aligning outer portion sleeve has a groove to admit the bearing oil to the bearing
rests on the bearing saddle. The bearing saddle is insulated surface. The upper sleeve consists of an overflow groove
from the stator end shield to prevent the flow of shaft currents through which the oil flows over the shaft journals and is fed to
and provide for insulation of the generator bearing from the lubricating gap. The oil is drained laterally from the
ground. The radial locator serves to locate the bearing in the lubricating gap, caught by wipers, collected in the bearing
vertical direction and is bolted to the upper half of the stator end compartment and returned to the turbine oil tank via pipes.
shield. The Iocator should be adjusted to maintain a clearance All generator bearings are provided with a hydraulic shaft lift
Siemens AG
BHEL,Haridwar MKD &MDB 2.1--5000--0024 / 1
Energy Sector 0114E
1008E
oil system to reduce bearing friction during startup of the 1 2 3
turbine--generator. High pressure oil is forced between the
bearing surface and the shaft journal, lifting the rotor shaft to
allow the formation of a lubricating oil film.
The bearing temperature is monitored with thermocouples
located approximately in the plane of maximum oil film
pressure. The thermocouples are screwed in position on both
sides of the lower bearing sleeve from outside with the
detectors extending to the babbitt liner.
1 Overflow groove
2 Babbitt
3 Stop
Fig. 2 Upper Bearing Sleeve
Siemens AG
BHEL,Haridwar 2.1--5000--0024 / 2
Energy Sector 1008E
0114E
A--A A
Air side H2 --side
Energy Sector
Description
BHEL,Haridwar
Turbogenerators
Siemens AG
2
4 16
MKD
5
&MDB
6
7
15
8
14
Generator Bearing -- Drawing
10 13
11 12
1 Endshield bearing 5 Support for vibration pick--up 10 Connection for seal oil inlet, air side 15 Fast H2 exhaust
2 Oil vapor and H2 exhaust 6 Drain for H2 side seal oil 11 Connection for ring relief 1 16 Connection for ring relief 2
3 Connection for Munters drier 7 Hydraulic shaft lifting 12 Connection for seal oil inlet, H2 side * Joint
(at standstill and unpressurized air filling) 8 Bearing oil inlet 13 Connection for seal oil inlet, air side
0114E
2.1--5001--0036
1008E
4 Connection for seal oil, H2 side 9 Bearing oil outlet 14 Connection for seal oil outlet, H2 side
Turbogenerators
Measuring of Bearing Temperature
Description
6
All Rights Reserved
3
4
3
Copyright
1 End shield
2 Thermocouple lead
3 Insulation
4 Spacer ring
5 Bearing shell support
6 Bearing sleeve
7 Thermocouple
8 Babbitt
Siemens AG
BHEL,Haridwar MKD10 &MDB 2.1--5003--0013
Energy Sector 1008E
0114E
Turbogenerators
Generator Bearing Insulation
Description
All Rights Reserved
Copyright
1 2 3 4 5 6 7
1 End shield
2 Bearing saddle
3 Bearing oil inlet
4 Spacer ring
5 Plug screw
6 Insulation
7 Mounting screw
BHEL,Haridwar
Siemens AG MKD &MDB 2.1--5005--0018
Energy Sector 1008E
0114E
B--B A--A
Energy Sector
Description
H2 side Air side
BHEL,Haridwar
A B
Turbogenerators
Siemens AG
1
MKD
5
&MDB
7
Oil System
8
Generator Bearing
10 A 9 B
1 Upper bearing sleeve 6 Bearing oil inlet

2 Bearing oil wiper 7 Lower bearing sleeve
3 Overflow groove 8 Babbitt
4 Oil pocket 9 Shaft lift oil system 1
5 Tangential locator 10 Shaft lift oil system 2
0114E
1008E
2.1--5007--0012
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Turbogenerators
Cooling Gas Temperature Control
Description
Due to load variations during operation and the resulting After startup and runup to rated speed, the cooling water
thermal expansions and contractions, the generator is sub- supply to the hydrogen coolers should be opened only when
jected to stresses. the temperature of the hydrogen gas has reached the preset
In order to reduce these stresses, the hydrogen cooling cold gas reference. The temperature difference between cold
circuit and the primary water cooling circuit are each provided gas and hot gas is determined by the no-load losses.
with a temperature control system to control the cooling gas The cooling water supply to the primary water coolers
and primary water temperatures so that the active generator should be opened only when the generator is carrying load,
components are maintained at the proper temperature Ievel. since only then current-dependent heat losses will have to be
The requirements for the temperature control system are dissipated.
described below: The temperature control systems are cold coolant tempera-
ture control schemes with variable set point as a function of the
cold = Cold gas temperature or cold primary water stator current. Set point adjustment is selectable between I and
temperature I2 or with an exponent between one and two. With rising stator
hot = Hot gas temperature or hot primary water current, the set point is reduced, so that the mean value (mean)
temperature of hot and cold coolant temperatures assumes a nearly
mean = Mean temperature of hot and cold gas or of hot and constant value, as shown in Fig. 1.
cold primary water temperature The difference between the setting values of the two set
' = hot -- cold with generator carrying full load points corresponds to half the temperature rise of the hydrogen
cooling gas at no-load, with 5 -- 10 K (9 -- 18 qF) to be taken as
a guiding value.
The temperature rise ' at full load is the temperature In order to maintain a low temperature level in the generator,
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difference between the hot and cold hydrogen gas as given in the reference should be set at the lowest possible value, ensur-
the hydrogen cooler design data or between the hot and cold ing that the cold coolant temperature will not drop below the
primary water as given in the design data of the primary water minimum level of 10 qC (50 qF) even when the generator is
cooler. carrying full load.
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Fig. 1 Coolant Temperature as a Function of Generator Load
BHEL,Haridwar
Siemens AG MKY MDB 2.1--8010--0002 / 1
Energy Sector 1008E
0114E
Parallel shifting of the curves shown in Fig. 1 is possible by The control valve must be absolutely tight when in the
adjustment of the cold coolant references. The temperature of closed position to ensure that the coolant temperature will not
the cold primary water must, however, always be higher than drop while the generator is being shut down.
the temperature of the cold hydrogen cooling gas over the For details on the operation and technical features of this
entire load range of the generator in order to avoid any equipment, see equipment suppliers operating instructions.
condensation of moisture contained in the gas on the The required temperatures for setting the coolant tempera-
generator components carrying primary water. ture control systems must be observed.
Siemens AG
BHEL,Haridwar 2.1--8010--0002 / 2
Energy Sector 1008E
0114E
Turbogenerators
Mechanical Equipment Protection
Description
1 Introduction hydrogen loss can be derived from the hydrogen consumption

of the generator.
Turbine generators are extremely complex electrical Operation of the generator, will be seriously ieopardized in
machines designed to ensure an uninterrupted power supply. the event of a major ingress of water which will collect in the
In addition to a suitable mechanical and electrical design as generator terminal box. Due to the restricted volume of the
well as appropriate operation, it is recommended that compartment the level can rise quickly, resulting in a terminal
automatic protection system be provided. short circuit or ground fault. In order to prevent such a failure,
The protective equipment detects dangerous operating three level detectors are connected to the generator terminal
conditions at an early stage and prevents them from box to activate the mechanical equipment protection before a
developing into damaging conditions. The protection relieves critical level is reached.
the operating personnel from making the necessary fast
decisions. 2.3 Exciter Unit Protection Against Overheating
The following criteria are sensed by the generator The protection circuit covering criterion 1.3 prevents
mechanical equipment protection and processed by the overheating of the exciter in case of insufficient cooling (failure
generator protection circuits: of exciter coolers).
The hot air temperature downstream of the main exciter is
sensed with resistance temperature detectors in a
1.1 High cold gas temperature in generator three-channel configuration and transmitted directly to the
1.2 Liquid in generator terminal box three-channel protection circuit.
1.3 High hot air temperature in exciter unit
1.4 High primary water inlet temperature
2.4 Protection of Water-Cooled Components Against

1.5 Low primary water volume flow through High Primary Water Inlet Temperature
stator winding The protection circuit covering criterion 1.4 prevents
1.6 Low primary water volume flow through bushings insufficient cooling and thus overheating of the water-cooled
components in case of high primary water inlet temperature.
Each of these criteria activates a turbine trip. The generator
The cold primary water temperature is sensed with
e Siemens AG 1998
is isolated from the system and de-excited through the

resistance temperature detectors in a three-channel
two-channel reverse power relay.
configuration and transmitted directly to the three-channel
protection circuit.
2 Protection Circuits
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2.5/2.6 Protection of Water-Cooled Components

Against Insufficient Primary Water Supply
The protection circuits covering criteria 1.5 to 1.6 prevent
2.1 Generator Protection Against Overheating by High
overheating and damage to the stator winding, phase
Cooling Gas Temperature
connectors and bushings in case of insufficient primary water
The protection circuit covering criterion 1.1 prevents
supply.
insufficient cooling and thus overheating of the
The variables are sensed with flow transmitters in a
hydrogen-cooled components in case of high cooling gas
three-channel configuration. To account for possible gas
temperature.
bubbles in the primary water (disturbed measuring section),
The cold gas temperature is sensed with resistance
the output signal obtained from the flow transmitters is
temperature detectors in a three channel configuration and
attenuated by an electrical damping element in the flow
transmitted directly to the three channel protection circuit.
transmitters. The attenuated signals are then transmitter to the
three-channel protection circuit.
2.2 Generator Protection Against Ground Fault or
Terminal Short Circuit in Terminal Box
The generator may be damaged by leaks in components
through which primary or secondary cooling water or seal oil 3 Protection Circuit Design
flows inside the generator.
Primary water flows through the stator winding, terminal All protection circuits of the mechanical equipment
bushings and phase connectors. Secondary cooling water protection are designed a 2-out-of-3 configuration with
flows through the hydrogen coolers located in the cooling facilities for functional testing, analog Signal comparison and
header. Generator operation will only be endangered by these backup energizing. Both channels must respond to activate a
coolants in the event of large leakages. As a result of the high trip.
hydrogen pressure, only little water will emerge from a small This redundant system prevents erroneous tripping due to
leak. Hydrogen will, however, enter into the water system. The an active fault.
Siemens AG
BHEL,Haridwar MKY &MDB 2.1--8320--0029
Energy Sector 1298E
0114E
Turbogeneratoren
Electrical Generator Protection
Description
J An interruption of the field circuit with arcing releases high

This is a principle description. The actual trippings see amounts of energy in the form of heat which may cause
generator-protection system. severe burning.
J A one-line-to-ground fault may develop to a double ground
Generators are high-quality machines for securing the best fault, resulting in dangerous magnetic unbalances,
possible continuity of power supply. In addition to a suitable especially on four-pole generators.
technical design and responsible mode of operation, provision
must therefore be made for automatic protection facilities. This To minimize the consequential damage, it is recommended
protection must ensure a fast and selective detection of any to provide two-pole and four-pole generators with a protection
faults in order to minimize their dangerous effects. circuit featuring a delayed response. In the core of four-pole
The protective equipment must be designed so that any generators, the rotor ground fault protection must always
serious fault will result in an immediate disconnection and operate to avoid the hazard of sudden, extremely high
de-excitation of the generator. Faults which do not cause any vibrations due to magnetic unbalances.
direct damage must be brought to the attention of the operating
staff, enabling them to operate the unit outside the critical Relay time: approximately 1 s
range or to take precautionary measures for shutdown.
Generators may be endangered by short-circuits, ground
4 Underexcitation Protection
faults, overvoltages, underexcitation and excessive thermal
Failure of the voltage regulator, maloperation of the
stresses.
generator or transformer control systems, and generator
The following protective equipment is recommended:
operation in a system with capacitive load may result in a
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reduction of the excitation required to ensure system stability

1 Differential Protection below a predetermined minimum value. Short-circuits or
Breakdown of insulation between different stator phase
interruptions in the field circuit result in a complete loss of field
windings results in an internal short-circuit. The fault is
and thus in instability of the generator. This causes higher
detected by a differential relay which initiates immediate
temperature rises in the rotor and core end portions, rotor
isolation and de-excitation of the generator. In order to obtain

overvoltage, system swings and torsional vibrations of the
a high sensitivity, the protected area should include the
shaft.
generator only.
A momentary excursion beyond the steady-state stability
limit must not necessarily result in a loss of stability. Therefore
Operating value: 0.2--0.4 /N
it is advisable to design the underexcitation protection so that
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Relay time: %60 ms a warning will be given when the steady-state stability limit is
reached. The generator will be shut down after a few seconds
In certain cases, the generator may also be included in the only.
differential protection for the main transformer and station The protection must operate instantaneously if a loss of field
service feeder. Generator faults are then detected by two occurs when the steady-state stability limit is reached.
differential protection devices. lf the loss of field cannot be detected directly (e.g. exciters
with rotating diodes), it is recommended to introduce a second
2 Stator Ground Fault Protection stator criterion covering the range of the permeance values
Breakdown of insulation between the stator winding and 1/xd and 1/xd and to provide for instantaneous tripping when
frame results in a stator ground fault. If possible, the stator this criterion is exceeded.
ground fault protection should cover the complete winding,
including the neutral point of the generator. The protection is to 5 Overcurrent Protection
initiate immediate isolation and de-excitation of the generator. System faults may result in in admissible thermal stressing
of the generator. For this reason, an overcurrent protection
should be provided which operates on failure of the system
Relay time: %1s
protection.
A definite-time delay overcurrent relay may be used for this
The load resistance of a grounding transformer and any purpose, however, its relay time should be longer than that of
required boost to raise the neutral point potential should be the system protection.
selected so that the ground current due to a fault will amount

to less than 15 A. Operating value: 1.3/N
Relay time: 6--8 s maximum
3 Rotor Ground Fault Protection
Rapid fault detection is required for the following reasons: To avoid long relay times, it is recommended to equip large
generators with an inverse-time-delay (impedance) relay. This
Siemens AG
BHEL,Haridwar MKY &MDB 2.1--8330--0008 / 1
Energy Sector 0114E
1008E
relay is energized by overcurrent and operates with long or Since the frequency deviation due to a system disturbance
short-time setting, dependent on the location of the is normally accompanied by a voltage deviation, the protection
short-circuit. should be designed on the basis of the permissible load
lf connected to the generator neutral point, the overcurrent characteristic of the generator on frequency and voltage
protection serves as back-up protection for the differential deviations.
protection.
9 Reverse Power Protection
A rise in system frequency for any reason whatsoever
6 Load Unbalance Protection
Generators operating in an interconnected system are results in closing of the control valves, and the turbine is driven
by the motoring generator. Since the turbine is then no longer
normally subjected to small load unbalances only. However, all
one- and two-line-to-ground faults occurring in the system, supplied with cooling steam, the unit must be disconnected
phase breakages or circuit breaker failures are in fact load from the system. The relay must be provided with a time delay
unbalances which may result in unduly high thermal stressing of approximately 20s to prevent undesired response to system
of the rotor. swings (long time setting).
Specific faults in the turbine-generator interior initiate
lt is recommended to provide a two-stage load unbalance
protection. When the continuously permissible load unbalance emergency tripping. The steam supply to the turbine is
interrupted. A reliable criterion of perfectly tight closure of the
is reached, an alarm is given, whereas a time-dependent
isolation from the system occurs when this value is exceeded. emergency stop valves is the flow of power from the system
In case of large units, it is recommended to provide a back into the generator.
protection with unbalanced load/time characteristic. Operating Disconnection of the unit from the system by the generator
value and relay time should be matched to the load circuit breaker with a time delay of 4 s is only permissible after
unbalance/time characteristic applicable to the particular the reverse power has been drawn by the generator
generator. (short-time setting).
Operating value: about 50--80 % of reverse power

7 Rise-in-Voltage Protection Relay time: long-time setting: approximately 20 s
Rejection of partial or complete system loads causes a short-time setting: approximately 4 s
voltage rise, followed by an increase in the prime mover speed.
This may result in the generator and the apparatus connected
to it being endangered by unduly high voltages. Maloperation 10 Overvoltage Protection
during manual voltage regulation of the generator may also The use of surge diverters on the high-voltage side of the
result in inadmissible voltage stressing of these devices. Due unit transformer is considered sufficient for protecting the
to the sudden voltage variations resulting from switching generator against atmospheric overvoltages and switching
operations, it is advisable, at least in the case of large units, to surges in the system.
provide a two-stage rise-in-voltage protection, i.e.: With a view to a possible flashover from the high-voltage
winding to the low-voltage winding in the unit transformer, it is,
J with high (1.45 u UN) operating value and instantaneous however, advisable to provide surge diverters for the
tripping; generator too, which should be connected between the
J with low (1.2 u UN) operating value and delayed tripping. phases and ground.
Normally, the surge diverters are installed in the direct
8 Under-Frequency Protection vicinity of the unit transformer. lt is assumed that switching
Major disturbances in an interconnected system may result surges due to a load isolator or circuit breaker connected
in operation of the generator at under-frequency. At rated between the generator and transformer will not endanger the
voltage, the generator can be continuously operated at rated generator.
kVA up to 95 % of rated frequency. Care should be taken to provide explosion-proof surge
To avoid excessive magnetic and thermal stressing, it is diverters or suitable constructional measures in order to avoid
recommended to provide an under-frequency protection. danger to persons or nearby plant components.
Further information especially of the detail design can be found in

section electrical unit protection CHA of the documentation.
Siemens AG
BHEL,Haridwar 2.1--8330--0008 / 2
Energy Sector 1008E
0114E
Turbogenerators Arrangement of Brush Holders
Description for Rotor Grounding System
Grounding brushes are fitted to the outer turbine end The brush holders are arranged with 90_ displacement,
labyrinth ring to remove the static recharges of the shafts. which ensures that at least one brush will be in contact with the
rotating shafts.
View Z
1 4
A Two-layer
contact brush
Two-layer (Design B)
contact brush
(Design A)
A 6
Direction
of Rotation
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A--A
5
1 2 1 Brush holder bolt

2 Brush holder
3 Brush (Design A or B) Design A Design B

4 Insulation
5 Labyrinth ring
6 Rotor shaft / turbine shaft EG5U
AG20
EG5U
AG20
3
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6
3
View from gas turbine View from generator

to generator to steam turbine
Z Z
Rotor potential for

generator protection
BHEL,Haridwar
Siemens AG MKY &MDB 2.1--8351--0011
Energy Sector 0103E
0114E
Measuring Devices and
Turbogenerators
Supervisory Equipment
Description
Introduction
The equipment consists of alarms and measuring de- Closely associated with the supervisory equipment are
vices. The measuring devices give a visual indication of the regulating systems, automatic controls and protective
system parameters, the alarm devices initiate visual or audi- devices which provide for a reduction of the manual
ble signals in the event of a controlled quantity falling below supervisory work.
or exeeding the predetermined limit values. In many cases,
the measuring and alarm devices are combined to form one
supervisory unit.
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Copyright
Siemens AG
Energy Sector 1010E
0114E
Temperature Detectors
Turbogeneratoren
Resistance Temperature Detectors and
Description
Thermocouples
1 Resistance Temperature Detectors (RTDs) U0
RTDs are used for temperature measurements on the

generator to measure, for example, the slot temperatures and
RL1
the cold gas and hot gas temperatures. Both RTDs with
four-wire connection and double-element RTDs with four-wire RL3
connection each are used.
When making measurements with RTDs the resistance

element is exposed to the temperature to be measured. The V
RTD works on the change in electrical resistance of a Rx
RL4
conductor as a function of temperature. The approximate U0
value may be calculated by the following formula:
RL2
R = Ro u (1 + B u T)
where
Ro = reference resistance at 0 _C
B = temperature coefficient and
T = temperature in _C. Fig. 2 Wire-Wire Connection
The standard reference resistance of the platinum Due to the mostly very high input resistance of amplifier V, the
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resistance element is 100 ohms. The temperature coefficient resistance of lead wires RL3 and RL4 from the RTD to the amplifier
is B = 3.85 u10-3 degC-1, this being the mean value for the is negligible, even if it would be substantially increased by the
range 0--100 _C. provision of a safety barrier (explosion protection).
To obtain optimum results, the four-wire connection is
180 generally used.
ohm
160 2 Thermocouples
Thermocouples are used for temperature measurements

140
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on the generator to measure, for example, the generator and

exciter bearing temperatures. Thermocouples are mainly
employed where small time constants require fast temperature
120
indication.
100 2.1 Principle

0 40 80 120 160 200 _C 240 Temperature measurement with thermocouples is carried
out as follows:
Fig. 1 Resistance Characteristic for Platinum RTDs 100 8 at 0_C Two conductors of dissimilar materials, i.e. the positive and
the negative conductor (thermoelectric elements), are joined at
1.1 Circuit Connections one end (hot junction) so as to produce an electromotive force
The two-wire connection so far commonly used involves (emf), i.e. a thermoelectric emf (in mV).The magnitude of the
errors in the case of long leads. Long leads are exposed to emf is dependent upon the temperature difference between
different temperatures, and the lead resistances then reach the temperature to be measured and that of the other two ends
values in the order of the resistance of the RTD element. of the conductors. To use the thermoelectric emf for temperature
measurement, the free ends of the conductors are exposed to a
1.1.1 Four-Wire Connection constant temperature (cold junction temperature) and connected
If the two element leads are not alike, a four-wire circuit to a millivoltmeter calibrated in _C.
should be used. Fig. 2 shows the circuit diagram of the
four-wire method. 2.2 Compensating Leads

Leads RL1 and RL2 form the pair of Iead wires to the RTD The compensating leads serve to extend the thermocouple
Pt 100, while the other set of lead wires RL3 and RL4 from the up to the cold junction. When exposed to a temperature up to
RTD are connected to amplifier V. Being a normal differential 200 _C they produce the same thermoelectric emf as the
amplifier, it amplifies only the voltage drop across the RTD to associated thermocouple. See DIN 43710 for calibration data
the required output voltage Ievel. and limits of error of compensating leads.
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BHEL,Haridwar MKY &MDB 2.1--8410--0004 / 1
Energy Sector 1010E
0114E
2 3 5 6
Thermoelectric U therm in mV
10
NiCr-CuN
1 4 Fe-CuNi
7
6 Cu-CuNi
NiCr-Ni
1 Hot junction 5 Connecting cables
2 Thermocouple 6 Millivoltmeter
3 Compensating lead 7 Compensating resistor 4
4 Cold junction erection
Fig. 3 Thermocouple 2
The sheath enclosing and protecting the compensating 20 40 60 80 100 120 140
lead wires has also been colour-marked for the various Temperatur in _C
thermocouples. Fig. 4 Voltages as a Function of Temperature for
Standardized Thermocouples acc. to DIN IEC 584, sect. 1
2.3 Cold Junction temperature to the measured thermoelectric emf and read
For measuring a temperature by means of a thermocouple, measuring point temperature to obtain the total thermoelectric
the cold junction temperature must be known. A cold junction emf.
at a temperature of 0 _C can be easily produced by melting ice. The cold junction can, however, also be implemented by
The use of thermostats with reference junction temperatures using a Pt100 RTD for determination of the actual temperature.
of 20 _C and 50 _C is also possible. Note that in these cases The temperature is referred to the calibration figure for 0_C by
certain corrections must be added to the calibration figures of electronic means. The electronic cold junction also avoids the
the particular thermocouple which are referred to 0 _C. To do temperature error due to the junction between the compensating
this, add the thermoelectric emf due to the cold junction leads and the copper leads.
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BHEL,Haridwar 2.1--8410--0004 / 2
Energy Sector 1010E
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Turbogenerators
Description Supervision of Generator
The arrangement of the measuring points and supervisory connected gastight to pipes from the low-level points of the
equipment at the generator is illustrated in the attached generator. See Fig. 2 and 3.
diagram.
J Temperature monitoring 1 2 3
J Stator liquid detection im Inneren des Generators
1 Temperature Monitoring
1.1 Stator Slot Temperature

The slot temperatures are measured with resistance
temperature detectors (RTDs). The platinum measuring wire
is embedded in a molded plastic body which provides for
insulation and pressure relief.
The RTDs are embedded directly in the stator slots
between the bottom and top bars at points where the highest 4 5
temperatures are expected.
The RTDs are characterized by a constant temperature vs.
1 Thread 4 Detectors
resistance characteristic, high mechanical strength and 2 Housing 5 Cable connection
insensitivity to electrical and magnetic fields. 3 Remove seal cup by turning
Fig. 2 Level Detector

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1 2
1 2 3 4 5 6 7 8
3
4
5
1 Resistance temperature detector 4 Bottom bar

2 Top bar 5 Stator core
9
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3 Separator
Fig. 1 Stator Slot Resistance Temperature Detector
10
1.2 Cold and Hot Gas Temperatures
The temperatures of the hot and cold gases are measured 11
by RTDs upstream and downstream of the hydrogen coolers.
The temperatures measured are provided to be used with the
hydrogen temperature control system and the generator
electronical equipment protection. 1 Liquid from stator frame, center
Temperature detectors located in the generator interior are 2 Liquid from terminal box, top
3 Liquid from cooling header, coolers C/D
mounted in gastight protective tubes welded to the stator 4 Liquid from cooling header, coolers A/B
frame. 5 Liquid from cooling header, center
6 Liquid from EE end winding, above hard-paper cover, top
7 Liquid from terminal box, bottom
1.3 Primary Water Temperatures 8 Liquid from EE end winding, above hard-paper cover, bottom
9 Shutoff valve upstream level detector
The temperature of the hot primary water in the drain water 10 Level detector
manifold of the stator winding is measured with resistance 11 Drain valve downstream level detector
temperature detectors. The temperature detectors are welded Fig. 3 Level Detector Rack
to the drain water manifold in protective tubes exposed to the Below the cooling header from where three pipes are
primary water temperature. routed to a shared level detector (see Items 3, 4 and 5 in
Fig. 3), sight glasses are installed in the pipes to enable the
identification and location of liquid in the cooling header.
Handhabung: OFFEN
One of the two pipes (Items 6 and 8 in Fig. 3), which are
2 Stator Liquid Detection used for detecting liquid above the hard-paper cover, is con-
nected a few centimeters above the other. The objective of this
Liquid (cooling water from hydrogen cooler or seal oil) approach is to ensure that liquid can only flow to the level de-
entering the generator housing is sensed by level detectors tector rack once it has reached a certain level. This pipe
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Energy Sector 0711E
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(Item 6 in Fig. 3) is routed via three level detectors which are generator protection system is activated.
connected in parallel. If two of the three detectors signal the in- The other level detectors only trigger alarms.
gress of liquid, the mechanical generator protection system is
activated.
One of the two pipes (Items 2 and 7 in Fig. 3), which are con- 3 Dew Point Temperatures Measuring Unit
nected to the terminal box, does not end flush with the inside
surface of the box but slightly protrudes into the interior. The A possible risk to the generator cannot be excluded when
objective of this approach is to ensure that liquid can only flow the temperature of the generator components reaches or
to the level detector rack through this pipe once it has reached even falls below the drew point temperature of the cooling air.
a certain level. This pipe (Item 2 in Fig. 3) is routed via three This condition can occur after a drop of the component
level detectors which are connected in parallel. If two of the temperature or a rise of the dew point temperature in response
three detectors signal the ingress of liquid, the mechanical to an increase un the relative humidity.
Siemens AG
BHEL,Haridwar 2.1--8420--0034 / 2
Energy Sector 0711E
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Turbogenerators
Supervision of Bearing Temperatures
Description
1 Generator Bearing Temperatures 1

The temperatures of all bearings are measured with
2
thermocouples located in the bearing lower halves. The actual
3
measuring point is located at the babbitt/sleeve interface.
Measurement and recording of the temperatures are
performed in conjunction with the turbine supervision. The
overall turbine protection is tripped when the maximum
permissible temperature is exceeded.
1 Rotor Shaft
2 Babbitt
3 Thermocouple
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4 Lower bearing sleeve
Fig. 1 Arrangement of Bearing Temperature Measuring Point

Copyright
Siemens AG
BHEL,Haridwar MKD &MDB 2.1--8440--0001
Energy Sector MKY 1008E
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Turbogenerators
Supervision of Seal Oil System
Description
The location of the transmitters of the measuring and Pressure Downstream of Standby Seal Oil Pump
supervisory equipment in the seal oil system is shown in the A pressure transmitter signals the takeover of the seal oil
Seal Oil Diagram(see 2.1--7111). supply by the standby seal oil pump.
The most essential measuring and supervisory devices in Local indication is provided for setting the pressure
the seal oil system are: regulator and for observation.
J Level detectors Seal Oil Pressure Downstream of Filter

J Pressure measuring devices At this pressure gauge the seal oil pressure downstream of
J Temperature measuring devices the filter can be observed.
J Volumetric flow rate measuring devices The pressure switch activates the standby seal oil pump,
if the set seal oil pressure is not reached.
1 Level Detectors
Within the seal oil system Seal Oil Pressures Upstream of TE and EE Shaft Seals
The readings are required for manual adjustment of the
J the oil levels in the TE and EE prechambers seal oil pressures. Pressure transmitters trigger alarm signals
J the oil level in the seal oil tank if the seal oil pressure drops below a specified low limit.
J the oil level in the seal oil storage tank
J the oil level in the intermediate oil tank Vacuum in Seal Oil Tank
This pressure transmitter signals a loss of vacuum.
are supervised.
A high oil level in the generator prechambers, due to an Dfferential Pressure Across Seal Oil Filter
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increase in the amount of seal oil on the hydrogen side of the This local indicator displays the degree of filter
shaft seal, results in an alarm. The alarm is initiated when the contamination on a dial (red/white) and activates an alarm at
probe is immersed in oil. a preset pressure differential.
A low oil level in the intermediate oil tank and in the seal oil
storage tank is monitored such that an alarm is activated when 3 Temperature Measuring Devices
the probe is no longer immersed in oil. The following temperatures are measured locally:
At high oil level in the seal oil tank, the vacuum pump is
stopped to prevent it from drawing seal oil. The alarm is J Seal oil temperature upstream and downstream of seal oil
activated when the probe is immersed in oil. coolers
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To prevent dry running of seal oil pumps 1 and 2 with low

oil level in the seal oil tank, a second probe is provided to stop In addition, the following temperatures are measured by
seal oil pumps 1 and 2 when the probe is no longer immersed means of resistance temperature detectors for remote
in oil. indication:
2 Pressure Measuring Devices J Seal oil temperature downstream of filter

The following pressure measuring points are provided: J Seal oil temperature in hydrogen side seal oil drain,
TE and EE.
Pressure Downstream of Seal Oil Pump 1
On failure of seal oil pump 1, a pressure transmitter 4 Volumetric Flow Rate Measuring Devices
activates seal oil pump 2. If the latter is not ready for operation, The following volumetric flow rate measuring points are
the standby seal oil pump is automatically started. provided:
Local indication is provided for setting the pressure
regulator and for observation. Volumetric Flow Rates for TE and EE Shaft Seals
The volumetric flow rate of the seal oil supplied to each
Pressure Downstream of Seal Oil Pump 2 shaft seal is indicated by a volumetric flow rate indicator
On failure of seal oil pump 2, a pressure transmitter upstream of the shaft seal.
activates seal oil pump 1. lf the latter is not ready for operation,
Volumetric Flow Rates for TE and EE Seal Ring Relief
the standby seal oil pump is automatically started.

Local indication is provided for setting the pressure The volumetric flow rate of the seal ring relief oil supplied
regulator and for observation. to each shaft seal is indicated by a volumetric flow rate
indicator upstream of the shaft seal.
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Energy Sector 0309E
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Turbogenerators
Supervision of Gas System
Description
The location of the transmitters of the measuring and 3 Pressure Measuring Points
supervisory equipment in the gas system is shown in the Gas
Diagram (see 24--2604--...). The following measuring points are provided:
The essential measuring and supervisory devices in the
gas system are: CO2 bottle pressure
The bottle pressure during CO2 filling can be observed at a
J Purity meter systems local pressure gauge.
J Volume flowmeter
H2 bottle pressure
J Pressure measuring points The bottle pressure can be read at the pressure gauge. The
J Temperature measuring points electrical signal of the pressure transmitter is used for
activating an alarm.
H2 pressure at pressure reducers

For observation of the pressure setting.
1 Gas Purity Meter System
H2 casing pressure
The H2 casing pressure is monitored with a local pressure
The gas purity meter system measures the purity of the gauge, the electrical signal of the pressure transmitter being
hydrogen gas in the generator as weIl as the composition of the used for remote control and supervision.
gas mixtures (CO2/air and H2/CO2) during filling of the
generator. The gas purity meter system is also used when H2 high pressure before central supply
All Rights Reserved
removing the hydrogen from the generator, where the The high pressure is monitored with a pressure transmitter
hydrogen is replaced with carbon dioxide and the carbon initiating a signal. In addition, a local indicator is used to monitor
dioxide in turn with air. The gas required for the measurement the H2 high pressure.
is taken from the generator or from the filling Iines, respectively,
Pressure in gas dryer chamber
and, on completion of the measurement, is discharged to the
The operation condition of the relevant gas dryer is

atmosphere through a vent line.
indicated by the local pressure gauges. If the gauge indicates
The flow gauge of the gas purity meter system is equipped
the H2-housing pressure, the gas dryer is in operation. If 0 bar
with a minimum limit switch which provides a signal to initiate
is indicated, this gas dryer is undergoing treatment or has been
an alarm when the volume flow drops below a preset value.
treated and is ready for operation.
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4 Temperature Measuring Points

2 Volume Flowmeter for Hydrogen
Within the gas system, temperature detectors are used for
supervision of the gas dryer.
The gas volume admitted to the generator from the central The temperature of the gas dryer heater is detected by
H2 supply is passed through a volume flowmeter. If the means of a thermostat and used for control functions. In
maximum value is exceeded within one hour, an alarm is addition, the temperature in the dryer is indicated locally by a
initiated. If the limit value is exceeded within 24 h, a solenoid thermometer.
valve is automatically closed. At the same time an alarm is A temperature detector installed in the vent line stops the
initiated. precess if a preset temperature value is reached.
MKY
Siemens AG
BHEL,Haridwar MKG &MDC 2.1--8460--0028
Energy Sector 0106E
0114E
Turbogenerators Gas Analyzer for the Detection
Description of Hydrogen Leakages
If an undue loss of hydrogen occurs on the generator or in For this reason, the second principle of measurement is
the gas system, the location of the leak must be determined by used in the lower concentration range.
means of a suitable gas analyzer. To do this, we recommend
the Type 634P Exotector gas analyzer and gas alarm unit
Catalytic Combustion Method
(product of Gesellschaft fr Gertebau mbH, Dortmund).
The combustible constituents of a gas-air mixture are
The Type G634P Exotector gas analyzer and gas alarm unit
ignited at a heated detector, the active catalyst. The resulting
is calibrated for hydrogen and has three ranges, i.e.:
temperature rise leads to a change in resistance. Together with
a reference catalyst, the active catalyst forms the arm of a
Range I: 0 -- 100 vol % H2
Wheatstone bridge circuit. The current flowing through the
Range II: 0 -- 4 vol % H2
bridge circuit is proportional to the gas concentration, with the
Range III: leak detection, approx. 0 -- 15 vol of
various gases and vapors exhibiting different characteristic
lower explosion limit of H2
curves. The signals measured are transmitted to the display
unit and to the alarm section via an amplifier.
The Exotector instrument has been tested for explosion
protection by the BVS-Institut fr Explosionsschutz und
Sprengtechnik (Institute for Explosion Protection and Blasting
1
Technology). The following type of protection has been
approved: 10
2
(EX) i, s G5 Approval No.: T 6725 9

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The Exotector is a portable instrument containing a

8
rechargeable battery (2 Ah/3.6 V). A fully charged battery is
sufficient for approximately 16 hours of continuous operation 3
in the diffusion mode. If the pump is in service as well or if an
7
alarm is activated the power consumption will be higher, result-

4
ing in a shorter useful service period.
When using a special charger, the Exotector battery can be
charged and put into float service so that the instrument is
always ready for operation.
6 5
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To ensure sufficient accuracy of the results for all three mea-

suring ranges, the Exotector instrument uses two different op-
erating principles, i.e.
J thermal conductivity (range II) and

J catalytic combustion (ranges I and III).
Thermal Conductivity Method 1 Suction nozzle 6 Charging socket

2 Diffusion area 7 Zero adjustment
The gas absorbs the heat loss of a heated platinum wire. 3 Pump 8 Analog indication
The heat loss causes a change in resistance, resulting in 4 Battery check 9 Function display
5 Range selector 10 Visual alarm
unbalancing of a bridge circuit. Since no combustion takes
Fig. 1 Gas Analyzer and Alarm Unit
place, the principle of measurement can also be used when
oxygen is not present or only in very low concentrations. The
conductivity of the various gases is known, and the instrument The suction nozzle of the Exotector should be led over the
can be calibrated accordingly. The thermal conductivity surface of the test object as slowly as possible. Note that the
method lacks accuracy in the lower concentration range and leak detection should be carried out above the object because
may lead to fabrified results. the leakage has (hydrogen) is lighter than air.
Siemens AG
Energy Sector 1008E
0114E
Turbogenerators Primary Water System
Description Supervision
The Primary Water Diagram shows the location of the trans- 4 Pressure Gauges
mitters of the measuring and supervisory equipment for the Pressure levels and differential pressure levels in the
primary water system. primary water system are measured at the following locations:
The main measuring and supervisory systems and instru-
ments in the primary water system are as follows: J Downstream of primary water pump 1
J Downstream of primary water pump 2.
J Conductivity meter system
J Level monitoring system The two pressure measuring points are equipped with
J Volume flowmeter system pressure switches, and are required for the automatic control
J Pressure gauges of the primary water pumps.
J Temperature detectors. In addition, a pressure gauge is provided downstream of
each pump to allow the pressure to be monitored locally.
J Pressure upstream of the stator winding.

1 Conductivity Meter System
The conductivity of the primary water system is monitored
This measuring point is equipped with a pressure switch
J Upstream of the primary water inlet of the generator. and a local pressure gauge. If the primary water system
pressure exceeds a specified maximum level, the pressure
This measuring point allows the conductivity of the entire switch activates an alarm.
primary cooling water to be monitored. The pressure gauge is used for monitoring the pressure
locally.
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The conductivity meter system is provided with an alarm

function.
J Differential pressure across the stator winding.
The differential pressure gauge is used to monitor the

2 Level Monitoring System pressure drop across the stator winding.

The coolant level in the primary water tank is indicated by
a local water-level indicator. J Differential pressure across the main filter
An alarm is triggered if the coolant drops below a specified J Differential pressure across the fine filter.
minimum level.
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The degree of filter fouling is displayed on a scale. In addi-

tion, contacts are provided which activate an alarm at specified
3 Volume Flowmeter System differential pressure levels.
The primary water flow through the
5 Temperature Detectors
J Stator winding Temperature detectors are used to measure the primary
cooling water system temperature at the following locations:
is measured and indicated using an eddy-current flowmeter
system. If the flow drops below a specified minimum rate, an J Downstream of the coolers.
alarm is activated. If the flow rate continues to drop, the elec-
tronic generator protection is tripped. Resistance temperature detectors (RTDs) are used to
The amount of primary water flowing through the primary measure the primary cooling water system temperatures at the
water tank is measured using a local flowmeter. If the flow following locations for further conditioning according to
drops below a specified minimum rate, an alarm is activated. different methods:
The amount of makeup water added to the primary water
system during operation is determined by means of a flow- J Downstream of the coolers
meter. J Downstream of the stator winding.
MKY
Siemens
BHEL,Haridwar AG MKF &MDB 2.1--8470--0008
Energy Sector 0708E
0114E
Turbogenerators Preparations for Startup
Operation Introduction
lt is a prerequisite for startup of the turbine-generator that 1.2.2 Hydrogen (H2)

continuous contacts be maintained between all plant sections The hydrogen gas quantity to be provided shall be sufficient
directly or indirectly involved in the startup procedure. for displacing the CO2, for filling the generator to operating
Prior to startup, it should be ensured that the following pressure and to compensate for the H2 losses during
auxiliaries are in operation and will continue to remain in operation (see also 2.1--1625, Gas Quantities).
service:
J Seal oil system 1.2.3 Nitrogen (N2)

J Gas system For primary water purging (see also 2.1--1625, Gas
J Primary water system Quantities).
J Cooling water supply
lf auxiliaries were taken out of operation, the operating 1.3 Primary Water Supply
fluids required to fill the auxiliary systems should be made The water quantitiy to be provided for filling the entire
available. primary water system shall amount to approximately two times
the primary water filling quantity. This allows for the water
quantity required for flushing the primary water system.
1 Operating Fluids
1.4 Cooling Water Supply
The operating fluids used, i.e. The coolers to be placed in operation shall be filled with
All Rights Reserved
water. To do this, the cooler vents shall be opened.

J Turbine oil NOTE:
J Carbon dioxide (CO2) Continuous vents shall remain open. The vents
J Hydrogen (H2) shall be kept open until the air on the water side
J Nitrogen (N2) of the coolers has been completely expelled.

J Primary water
Before startup, the operating staff shall ensure that a
sufficient supply of cooling water is available.
shall conform to the specifications (see also 2.1--1680, Tur-
bine Oil Specification; 2.1--1639--..../1, Primary Water Specifi-
Copyright
cation; 2.1--1640, Gas Specification).

2 Checking the Transmitters
1.1 Seal Oil System Prior to startup, all connections shall be rechecked. This
The seal oil systems is filled with turbine oil. The quantity of applies to piping as weIl as to cabling. When checking the
turbine oil required to fill the seal oil systems all be taken into cabling, special attention shall be paid to testing the instrument
consideration when filling the turbine oil tank. and signal cables. All alarm systems shall be checked.
All temperature measuring points shall also be checked.
1.2 Gas System This applies to temperature detectors with local and remote
1.2.1 Carbon Dioxide (CO2) indication. Unless temperature rises were brought about by
The carbon dioxide quantity to be provided shall be other preparatory work at the measuring points, temperatures
sufficient for two complete generator fillings (see also of approximately ambient or room temperature should be
2.1--1625, Gas Quantities), i e. for displacement of the air prior indicated. Where doubts exist regarding the electrical
to hydrogen filling and for immediate removal of the hydrogen temperature measurement, calibration and line
from the generator. compensation shall be repeated.
MKA
Siemens AG
BHEL,Haridwar MKF &MDC 2.3--5000--0002
Energy Sector 0806E
0114E
MKG
MKW
Turbogenerators
Hints for Cooler Operation
Operation
1 General example, by flushing the system without passing water

The heat exchangers of the generator and its auxiliaries through the coolers.
have copper, copper alloy or stainless steel tubes or plates. When using water directly obtained from natural water
Admiralty brass (CuZn28Sn) is primarily used for fresh-water sources, adverse influences should be minimized by suitable
applications, while aluminium brass (CuZn20Al) is selected for treatment procedures (e.g. filtration, dispersant dosing,
seawater service. chlorination and similar methods as specified in the literature).
Copper and copper alloy tubes must form a protective film
on the cooling water side to ensure adequate resistance to 4 Initial Operation of Coolers
corrosion attack. The formation and the preservation of the Prior to placing the coolers in operation for the first time, the
protective film are essentially dependent on the conditions cooling water system should be thoroughly cleaned by
during initial commissioning and subsequent service. flushing to remove impurities and foreign matter.
During this flushing procedure, the coolers should not be in
2 Cooler Tube Materials service on their cooling water sides, i.e. bypass arrangements
The coolers of the unit described have copper or copper must ensure that the flushing procedure can be carried out
alloy tubes. without passing water through the coolers. Following the
Details of the cooler tube materials are specified in the flushing procedure, cooling water must be continuously
Technical Data section of this manual (see Section 2.1--1620). passed through coolers with copper alloy materials for the
longest possible period of time (four to eight weeks) to ensure
the formation of an effective protective film on the cooler tubes.
2.1 Copper or Copper Alloy Cooler Tubes
Influences on the cooling water side can cause damage to
5 Preventing Standstill Corrosion
the copper or copper alloy tubes of the coolers, primarily in the
Depending on the cooler material and the kind and

form of erosion/corrosion and corrosion attack due to
properties of the cooling water, standby coolers through which
no cooling water flows for some period of time are subjected
J insufficient protective film formation
to all corrosive influences that can occur during an outage.
J excessive cooling water velocity
This involves the risk that the micro-organisms on the tube
J localized, excessive cooling water velocity resulting from
walls will die due to the lack of oxygen resulting from the loss
tube blockage by foreign bodies
of fresh water supply and form decay products during
J deposits on tubes caused by suspended material and/or
decomposition, such as ammonia. Depending on the material
remnants of micro-organisms which impair the formation of
used, this may lead to corrosion and/or stress corrosion
a protective film and promote corrosion, especially in
cracking.
(standby) coolers having no cooling water flow for some
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Corrosion damage can only be safely prevented if the

time.
standby coolers are drained on their water sides, cleaned,
completely dried, vented, and maintained in a dry condition.
2.2 Stainless Steel Heat Exchanger Tubes and Plates For cleaning, the coolers may be flushed with water having
Stainless steel heat exchanger tubes and plates are a low salt content (Cl content < 500 mg/l).
susceptible to pitting and crevice corrosion under deposits, For drying, the medium to be cooled can be passed through
especially when the cooling water has a high salt content and the coolers via the filler and vent pipes. However, this measure
primarily when no cooling water is passed through the cannot be always implemented in practice, especially in the
(standby) coolers for some time. The corrosion rate decreases case of brief outages and because of the need to maintain the
with increasing cooling water velocity. cooler ready for operation.
lf a cooler has to be maintained ready for service in filled
3 Cooling Water Properties condition (wet preservation), it should be flushed with the full
The cooling water used for the coolers must meet the cooling water volume flow for a brief period twice every week.
following requirements: In addition, it is recommended to perform a cooler changeover
once every week so that the normal-service cooler and the
J The cooling water must be free from coarse impurities. standby cooler will be alternately in operation.
J The amount of suspended material must be as small as
possible. 6 Preventing Deposits in Cooler Tubes
J The growth of micro-organisms and, in case of seawater Deposits in the cooler tubes are best prevented by
installations, the growth of mussels must be prevented. supplying the normal-service coolers with the full cooling water
volume flow.
Cooling water obtained from a closed secondary cooling lf the temperature of the medium to be cooled is controlled
water circuit mostly meets these requirements provided that by varying the cooling water volume flow, it is recommended
the necessary care is exercised during initial operation, for to supply the normal-service cooler with the full cooling water
Siemens AG
Energy Sector 0210E
0114E
volume for a brief period twice every week in order to flush 8 Cooler Changeover
away any deposits formed on the tubes due to insufficient Make sure to fill and vent standby coolers on their water
cooling water velocity. sides prior to changing over the coolers. Fully open shutoff
During occasional outages of sufficient duration or during valves. After cooler changeover, which must be performed by
an overhaul it should then be checked whether in-service experienced personnel, perform all measures required for
flushing is sufficient or whether manual clearing is required. If preservation of the cooler removed from normal service and
frequent manual cleaning is necessary on account of poor now on standby.
cooling water conditions, the installation of a high-velocity To do this, close shutoff valves upstream and downstream
water cleaning system or of a cleaning system using sponge of the standby cooler, since the cooling water system is mostly
rubber balls should be considered. designed only for supply of the cooling water flow through the
normal-service cooler(s). Then open the shutoff valve on the
7 Special Measures for Wet Preservation
outlet side by a small amount to avoid the effects of a water
lf a cooler has to be maintained ready for service in filled
expansion due to water heating.
condition, the water volume in the cooler must not be
A cooler changeover is necessary when, with the valves in
hermetically sealed from the cooling water system or from the
the cooling water circuit fully open, the temperature of the
surrounding atmosphere, respectively. Improper cooler
medium to be cooled is rising above the normal level or when
changeover would then result in heating and excessive
required on account of abnormal events (e.g. leakage).
expansion of the cooling water volume, leading to damage to
the cooler, gaskets or piping due to excessive pressure.
For wet preservation, always open a cooler vent on the
water side or a shutoff valve by a small amount, making sure
to avoid a low-velocity water flow that would promote the entry
of suspended material.
NOTE:
Standby coolers should be maintained ready
for operation in dry condition in preference to
wet preservation.
Siemens AG
BHEL,Haridwar 2.3--5003--0006 / 2
Energy Sector 0210E
0114E
Turbogenerators Turning Gear Operation and
Description Runup of Generator
1 General control element for the cooling water downstream of the

The generator should be operated on the turning gear and primary water coolers.
brought up to speed in accordance with the turbine startup
diagrams. 4 Runup
During runup to rated speed, the bearing oil inlet
2 Turning Gear Operation temperature should not be less than 35 qC but not higher than
Prior to operating the generator on the turning gear, the 45 qC. The oil inlet temperature at the shaft seals should not be
shaft lift oil pump and the bearing oil system must be started up. less than 38 qC.
The seal oil system for lubrication and sealing of the shaft
seals and the primary water system must be placed into
operation. CAUTION
The oil flow to the bearings and shaft seals should be
Do not run up generator to rated speed and voltage as long
checked prior to turning gear operation to ensure an adequate
as generator casing pressure is not at rated value.
flow. In addition, drains should be inspected for proper
operation. During runup, the critical speed ranges should be passed
NOTE: through quickly and at a uniform rate.
The generator may be filled with hydrogen prior Balancing quality depends on several factors. Even
to or during turning gear operation provided temperature differences of 1--2 K between opposite sides of
that leakage tests have been performed and the the rotor may result in rotor distortion which could lead to
seal oil system is in operation. inadmissible vibrations due to unbalance.
During runup, the bearing and oil temperatures should be
All Rights Reserved
3 Generator Cooling Gas Temperatures read and recorded at short intervals.

The hydrogen coolers should be placed into service on their To prevent these thermal unbalances during runup, the
cooling water sides as soon as the generator is filled with turbine-generator should be run on the turning gear. If the
hydrogen and on turning gear. The H2 coolant temperature generator is run up following prolonged turning gear operation,
control system should be changed over from the Automatic to no restriction regarding the rate of runup need be observed
the Manual mode. Use manual mode to adjust a cooling water other than those required for the turbine.
volume flow through the hydrogen coolers of approximately 5
to 10 % of the nominal flow rate. 5 Generator Air Operation
This causes the moisture contained in the gas to be Besides the above operating conditions, it may be
removed by condensation on the cooler tubes and fins. necessary in certain cases to operate the generator without
Copyright
The cooling water volume flow through the hydrogen hydrogen, i.e. during initial runup of the unit to check the
coolers should not be increased as long as the H2 cold gas bearings and vibrations and for clean-up. In view of the high
temperature ist not at rated value. windage losses and the resulting high temperature rise of the
During runup, the cooling water volume flow through the air such air operation is only permissible for brief periods and
hydrogen coolers should be increased by manual adjustment only with generator non-excited.
to maintain the cold gas temperature at lest 5 K below the The cold air temperature downstream of the coolers should
primary water inlet temperature. Changing over the H2 coolant not exceed 40 qC. At higher cold air temperatures, the
temperature control system from the Manual to the Automatic hydrogen coolers should be placed into service.
mode is permissible as soon as the primary water temperature During generator air operation, the supply of seal oil to the
control system, set for the automatic mode, opens the final shaft seals must be ensured as well.
Siemens AG
BHEL,Haridwar MK &MDC 2.3--8010--0012
Energy Sector 0210E
0114E
Turbogenerators
Simplified Generator Startup Procedure
Operation
Speed
Command: Generator startup Condition
in %
Vapor exhausters in operation
Primary water supply in operation
Primary water flow rates set (see also 2.1--1634, Operating and Setting Values)
Primary water cooler, cooling-water side in operation and vented
Primary water temperature control in operation
Seal oil system in operation
Seal oil inlet temperature 38 to 42 _C (100 to 108 _F)
Gas system in operation
0
Generator hydrogen pressure p = 0.3 bar below rated gas pressure
Hydrogen purity 95 %
Gas dryer ready for operation
Measuring and supervisory equipment apply power
Hydrogen coolers activate on, cooling-water side
H2 temperature control set to Manaul
Cooling water flow rate 5...10% at rated flow (manual control)
Automatic voltage regulator ready for operation
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Speed
Command: Generator runup Condition
in %
0 Frequency converter (Turning gear)

apply power (see steam turbine manual)
2 Steam turbine
disconnect power
Frequency converter (Turning gear)
(see steam turbinemanual)
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16.6 Bearing vibrations

normal
Bearing metal temperatures
Seal oil temperature normal
Temperature difference between cold H2 gas and
5K
cold primary water
90 H2 temperatur control set to Automatic

Excitation in operation
Setpoint for rated voltage set to 100 %
Speed
Synchronizing, paralleling and loading Condition
in %
Synchronizing and paralleling see MKC/MKY manual
100 to required load, but within the limits of the capability
Loading
curve
NOTE:
The above tables list the main startup criteria for the turbogenerator.
Siemens AG
Energy Sector 0210E
0114E
Startup
Turbogenerators
Voltage Regulation With Automatic Control
Operation
Static Excitation System
Startup and synchronizing The turbine-generator is at standstill or on turning gear. The

1 Voltage regulator is on Auto (Auto signal lamp on), or
of generator
Manual (Manual signal lamp on).
The Excitation is Off (state is indicated by a signal lamp).
2
Preparatory work
2.1
Set voltage regulator on Auto If the voltage regulator is on Manual, press the Auto
pushbutton; observe the signal lamps for Manual and Auto.
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2.2
Raise speed to 90 % of rated value Follow turbine operating instructions.
3
Excite generator Excite the generator using the Excitation On pushbutton.
Observe the corresponding signal lamps and the instrument
for the generator voltage. This signal is interlocked via a speed
limit value and blocked by faults of the Excitation equipment.
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NOTE:
Excitation On command is blocked if the exci-
tation equipment is impaired by a fault.
4
Raise speed to rated value
5
Synchronize Observe the operating instructions for automatic
synchronization.
Switch on synchronizer by synchro selector at
approximately rated voltage and rated speed.
After pressing the synchronizer startbuttons, the voltage
and frequency balancing device matches the generator
voltage and frequency, and the synchronizer gives a closing
signal to the generator circuit breaker.

If manual synchronization is also possible, the permissible
synchronizing criteria in accordance with diagram
no. 2.1--1617--0001 have to be considered.
After synchronizing the generator is loaded.
Siemens AG
BHEL,Haridwar MKC &MDC 2.3--8030--0021
Energy Sector 0806E
0114E
On-Load Running
Turbogenerators
Operation
Loading of generator with

1
active and reactive power
2
Loading Follow turbine operating instructions.
2.1
Set active power The active power is changed by adjustment of the turbine
controller.
2.2
Set reactive power The reactive power controller can be activated externally,
but only if automatic mode is selected, meaning that the
generator voltage controller is active, and the generator is
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connected to the grid.

Under reactive power control, in response to deviation bet-
ween the reactive power setpoint and actual value, the generator
voltage is varied within a maximum range of 95--105 % until the
set reactive power setpoint is reached. Control action is
implemented by Higher and Lower commands (via Profibus)

to the generator voltage reference value setter.
The reactive power controller is deactivated by:

J Switching OFF command from OM-System
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J Switching back to automatic mode (generator voltage

controller)
J Switching to manual mode (excitation current controller)
J Activation of the zero power adjustment function
If the generator is no-load, automatic switchover to

automatic voltage controller takes place.
To give bumpless switchover between the various
operating modes, automatic tracking is implemented.
Siemens AG
Energy Sector 0209E
0114E
On-Load Running
Turbogenerators Changeover of Automatic Voltage Regulator
Operation from Automatic to Manual
Changeover from A follow-up control tracks the Manual setpoint adjuster so

1 that a changeover does not vary the excitation current
Auto to Manual
substantially.
2
Changeover to Manual Because of the Automatic follow-up control a balancing
instrument is not provided.
Press the Manual pushbutton. Monitor Manual/Auto
signal lamps and generator voltage and/or reactive power.
3
Continue on-load running
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Copyright
Siemens AG
BHEL,Haridwar MKB &MDC 2.3--8150--0021
Energy Sector 0709E
0114E
On-Load Running
Turbogenerators Changeover of Automatic Voltage Regulator
Operation from Manual to Automatic
Changeover from A follow-up control tracks the Auto setpoint adjuster so that
1 a changeover does not vary the excitation substantially.
Manual to Auto
2
Changeover to Auto If the voltage regulator is on Manual, press the Auto push-
button and monitor the signal lamps for Manual and Auto.
3
Continue on-load running
e Siemens AG 2009
Copyright
BHEL,Haridwar
Siemens AG MKC &MDC 2.3--8160--0019
Energy Sector 0709E
0114E
Turbogenerators
Generator Load Limits
Operation
1 Load Limits to be operated at reduced load in order to avoid damage to the

unit. The following restrictions should be observed for the
For the permissible generator loading, refer to the reactive conditions indicated:
capability curve (see Section 2.1--1611).
The following conditions are required: 4.1 Operation With Hydrogen Coolers Out of Service
If one of the four hydrogen cooler sections is out of service,
J Primary water cooling system is fully operational. operation of the generator is permissible at not more than 75 %
J Generator is filled with hydrogen at the rated pressure and of rated load.
all four hydrogen cooler sections are in operation Operation at reduced load is only possible if the following
J Generator is operated at rated frequency. conditions are the filled:
J Generator is operated at rated voltage.
J The primary water cooling system of the generator is fully
Any desired load setting is possible within the limits of the operational.
reactive capability curve provided the load is not increased J The dew point temperature of the hydrogen atmosphere in
beyond the specified limit. the generator is sufficiently below the cold gas tem-
Load operation for long periods of time at reduced H2 perature.
pressure is not allowed if the primary water pressure in the
stator winding exceed the H2 casing pressure. Any leak in the The condition is normally obtained by drying the closed
primary water system inside the generator could lead to water generator with the gas drying system for not less than four
coming into contact with high-voltage components and thus to weeks, with no leak developing in the generator interior during
a catastrophic failure due to short-circuiting. this period.

NOTE:
The transmitters for the hydrogen temperature
2 Rate of Loading control are located downstream of coolers a/b
and c/d (max. value selection).
During operation, load variation is permissible within the
e Siemens AG 2010
limits of the reactive capability curve. The permissible rate of 4.2 Deviation from Rated Hydrogen Pressure
loading depends on the condition of the winding insulation. lf the hydrogen pressure cannot be maintained at the spe-
Generators with a Micalastic stator winding insulation and a cified level due to e.g. gas loss or insufficient gas supply (see
rotor winding of silver-alloyed copper with glass laminate Section 2.1--1607) and has dropped 0.3 bar (30 kPa) below the
specified operating pressure, the generator load must be re-
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insulation can be suddenly loaded and unloaded if an auto-

matic coolant system is provided and fully operational. The duced to 85 % (see Section 2.3--9640).
actual rate of loading should be matched to the permissible Trace and eliminate the cause of the pressure loss.
limits of the turbine.
4.2.1 Operation With Primary Water Cooler Out of
Service
3 Unbalanced Load If one of the two primary water coolers is out of service, op-
eration of the unit is permissible at no more than 70 % of rated
The continuously permissible unbalanced load as speci- load. Operation at reduced load is, however, only possible if
fied (see Section 2.1--1614) must not be exceeded under any the gas cooling system of the generator is fully operational.
operating condition. Unbalanced load is defined as the ratio of
negative sequence current to rated current, with the rated cur- 4.3 Loss of Primary Water Supply
rent not being exceeded in any of the three phases. The rated If loss of primary water supply occurs, the generator is dis-
stator current is also specified in Section 2.1--1614. connected from the system by the mechanical equipment
protection and de-excited. Operation of the generator fol-
lowing the loss of the primary water system is not permissible.
4.4 Deviation of Rated Voltage and Rated Frequency

4 Load Restrictions
Loading of the generator with deviation from the rated
generator voltage and/or frequency is only permissible up to

During the service life of the generator, operating condi-
the limits shown in Section 2.1--1612.
tions may arise at the generator which require the generator
Siemens
BHEL,Haridwar AG MK &MDC 2.3--8170--0050
Energy Sector 0210E
0114E
Turbogenerators
Shutdown of Generator
Operation
1 General without interruption until the rotor has cooled down to nearly
During shutdown of the generator, the shaft lift oil pump room temperature.
must be started as soon as the unit reaches the speed
specified in the Turbine Instruction Manual. 3 Coolers
When the generator is on the turning gear, the hydrogen
coolers remain active for 15 hours. The purpose of this
approach is to ensure that the moisture contained in the gas
2 Turning Gear Operation condenses on the cooler tubes and fins.
To prevent any difficulties during a subsequent runup due
to thermal unbalances and resulting rotor distortion, the 4 Gas Dryer Circulating Fan
turning gear must be started as soon as the turbine-generator Below the turning gear operation automatically the
coasts down to the speed (turning gear speed) specified for circulating fan downstream the gas dryer is connected.
the turbine (normally automatic) and maintained in operation Thereby the gas dryer remains further in operation.
All Rights Reserved
Copyright
Siemens AG
Energy Sector 0114E
0610E
Turbogenerators
Generator Shutdown Diagram
Operation
Actual Condition
1 Command: Unload generator
Generator load SN < 0,05 SN
D
Generator main circuit breaker automatic trip through reverse-power protection
D
Speed approximately 90 %
D
Excitation field circuit breaker tripped
D
Turning gear operation see Turbine Instruction Manual
D
Hydrogen coolers in service with reduced flow (approx.10% of nominal flow)
All Rights Reserved
D
Seal oil system in operation
D
Gas system in operation

D
Primary water system in operation

D
Copyright
Speed n = 0 s --1; at room temperature

D
Shutdown procedures completed

D
Siemens
Energy Sector 0709E
0114E
Unloading and Shutdown
Turbogenerators
Operation
Unloading and shutdown The generator is synchronized.

1
of generator
2
Unloading Follow turbine operating instructions.
2.1
Remove active power The active power is changed by adjustment of the turbine
controller.
2.2
All Rights Reserved
Remove reactive power Reduce reactive power uniformly together with active
power:
J Under reactive power control, in response to deviation bet-

ween the reactive power setpoint and actual value, the gener-
ator voltage is varied within a maximum range of 95--105 %

until the set reactive power setpoint is reached. Control ac-
tion is implemented by Higher and Lower commands (via
Profibus) to the generator voltage reference value setter.
Copyright
3
Main circuit breaker off
4
Shutdown The Excitation Off command is automatically given after
the main circuit breaker is open.
Siemens AG
Energy Sector 0806E
0114E
Turbogenerators Supervision of Generator During Standstill
Operation General
1 Generator at Standstill with Seal Oil, Gas 2 Generator at Standstill with Seal Oil, Gas
and Primary Water Systems in Operation and Primary Water Systems Out of Operation
Due to operational conditions, it may become necessary to Preservation measures will have to be taken when the
shut down the generator for a short period. When the unit is at generator is to be shut down for a period exceeding two
standstill, the bearing oil system can be taken out of service. months with the seal oil, gas and primary water systems to be
In the absence of any operational needs, e.g. inspection or taken out of operation. The scope of the preservation work
faults on generator, the primary water and hydrogen should required depends on the duration of the shutdown, on the
remain in the generator in order to retain the most favorable overall conditions in the vicinity of the unit and the extent to
prerequisites for a dry condition. All observations required for which checks an inspections are possible during such period.
a generator partly taken into service should be performed, After the hydrogen has been removed from the generator
such observations being essentially limited to the seal oil, gas by purging with Inert gas (CO2 or Argon), and the generator is
and primary water systems. depressized and filled with air, it is recommended that the
Normally it can be assumed that the generator was generator be opend by removing two manhole covers and to
operated with the gas dryer during the preceding service connect a dryer or hot air blower for continuous drying or
period. The generator interior will thus be in a dry condition circulation of the air in the generator. Care should be taken to
provided that the cooling gas was not replaced. ensure that this equipment is connected in such a way that a
Special measures should be taken to prevent corrosion circulation through the entire generator interior will be
damage to the tubes of the coolers during idle periods. During accomplished.
a brief outage, the coolers should be supplied with a small The hydrogen, primary water and seal oil coolers should be
cooling water flow. In addition, the coolers should be flushed drained on their cooling water sides and dried by suitable
All Rights Reserved
with the full cooling water flow at least twice weekly. measures.
In the case of prolonged outages, the coolers should be These measures are intended to prevent any condensation
drained on their cooling water sides and dried. in the generator interior even under varying environmental
conditions.
The sliprings should be cleaned at shutdowns, if required,
preferably using clean brushes and dry linen cloths leaving no

fluff. It may be necessary to dress the sliprings by means of
polishing cloth. At such occasional inspections, the slipring
grooves should be checked for the formation of burrs which
would accelerate the brush wear. Such burrs should be
Copyright
removed by breaking the edges. Polishing over the sliprings

and careful removal of the metal dust will be required after-
wards.
The preservation measures should be implemented and
abolished by Siemens Power Generation product service
personnel.
Siemens
Energy Sector 0709E
0114E
Turbogenerators Supervision of Generator During Standstill
Operation Slipring Assembly
1 Carbon Brushes
Hose
Removing the plug-in brush holders during a brief outage
(< 2 days) is not required. In the case of a prolonged outage
(> 2 days), it is, however, recommended to remove the plug-in
brush holders to prevent the formation of rust between the
slipring and the carbon brushes. After removal of the plug-in
brush holders, check the carbon brushes for breakage and for
reduction in brush length due to wear (see also 2.1--1609,
Mechanical Data).
2 Hose
For brief outages it is also recommended that the hose
between the fan casing and the labyrinth ring of the slipring
bearing compartment be disconnected, cleaned with com-
pressed air and then be reconnected.
The purpose of this measure is to remove any dirt which
could act as electrical conductor between the insulated
bearing compartment and the fan casing.
Fig. 1 Arrangement of Hose Between Fan Casing

and Bearing Compartment
All Rights Reserved
Copyright
Siemens AG
Energy Sector 0901E
0114E
Turbogenerators Fault Tracing
Trouble-Shooting General
The details given herein on faults, their possible causes and can be taken in accordance with the following instructions, the
the corrective measures cannot be considered complete in turbine-generator should be shut down and the hydrogen
every respect, since all possible troubles cannot be covered in should be replaced with inertgas. If required, the services of the
advance. In most cases, the operator will have to decide on the manufacturer should be requested. In most cases, however,
measures to be taken. The individual measures required sufficient details will be found in the Turbogenerator Manual.
depend on the mode of operation. Unless corrective measures
All Rights Reserved
Copyright
BHEL,Haridwar
Energy Sector 0808E
0114E
Trouble-Shooting Stator and Generator Supervisory Equipment
Fault/Cause Remedy
Differences in slot temperatures between individual

stator phase windings
The embedded RTDs should be checked when different
slot temperatures are indicated while stator currents are of
equal magnitude in all the three phases. Such a check should
only be made with the generator at standstill and in non-excited
condition. The check should include resistance measure-
ments as well as testing of the detector leads, the measuring
point selector switches and the indicators. Care should be ta-
ken during resistance measurements of the embedded RTDs
to ensure that they are not heated as this will distort the results.
In many cases, a fault can be cleared by recalibration of the
RTDs.
High hot gas temperature

and/or
All Rights Reserved
High cold gas temperature

NOTE:
If the cold gas temperature continues to rise,
the mechanical equipment protection system
is tripped.
J Faulty hydrogen temperature control. Insufficient cooling Verify cause of fault by checking analog indicators (uniform
water flow volume through hydrogen coolers. rise of temperatures in all coolers). See 2.3--9280 for remedial
action.
Copyright
J Insufficient cooling water volume flow through a single Verify cause of fault by checking analog indicators (uniform
hydrogen cooler. rise of temperatures at one coolers).
Check positions of cooling water valves at the
corresponding cooler. Check to ensure that the cooling water
inlet valve is fully open. Lower cold gas temperature of
defective cooler by adjusting the cooling water volume flow
with the cooling water outlet valve. Ensure that cold gas
temperatures downstream all hydrogen coolers are equal.
Unbalanced load due to unequal phase loading of the

system connected to generator
If the generator is operated with unbalanced load due to
particular system conditions, care must be taken that the
continuously permissible unbalanced load is not exceeded
(see also 2.1--1607). The unbalanced load is defined as the
ratio of negative sequence current to rated current. The
permissible rated stator current should not be exceeded in any

stator phase. When the unbalanced load is higher than the
continuously permissible unbalanced load, steps should be
taken for bringing about a uniform system load. The generator
should be shut down if it is impossible to distribute the system
load more uniformly over the three phases.
Siemens AG
BHEL,Haridwar MKA &MDC 2.3--9200--0031 / 1
Energy Sector 0114E
0710E
Fault/Cause Remedy
Liquid in generator
NOTE:
If two of the three parallel-connected liquid de-
tectors (see Fig. 1, Item 1) signal the ingress of
liquid, the mechanical equipment protection is tripped.
The liquid in the generator casing should be inspected to

determine its origin, i.e. defective hydrogen cooler section, oil
from shaft seals, primary water or condensate.
DANGER
Fire and explosion hazard due to escaping hydrogen gas.
The pipes of the liquid detector rack are H2-filled and
under pressure.
To prevent H2 leaks, close the shutoff valves before the
level detectors before draining the liquid.
To do this
J Close shutoff valve(s) upstream of level detector which
activated the alarm.
J Remove drain plug from drain valve downstream of the
corresponding level detector.
J Drain the liquid via the drain valve and inspect liquid.
J Then close drain valve and reopen shutoff valve upstream
of level detector.
J Repeat this procedure until no liquid is discharged from the
drain valve.
J Close drain valve downstream of the level detector and
open shutoff valve upstream of level detector. Insert and
tighten drain plug to seal the system (gastight).
1 2 3 4 5 6 7 8
10
11
1 Liquid from stator frame, center

2 Liquid from terminal box, top
4 Liquid from cooling header, coolers A/B
5 Liquid from cooling header, center
8 Liquid from EE end winding, above hard-paper cover, bottom
10 Level detector
11 Drain valve downstream level detector
Fig. 1 Level Detector Rack
If the liquid cannot be drained from the generator in this

manner within a reasonable period of time, which will be the
case in the event of major leaks, the generator should be shut
down immediately.
Siemens AG
BHEL,Haridwar 2.3--9200--0031 / 2
Energy Sector 0710E
0114E
Fault/Cause Remedy
J Moisture condensate Very small water quantities are indicative of condensate.

Place gas dryer in operation.
A hydrogen sample should be extracted from the generator
and examined in a laboratory to determine its moisture
content.
J Cooling water from a defective hydrogen cooler Lager amounts of water point to a leaking cooler section.
Identify defective cooler section. Reduce generator load
(see also 2.3--8170) and take cooler section out of service by
closing the shutoff valves. Than take measures outlined in the
corresponding instructions (see also 2.3--9440).
J Primary water Since the primary water pressure is lower than the H2
casing pressure during generator operation at rated hydrogen
pressure, liquid accumulation in the generator can only occur
in case of a major leak (tube failure, burst Teflon hose). The
leakage water quantities require, however, a shutdown of the
turbine-generator.
As soon as the generator has been disconnected from the
system and is de-excited, take primary water pumps out of
service and close control valve upstream of the stator winding
and bushings. Remove hydrogen from the generator
immediately and fill with inert gas. Fault tracing and corrective
action may be started as soon as the generator is filled with air
at atmospheric pressure.
J Oil Oil level control in seal oil tank is faulty.

Prechambers in generator are overflowing.
Take corrective actions as described in (see also 2.3--9561)
immediately.
Siemens AG
BHEL,Haridwar 2.3--9200--0031 / 3
Energy Sector 0710E
0114E
Operation Rotor
Fault/Cause Remedy
Sudden deterioration of rotor running condition

Check whether the deteriorated running condition
originated due to the turbine or whether the rotor bearings are
damaged. A deterioration of the running condition may be
caused by a change in the balancing condition or by a rotor
winding short. Unload and shut down turbine generator as
soon as feasible if cause cannot be located and corrected for
severe condition. Since it is very difficult in most cases to find
a definite cause, it is advisable to obtain the help of
manufacturers product service personnel.
All Rights Reserved
Copyright
Siemens
Energy Sector 1208E
0114E
Operation Cooler
Fault/Cause Remedy
Cooling water in generator
DANGER
J Leak or tube rupture in H2 cooler tube bundle Risk of explosion and fire due to leaking hydro-
gen. The generator is filled with hydrogen. Do
not unfasten any screws or bolts at the coolers
while the generator is filled with pressurized
hydrogen. Do not start any work on the cooler until the
hydrogen has been completely removed from the genera-
tor and the generator is filled with air at atmospheric
pressure.
Shut down the generator and seal off the cooling water
supply to the H2 cooler section.
Reduce the H2 pressure in the generator (see 2.3--8610).

NOTE
The hydrogen must be removed from the generator by
e Siemens AG 2011
scavenging the unit with carbon dioxide or argon(see

2.3-8620 and 2.3-8630).
Subsequently purge the generator with air to remove the

carbon dioxide or the argon.
Copyright
Identify the detective cooler and pass with a hydrostatic

test.Drain the cooler water from the defective cooler. Ensure
that the water is completely drained, if necessary use dry com-
pressed air at low pressure to force any remaining water from
the cooler. Remove extension pipes, install the cooler jacking
screws and remove the cooler inlet chambers.
There are two types of tube leaks: tube wall leak and tube
to tube plate (tube roll) leak. Each require specific test to de-
termine what kind of leak is present. Perform testing per tube
testing equipment manufacturers recommendations.
Plug tube per tube plug manufactures recommendations.
Two part plugs for tube leaks are preferred.
Tube roll leaks require different repair. The tube should be
drilled and reamed out at both tends of the tube at the tube
plate to expose the bare tube plate hole and a slight tapered
brass plug tapped into the hole to achieve a tight joint. Be care-
ful to not use too much driving force to seat the brass plug into
the tube plate hole because adjacent tube--tube plate joints
may be loosened. Note that it is not necessary to completely

drill/ream the tube from the tube plate. It is better to leave 3 to
6 mm of the tube projecting into the tube hole to act as a
restraint against tube motion (flapping) during service and to
form a barrier against tube wall metal chips escaping into the
finned side of the tube bundle.
Siemens
BHEL,Haridwar AG MKA70 &MDC 2.3--9440--0030 / 1
Energy Sector 0511E
0114E
Fault/Cause Remedy
Increasing approach temperatures

MKA75CT0XX
J Tube side fouling Tube side fouling is caused by improper chemistry control
or excessive silting in open loop systems. Biological corro-
sion (MIC) is also due to improper chemistry control. Tubes
may be cleaned by a number of methods. See tube cleaning
equipment manufacturers and water chemistry vendors for
recommendations. Contact Siemens Generator Engineering
for further information.
J Tube side plugging Tube side plugging may occur because of biological
growth or silting. See tube cleaning equipment manufacturers
and water chemistry vendors for recommendations. Contact
Siemens Generator Engineering for further information.
J Gas purity levels Low gas purity levels decrease the performance of the
MKG31 CQ001, MKG32 CQ001 coolers below 98% Hydrogen purity. See recommendations
in Gas System Troubleshooting to increase Hydrogen purity.
J Gas side fouling Gas side fouling occurs when either oil or other fluids enter
the gas stream and collect on the surfaces of the fins. This
leads to an increase in thermal resistance as with tube side
fouling.
Coolers should be removed. Contact Siemens Generator
Engineering for further information.
J Decrease in water flow A decrease in cooling water flow is evident when the gas
side temperature drop remains nearly constant and the water
side temperature rise increases. Check to see if flows measu-
red to the coolers are near design requirements.
J Increase heat load An increase in heat load is improbable but is indicated by

the same relative increase of gas side temperature drop over
water side temperature rise with increasing water tempera-
ture rise or gas temperature drop. Investigation into the gene-
rator operation should be conducted. Such changes such as
reduction in gas purity can lead to higher heat load.
Siemens
BHEL,Haridwar AG 2.3--9440--0030 / 2
Energy Sector 0114E
0511E
Operation Bearings
Fault/Cause Remedy
Generator bearing temperatures vary

Temperature variations at the generator bearings may be
due to different causes. Turbogenerator can be kept in
operation as long as permissible bearing temperature is not
exceeded. When a variation is noted, the operating temper-
atures should be carefully monitored to ensure the limit
temperature is not exceeded.
WARNING
WARNUNG
Risk of personal injury. Faulty oil cooling can lead to unallo-
wably high or low lube oil temperatures. This can cause
damage to the rotor bearings and bearing oil can leak at high
pressure and flow rate. Damaged shaft bearings can also lead
to damage of the shaft journals and can cause severe personal
injury due to ejected parts. Check the oil quality and oil filters
as per the corresponding maintenance schedule. Ensure com-
pliance with the instructions for changing the bearing oil and
All Rights Reserved
flushing the oil system. Check the cooler data as per the corre-
sponding maintenance schedule and ensure compliance with
the information about and instructions for the oil system in the
turbine maintenance manual.
If a deviation occurs, first check cold oil temperature (oil

temperature after cooler) and bearing oil pressure for deviation
from normal. If bearing temperature rise does not result from
a variation of these values, the oil pressure indicated in the
shaft lift oil pipe should be checked. If bearing temperature
exceeds permissible value, turbogenerator should be shut
Copyright
down.
Bearing oil pressure indicated in the shaft lift oil pipe

drops
Oil pressure depends in part on the bearing oil inlet temper-
ature. Check first to determine whether the pressure drop was
caused by an oil temperature variation. If not, the shaft lift oil
system should be checked for leakages. The fault may be due
to a leak at the check valve in the lift oil pipe. To determine if
the check valve is leaking, close globe valve in the lift oil line.
Prior to closing valve, check and record the setting (throttling
valve as set for operation). This check is performed by
counting the number of turns or by measuring the travel.
If, on closing the globe valve, the pressure gauge shows an
increase over the previous operating value, the check valve is
leaking. Replace or repair the check valve at the next shut-
down or inspection. A precise adjustment of the throttling ele-
ment will again be necessary during recommissioning.
Siemens
BHEL,Haridwar AG MKD &MDC 2.3--9450--0001
Energy Sector 0710E
0114E
Trouble-Shooting General
The details given herein on faults, their possible causes and can be taken in accordance with the following instructions, the
the corrective measures cannot be considered complete in turbine-generator should be shut down and the hydrogen
every respect, since all possible troubles cannot be covered in should be replaced with inertgas. If required, the services of the
advance. In most cases, the operator will have to decide on the manufacturer should be requested. In most cases, however,
measures to be taken. The individual measures required sufficient details will be found in the Turbogenerator Manual.
depend on the mode of operation. Unless corrective measures
All Rights Reserved
Copyright
BHEL,Haridwar
Energy Sector 0114E
0808E
Trouble-Shooting Stator and Generator Supervisory Equipment
Fault/Cause Remedy
Differences in slot temperatures between individual

stator phase windings
The embedded RTDs should be checked when different
slot temperatures are indicated while stator currents are of
equal magnitude in all the three phases. Such a check should
only be made with the generator at standstill and in non-excited
condition. The check should include resistance measure-
ments as well as testing of the detector leads, the measuring
point selector switches and the indicators. Care should be ta-
ken during resistance measurements of the embedded RTDs
to ensure that they are not heated as this will distort the results.
In many cases, a fault can be cleared by recalibration of the
RTDs.
High hot gas temperature

and/or
All Rights Reserved
High cold gas temperature

NOTE:
If the cold gas temperature continues to rise,
the mechanical equipment protection system
is tripped.
J Faulty hydrogen temperature control. Insufficient cooling Verify cause of fault by checking analog indicators (uniform
water flow volume through hydrogen coolers. rise of temperatures in all coolers). See 2.3--9280 for remedial
action.
Copyright
J Insufficient cooling water volume flow through a single Verify cause of fault by checking analog indicators (uniform
hydrogen cooler. rise of temperatures at one coolers).
Check positions of cooling water valves at the
corresponding cooler. Check to ensure that the cooling water
inlet valve is fully open. Lower cold gas temperature of
defective cooler by adjusting the cooling water volume flow
with the cooling water outlet valve. Ensure that cold gas
temperatures downstream all hydrogen coolers are equal.
Unbalanced load due to unequal phase loading of the

system connected to generator
If the generator is operated with unbalanced load due to
particular system conditions, care must be taken that the
continuously permissible unbalanced load is not exceeded
(see also 2.1--1607). The unbalanced load is defined as the
ratio of negative sequence current to rated current. The
permissible rated stator current should not be exceeded in any

stator phase. When the unbalanced load is higher than the
continuously permissible unbalanced load, steps should be
taken for bringing about a uniform system load. The generator
should be shut down if it is impossible to distribute the system
load more uniformly over the three phases.
Siemens
BHEL,Haridwar AG MKA &MDC 2.3--9200--0031 / 1
Energy Sector 0710E
0114E
Fault/Cause Remedy
Liquid in generator
NOTE:
If two of the three parallel-connected liquid de-
tectors (see Fig. 1, Item 1) signal the ingress of
liquid, the mechanical equipment protection is tripped.
The liquid in the generator casing should be inspected to

determine its origin, i.e. defective hydrogen cooler section, oil
from shaft seals, primary water or condensate.
DANGER
Fire and explosion hazard due to escaping hydrogen gas.
The pipes of the liquid detector rack are H2-filled and
under pressure.
To prevent H2 leaks, close the shutoff valves before the
level detectors before draining the liquid.
To do this
J Close shutoff valve(s) upstream of level detector which
activated the alarm.
J Remove drain plug from drain valve downstream of the
corresponding level detector.
J Drain the liquid via the drain valve and inspect liquid.
J Then close drain valve and reopen shutoff valve upstream
of level detector.
J Repeat this procedure until no liquid is discharged from the
drain valve.
J Close drain valve downstream of the level detector and
open shutoff valve upstream of level detector. Insert and
tighten drain plug to seal the system (gastight).
1 2 3 4 5 6 7 8
10
11
1 Liquid from stator frame, center

2 Liquid from terminal box, top
4 Liquid from cooling header, coolers A/B
5 Liquid from cooling header, center
8 Liquid from EE end winding, above hard-paper cover, bottom
10 Level detector
11 Drain valve downstream level detector
Fig. 1 Level Detector Rack
If the liquid cannot be drained from the generator in this

manner within a reasonable period of time, which will be the
case in the event of major leaks, the generator should be shut
down immediately.
BHEL,Haridwar
Siemens AG 2.3--9200--0031 / 2
Energy Sector 0710E
0114E
Fault/Cause Remedy
J Moisture condensate Very small water quantities are indicative of condensate.

Place gas dryer in operation.
A hydrogen sample should be extracted from the generator
and examined in a laboratory to determine its moisture
content.
J Cooling water from a defective hydrogen cooler Lager amounts of water point to a leaking cooler section.
Identify defective cooler section. Reduce generator load
(see also 2.3--8170) and take cooler section out of service by
closing the shutoff valves. Than take measures outlined in the
corresponding instructions (see also 2.3--9440).
J Primary water Since the primary water pressure is lower than the H2
casing pressure during generator operation at rated hydrogen
pressure, liquid accumulation in the generator can only occur
in case of a major leak (tube failure, burst Teflon hose). The
leakage water quantities require, however, a shutdown of the
turbine-generator.
As soon as the generator has been disconnected from the
system and is de-excited, take primary water pumps out of
service and close control valve upstream of the stator winding
and bushings. Remove hydrogen from the generator
immediately and fill with inert gas. Fault tracing and corrective
action may be started as soon as the generator is filled with air
at atmospheric pressure.
J Oil Oil level control in seal oil tank is faulty.

Prechambers in generator are overflowing.
Take corrective actions as described in (see also 2.3--9561)
immediately.
Siemens AG
BHEL,Haridwar 2.3--9200--0031 / 3
Energy Sector 0710E
0114E
Operation Rotor
Fault/Cause Remedy
Sudden deterioration of rotor running condition

Check whether the deteriorated running condition
originated due to the turbine or whether the rotor bearings are
damaged. A deterioration of the running condition may be
caused by a change in the balancing condition or by a rotor
winding short. Unload and shut down turbine generator as
soon as feasible if cause cannot be located and corrected for
severe condition. Since it is very difficult in most cases to find
a definite cause, it is advisable to obtain the help of
manufacturers product service personnel.
All Rights Reserved
Copyright
Siemens
Energy Sector 1208E
0114E
Operation Cooler
Fault/Cause Remedy
Cooling water in generator
DANGER
J Leak or tube rupture in H2 cooler tube bundle Risk of explosion and fire due to leaking hydro-
gen. The generator is filled with hydrogen. Do
not unfasten any screws or bolts at the coolers
while the generator is filled with pressurized
hydrogen. Do not start any work on the cooler until the
hydrogen has been completely removed from the genera-
tor and the generator is filled with air at atmospheric
pressure.
Shut down the generator and seal off the cooling water
supply to the H2 cooler section.
Reduce the H2 pressure in the generator (see 2.3--8610).

NOTE
The hydrogen must be removed from the generator by
e Siemens AG 2011
scavenging the unit with carbon dioxide or argon(see

2.3-8620 and 2.3-8630).
Subsequently purge the generator with air to remove the

carbon dioxide or the argon.
Copyright
Identify the detective cooler and pass with a hydrostatic

test.Drain the cooler water from the defective cooler. Ensure
that the water is completely drained, if necessary use dry com-
pressed air at low pressure to force any remaining water from
the cooler. Remove extension pipes, install the cooler jacking
screws and remove the cooler inlet chambers.
There are two types of tube leaks: tube wall leak and tube
to tube plate (tube roll) leak. Each require specific test to de-
termine what kind of leak is present. Perform testing per tube
testing equipment manufacturers recommendations.
Plug tube per tube plug manufactures recommendations.
Two part plugs for tube leaks are preferred.
Tube roll leaks require different repair. The tube should be
drilled and reamed out at both tends of the tube at the tube
plate to expose the bare tube plate hole and a slight tapered
brass plug tapped into the hole to achieve a tight joint. Be care-
ful to not use too much driving force to seat the brass plug into
the tube plate hole because adjacent tube--tube plate joints
may be loosened. Note that it is not necessary to completely

drill/ream the tube from the tube plate. It is better to leave 3 to
6 mm of the tube projecting into the tube hole to act as a
restraint against tube motion (flapping) during service and to
form a barrier against tube wall metal chips escaping into the
finned side of the tube bundle.
Siemens
BHEL,Haridwar AG MKA70 &MDC 2.3--9440--0030 / 1
Energy Sector 0511E
0114E
Fault/Cause Remedy
Increasing approach temperatures

MKA75CT0XX
J Tube side fouling Tube side fouling is caused by improper chemistry control
or excessive silting in open loop systems. Biological corro-
sion (MIC) is also due to improper chemistry control. Tubes
may be cleaned by a number of methods. See tube cleaning
equipment manufacturers and water chemistry vendors for
recommendations. Contact Siemens Generator Engineering
for further information.
J Tube side plugging Tube side plugging may occur because of biological
growth or silting. See tube cleaning equipment manufacturers
and water chemistry vendors for recommendations. Contact
Siemens Generator Engineering for further information.
J Gas purity levels Low gas purity levels decrease the performance of the
MKG31 CQ001, MKG32 CQ001 coolers below 98% Hydrogen purity. See recommendations
in Gas System Troubleshooting to increase Hydrogen purity.
J Gas side fouling Gas side fouling occurs when either oil or other fluids enter
the gas stream and collect on the surfaces of the fins. This
leads to an increase in thermal resistance as with tube side
fouling.
Coolers should be removed. Contact Siemens Generator
Engineering for further information.
J Decrease in water flow A decrease in cooling water flow is evident when the gas
side temperature drop remains nearly constant and the water
side temperature rise increases. Check to see if flows measu-
red to the coolers are near design requirements.
J Increase heat load An increase in heat load is improbable but is indicated by

the same relative increase of gas side temperature drop over
water side temperature rise with increasing water tempera-
ture rise or gas temperature drop. Investigation into the gene-
rator operation should be conducted. Such changes such as
reduction in gas purity can lead to higher heat load.
Siemens AG
BHEL,Haridwar 2.3--9440--0030 / 2
Energy Sector 0511E
0114E
Operation Bearings
Fault/Cause Remedy
Generator bearing temperatures vary

Temperature variations at the generator bearings may be
due to different causes. Turbogenerator can be kept in
operation as long as permissible bearing temperature is not
exceeded. When a variation is noted, the operating temper-
atures should be carefully monitored to ensure the limit
temperature is not exceeded.
WARNING
WARNUNG
Risk of personal injury. Faulty oil cooling can lead to unallo-
wably high or low lube oil temperatures. This can cause
damage to the rotor bearings and bearing oil can leak at high
pressure and flow rate. Damaged shaft bearings can also lead
to damage of the shaft journals and can cause severe personal
injury due to ejected parts. Check the oil quality and oil filters
as per the corresponding maintenance schedule. Ensure com-
pliance with the instructions for changing the bearing oil and
All Rights Reserved
flushing the oil system. Check the cooler data as per the corre-
sponding maintenance schedule and ensure compliance with
the information about and instructions for the oil system in the
turbine maintenance manual.
If a deviation occurs, first check cold oil temperature (oil

temperature after cooler) and bearing oil pressure for deviation
from normal. If bearing temperature rise does not result from
a variation of these values, the oil pressure indicated in the
shaft lift oil pipe should be checked. If bearing temperature
exceeds permissible value, turbogenerator should be shut
Copyright
down.
Bearing oil pressure indicated in the shaft lift oil pipe

drops
Oil pressure depends in part on the bearing oil inlet temper-
ature. Check first to determine whether the pressure drop was
caused by an oil temperature variation. If not, the shaft lift oil
system should be checked for leakages. The fault may be due
to a leak at the check valve in the lift oil pipe. To determine if
the check valve is leaking, close globe valve in the lift oil line.
Prior to closing valve, check and record the setting (throttling
valve as set for operation). This check is performed by
counting the number of turns or by measuring the travel.
If, on closing the globe valve, the pressure gauge shows an
increase over the previous operating value, the check valve is
leaking. Replace or repair the check valve at the next shut-
down or inspection. A precise adjustment of the throttling ele-
ment will again be necessary during recommissioning.
Siemens
BHEL,Haridwar AG MKD &MDC 2.3--9450--0001
Energy Sector 0710E
0114E
Turbogenerators Maintenance and Supervision
Maintenance Introduction
The turbogenerator and their auxiliaries require continuous

maintenance and supervision to assure reliable operation and
serviceability of the complete plant.
Maintenance and monitoring are required both during
operation and when the unit is at standstill.
Some maintenance work should preferably be performed
with the unit at rest, e.g. in the case of any special conditions
being noted in the operation log, while other maintenance work
may be carried out during normal operation.
The maintenance work required on the generator described
herein is specified in detail in the following.
All Rights Reserved
CAUTION
Risk of personal injury. Increased risk of personal injury due
to maintenance work. Always ensure sufficient support and
wear suitable protective clothing.
Copyright
BHEL,Haridwar
Siemens AG MK &MDC 2.4--4200--0001
Energy Sector 0710E
0114E
Turbogenerators
Survey on Maintenance and Supervision
Maintenance
Maintenance intervals
Every 3 months
Every 6 months
see
Work required
Instruction
Annually
Monthly
Weekly
Daily
Check sight class after level detectors for liquid level x 2.4--4210--....
Check shaft grounding brushes x 2.4--4210--....
Check hydrogen cooler vents x 2.4--4240--....
Check EE generator bearing insulation x 2.4--4250--....
Check shaft seal insulation, EE x 2.4--4250--....
Measure insulation resistance of rotor winding x 2.4--4310--....
All Rights Reserved
Copyright
Handhabung: OFFEN
Siemens AG
Energy Sector 0212E
0114E
Turbogenerators
Maintenance and Supervision of Stator
Inspection
Every 3 mounths
Every 6 mounths
Work required
Mounthly
Annually
Weekly
Daily
Check grounding brushes x
Check sight glasses after level transmitters for liquid level x
1 Monitoring the Temperature of Components upstream and downstream of each cooler section. The tempe-
lt is important that all temperatures remain within the rature transmitters, installed downstream of the coolers, mea-
specified upper and lower limits. If a temperature deviation is sure the temperature of the gas used for cooling the generator.
observed the cause must be determined immediately and the The cooling water supply to the cooler section must be con-
original temperature restored. trolled in such a manner that the temperature of the gas exiting
lf there exists the danger of overheating, a corresponding the cooler sections is approximately identical. The volumetric
load reduction should be made. flow rate of the cooling water must be adjusted by means of the
The temperatures between the top and bottom bars of the control valves in the cooling water outlets. The shutoff valves
stator winding are measured with resistance temperature at the cooling water inlets must be fully opened.
All Rights Reserved
detectors (RTDs). To prevent undue stressing of the generator, it is desirable

The RTDs are embedded in the winding and distributed uni- to maintain a constant temperature in the generator by control
formly over the three phases. The RTDs in the stator winding of the cooling water flow.
should transmit approximately indentical values for identical In addition to the gas temperatures, the cooling water tem-
currents in all three phases. If different temperatures are indi- perature is also measured. The cooling water inlet tempera-
cated with identical currents in the three phases, a check tures of all cooler sections should be measured in the cooling
should be performed to determine if the slot RTDs are correctly water inlet pipes, while the cooling water outlet temperature
calibrated and/or compensated. Differences in the tempera- should be measured separately for each cooler section in the
ture indication up to 5 K may be due to tolerances in the slot cooling water outlet pipe after each cooler section.
RTDs, compensating resistors and tolerances caused by dif-
Copyright
ferences in the contact at the measuring point selector switch.

3 Hydrogen Pressure in Generator
Other small temperature differences may be due to different On-load running should always be performed at the
mounting conditions at the RTDs. Faulty indicators may also specified hydrogen pressure, since it results in minimum
be caused by defective spark gap fuses. thermal stresses in the generator interior.
The primary water temperature at the stator winding outlet lf the hydrogen pressure cannot be maintained at the
manifold is monitored in addition to the stator winding tempera- specified level due to e.g. gas loss or insufficient gas supply
ture. (see Section 2.1--1607) and has dropped 0.3 bar below the
specified operating pressure, the generator load must be
reduced to 85 % (see Section 2.3--9640).
1 2
4 Primary Water Flow Rate
3
Am insufficient cooling water flow rate reduces the heat
4
removal from the water-cooled components to unallowable to
5
the generator. Since the loss of the cooling water system
affects the generator operation extremely quickly, the genera-
1 RTD 4 Bottom bar
2 Top bar 5 Core tor is tripped when the flow rate drops to a specified low limit.
3 Center filler
Fig. 1 RTD in Stator Bar 5 Primary Water Temperature

Continuous recording of the primary water temperature is
2 Monitoring the Cooling Gas essential to ensure safe on-load running of the turbine-gene-
and Cooling Water Temperatures rator. Many faults can thus be recognized and remedied at an
The temperature of the cooling gas flowing through the early stage. This is particularly important for a disturbed cooler
generator is measured with one temperature transmitter performance (fouling, venting, etc.)
BHEL,Haridwar
Siemens AG MKA &MDC 2.4--4210--0061 / 1
Energy Sector 0210E
0114E
The carbon brushes should be replaced with new ones
having contact faces which match the rotor shaft contour.
DANGER
The temperature of the cold primary water should be NOTE:
higher than the H2 cold gas temperature by not less than When inserting new brushes, make sure that
5 K under all conditions of operation in order to avoid the carbon layer comes before silver layer in direc-
formation of condensate on the components carring tion of rotation.
primary water.
6
6 Primary Water Pressure
Upstream of Stator Winding
In combination with the pressure differential across the
stator winding, the pressure of the primary water upstream the
stator winding can be taken as a reliable criterion for a safe
cooling water supply to the various branches.
A small change in pressure up to a maximum of 10 % has
no influence on cooling of the stator winding. Major changes
with rising tendency may be indicative of a disturbance in uni-
form cooling in individual branches. To avoid any risk in cooling
of the stator winding, it is recommended to contact Direction of Rotation
manufacturers service department and to ask for removal of
the cause. 1 2 4 3 5
7 Liquid Leakage Detection at Level Transmitters 2 3

Liquid entering the generator housing is sensed by level
transmitters. Sight glasses, located before and after the level
transmitters, permit any leakage to be readily detected before
the liquid level will have risen up to the level transmitters.
1 Brush holder
8 Grounding Brushes 2 Two-layer contact brush (Design A)
3 Two-layer contact brush (Design B)
The carbon brushes should be checked at regular intervals. 4 Insulated Brush holder bolt
During operation, the useful length of each individual 5 Rotor shaft
6 Handle
carbon brush can be determined by a visual inspection. For
limits of wear, see Description 2.1--1609. Fig. 2 Brush Holder with Grounding Brushes
Siemens AG
BHEL,Haridwar 2.4--4210--0061 / 2
Energy Sector 0210E
0114E
Turbogenerators
Maintenance and Supervision of Rotor
Maintenance
Maintenance Intervals
Every 6 months
Every 3 months
Work required
Annually
Monthly
Weekly
Daily
Measure insulation resistance u
1 Monitoring Rotor Vibrations may lead to overspeed of the turbine. This could cause fire or
The vibrations of the generator rotor should be monitored personal injury by ejected parts. Shut down generator when
and any change should be carefully observed. Should a the speed control system is faulted
change in vibration characteristics be noted, it is recom-
mended to have the manufacturers product service personnel
determine the cause and assist in correcting any problems.
2 Measuring Insulation Resistance
The insulation resistance of the rotor winding toward
CAUTION ground should be measured once a year provided this is
possible during a short outage.(see 2.5--3300).
Risk of fire and personal injury. Failure of the speed control
All Rights Reserved
Copyright
Siemens AG
Energy Sector 0114E
0710E
Maintenance of Generator Coolers
Every 3 months
Every 6 months
Work required
Annually
Monthly
Weekly
Daily
Check cooler vents u
1 General 2 Coolers
Special measures should be taken to prevent corrosion During normal operation, the cooling water flows through all
damage to the cooler (see also 2.3--5003). Cooler sections cooler sections. Since the coolers are designed for 100 %
having no cooling water flows for some time may be subject to capacity at maximum cooling water temperature, the condition
standstill corrosion. ln addition to many other corrosive may arise that the coolers are supplied with smaller cooling
influences, such as the different elements of the cooling water, water flows for long periods. Depending on the purity of the
locally differing deposits, raw materials, etc., there exists the cooling water, this may result in deposits due to the lower water
danger that micro-organisms on the tube walls may die and velocity in the cooler. To prevent cooler damage, it is therefore
decay due to a loss of fresh water supply (lack of oxygen). recommended to rinse the coolers with the full water flow
Ammonia is formed from such decay which may lead to stress during short outages. ln addition, the coolers should be
All Rights Reserved
corrosion cracking. Corrosion damage can only be properly frequently cleaned with brushes. For heavy cooler
prevented if the cooler is drained on the water side, cleaned, contamination and if operational restrictions and shutdowns
completely dried and maintained in a dry condition. With the are undesirable, it is recommended to install a continuous
generator in commercial operation, such measures are often cooler water purification system.
unfeasible, particularly in cases of short outages. In such Remove cooler elements for cleaning.
cases, the measures outlined below should be taken.
DANGER
Fire and expolsion hazard due to escaping hydrogen gas.
Copyright
Do not perform any work on the hydrogen coolers until the

generator has been shut down and is filled with air at at-
mospheric pressure.
Fig. 1 Cooler Section (disassembled) Fig. 2 Purification Brush
Siemens AG
Energy Sector 0806E
0114E
Maintenance of Bearings
Every 3 months
Every 6 months
Work required
Annually
Monthly
Weekly
Daily
Check EE generator bearing insulation u
Check EE shaft seal insulation u
1 General contact surface, the bearing babbitt, leaking supply pipes, or

During normal operation, no service or maintenance work defective pressure limiting and check valves.
is required on the bearings of the generator, however, bearing The temperature of the lubricating oil supplied to the
vibrations, bearing temperatures, oil temperatures and oil bearings is controlled by the cooling water flow to the bearing
pressures should be continuously monitored. oil cooler. The temperatures of the generator sleeve bearings
The generator bearings require particular attention during are displayed in the control room.
each new startup following a brief shutdown. Careful monitor-
ing will also be necessary within the first few minutes after
runup until the normal operating values are restored. If the 2 Checking the Shaft Seal and Bearing Insulation
All Rights Reserved
operating values prevailing after a restart exceed the permis- Checking the shaft seal and bearing insulation during
sible limit values, the unit should be shut down immediately. operation (see Section 2.5--0300, Checking the Bearing and
The lift oil pressure for the shaft journals should be adjusted Seal Insulation) may be done by way of the shaft voltage pre-
so that the shaft is lifted by not more than 50 % of the bearing vailing with the generator running in an excited condition. For
this purpose, the potential of the insulated shaft seals and
top clearance. To prevent any damage to the bearings the

shaft lift oil system must be in operation at speeds as specified bearings is accessible external to the generator. With the
in the turbine instruction manual. generator running, the components coming into contact with
At higher speeds, the lift oil pressure will settle at 40 to the shaft are separated from the shaft by an oil film, which has
80 bar (580 to 1160 psig). The oil pressures should be insulating properties. Consequently, a non-defined resistance
recorded in the operating log. If a lower oil pressure is ob- value is set up at the potential measuring points of the shaft
Copyright
served, the respective bearings should be checked. Such seals and bearing sleeves which is dictated by the magnitude
pressure reduction may be indicative of damage in the area of of the resistances of the oil film and insulating parts.
Fig. 1 Generator Bearing and Seal Insulation
BHEL,Haridwar
Siemens AG MKD &MDC 2.4--4250--0004
Energy Sector 0109E
0114E
Turbogenerators
Introduction
Maintenance
Reliable operation of the turbine generator will be ensured The assignment and number of Siemens product service
only if inspections and overhauls are carried out at regular personnel required for an inspection should be planned well
intervals so that any faults can be detected and corrected in advance to enable Siemens to make the necessary
before they result in costly failures. Following each inspection, arrangements. In addition, the period available for execution
the next inspection should be scheduled. of the inspection should be indicated.
Provided that commercial tools can be used and that no The spare parts stored for repairs and overhauls should be
special skills are required for the dismantling and erection checked at regular intervals. Components packed in plastic
work, the inspections can be performed by skilled power sheeting mostly contain a desiccant which must be replaced
station personnel. In all other cases, however, such as for the of reactivated from time to time.
inspection of the shaft seals and their auxiliaries, the services
of experienced Siemens product service personnel will be
required. WARNING
The shutdown of a turbine generator for inspection should Rotating components. These may cause injury to per-
be made in exactly the reverse order of startup. It should be sons. When working on generator or auxiliary equipment
noted in particular that the hydrogen must be removed from ensure that this is electrically isolated and cannot acci-
the generator housing with argon only. Should opening of the dentally be reconnected.
gas system or of the generator proper be required during an In single shaft configurations, do not open the generator
inspection, it is necessary to replace the argon with air. frame and do not start any work on the rotor or the bear-
Following an inspection, the generator should be restarted ings until the gas turbine and the steam turbine as well as
in the same way as during initial startup. the generator have come to a complete standstill.
All Rights Reserved
Copyright
Siemens AG
Energy Sector 0210E
0114E
Turbogenerators
Determination of Dewpoint Temperature
Maintenance
500
Absolute and relative humidity at different temperatures
Absolute humidity in g/m 3
80
DT in O C
60
100
90
50
80
70
60
40
50
40
All Rights Reserved
30 30
20
20
Copyright
10 10
9 +9
8
7
6
5 0
4 --2
--4
3 --6
--8
--10
2
1
1 2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90 100
Relative humidity in %
Example: Relative humidity of ambient air = 50 % and room temperature = + 20 _C result in a
dewpoint temperature (DT) of + 9 _C, corresponding to an absolute humidity of 8.6 g/m3.
Siemens
Energy Sector 0109E
0114E
Turbogenerators Preservation, Packaging, Shipment and
Maintenance Storage of Generator Components
Components manufactured for use in power plants must

satisfy extremely stringent requirements with regard to preci-
CAUTION
sion and function. Consequently, such components must
arrive on site in a condition which allows them to be used as Risk of personal injury. VCI paper can damage your health.
specified. This, in turn, imposes equally stringent require- Only use VCI paper for packaging suitable metallic
ments on the preservation, packaging and shipment of these components and ensure compliance with the instructions of
components. the VCI paper supplier. Wear suitable protective gloves when
All factors involving component damage due to mechanical handling VCI paper and thoroughly wash with soap and water
impact or corrosion, also during long-term storage, should any areas of skin which may have been in direct contact with
therefore be taken into account. VCI paper.
This document details the packaging and organizational
measures implemented to protect generator components
during shipment and storage.
NOTE
The procedures described in this document are deemed as
Risk of damage to property. The active ingredients con-
the standard scope of supply. In the event that deviations
tained in VCI paper can cause damage to materials if the
should be specified from the provisions of these procedures,
material is exposed to VCI paper for prolonged periods. Only
the supplier must be notified in due time. Any shipping and/or
storage period exceeding 12 months must be duly noted in the use VCI paper for packaging suitable metallic components
purchase order. and ensure compliance with the instructions of the VCI paper
supplier.
1.2 Air-Tight Packaging

All Rights Reserved
1 Preservation Airtight packaging must be used for sensitive components

if required to preserve the material properties or the proper
functioning of these components, or where the climatic condi-
The preservation of components and other small items tions likely to prevail during shipment or in the country of
must be effected by:
destination necessitate such packaging.

J painting Prior to shipment of such components, the customs author-
J waxing ities and forwarding agents should be contacted to arrange for
J oiling airtight packages to remain sealed until they have reached
J sealing with Denso tape their final destinations in order to prevent any corrosion
insertion of impregnated paper (VCI paper) damage to the components.
Copyright
J
J wrapping in polyethylene sheeting Differentiation is made between two types of airtight pack-
J sealing of openings to render components airtight, e.g., for aging:
casings (rigid barrier) J Packages sealed with metal plates and closures and
J sealing in foil or film, e.g. rotors and shafts (flexible barrier). Denso sealing tape (rigid barrier)
Any component that is suitable for rigid-barrier packaging
The preservation methods are based on the following peri-
should be sealed with metal plates and Denso tape
ods of time:
because of their robustness and reliable airtight enclosure.
J up to 6 months (shipping and storage It is important in this respect to avoid the use of seals and
J up to 12 months (storage) gaskets made of substances that are hygroscopic or per-
J up to 24 months (long-term storage) or longer, assuming meable to air, e.g. foam rubber or felt in combination with
regular in-storage inspections. metal plates and covers.
An inspection window sealed with Denso tape should be
provided in an appropriate position. A moisture indicator
1.1 Volatile Corrosion Inhibitor (VCI)
shall be positioned in a visible location behind the inspec-
Impregnated Paper U5
tion window.
When VCI-impregnated paper is used, the wrapped
components, including the paper, should be given an outer J Packages sealed with foil or film (flexible barrier)
wrapping of polyethylene sheeting to create an airtight space In cases where a rigid barrier is not feasible or economical,
in which the corrosion-inhibiting substances can develop their laminated aluminum foil must be used to achieve airtight
full protective effects through evaporation and chemical packaging. To prevent damage to the laminated aluminum
conversion processes. foil, the sharp edges of components must be protected with
Approximately 7 m2 VCI-impregnated paper is required per suitable padding material prior to wrapping. The airtight
cubic meter of enclosed space with this method of packaging. package must not contain any hygroscopic materials such
The effectiveness of the paper is limited to a distance of as excelsior, corrugated cardboard or felt. Care must be
approximately 300 mm under loose cover. taken to ensure that the aluminum foil is nor damaged in the
Siemens
BHEL,Haridwar AG MK &MDC 2.5--0030--0003 / 1
Energy Sector 0710E
0114E
course of the packaging process because even the slight- tion 4), the adsorptive capacity of the desiccant in the airtight
est damage, e.g., a hairline crack in the foil, would render package must be checked. This can be performed by means
the airtight package ineffective. The seams of airtight of indicators located inside the package. The minimum clear-
packages must be heat-sealed with great care at corners, ance between the indicators and the foil is 5 cm. The indicators
and intersecting seams must be executed in criss-cross are marked with a unique position code and show the relative
fashion. humidity inside the package for three ranges ( 30 %, 40 %
Airtight packages of aluminum foil must be subjected to a and 50 %). If the package is dry, all circles are blue. When
leaktest. To this end a vacuum cleaner must be used to the color changes to pink, the relative humidity is shown in the
remove the air from the package, which can be deemed air- corresponding circle (cf. Fig. 1). When the 40 % indicator
tight if it retains its full vacuum condition for at least one changes to pink, the desiccant must be removed and replaced
hour (pinch test). or reactivated by drying.
For components destined for long-term storage or sea This period should not exceed 20 hours and the opening
freight, laminated aluminum foil is, as a rule, the preferred through which the desiccant was removed should be pro-
material for airtight packaging. visionally sealed during this period. Before removing the
desiccant, be sure to check that either replacement desiccant
1.3 Desiccant or the necessary reactivation equipment is available.
1.3.1 Type and Position
The desiccant is supplied in dustfree and moisture-perme-
able linen bags. The bags of desiccant should be strung
together and should, at the time of insertion in the package, be
in an active condition, i.e. they must be absolutely dry. The
desiccant should be located to ensure easy accessibility to
facilitate replacement and must not make any direct contact
with parts made of steel or nonferrous metals (danger of corro-
sion).
The bags of desiccant should be placed near to and on both
ends of the rotor retaining rings and rectifier wheels.
1.3.2 Desiccant Quantities

The required amount of desiccant per shipping unit should
be calculated for the following periods of time:
J Overland transport (short-term storage):
Desiccant for at least 24 hours but not more than 3 months
(depending on the planned storage period)
J Sea freight (or short-term storage):
Desiccant for least 6 months but not more than 12 months
(depending on the planned storage period)
J Long-term storage:
Fig. 2 Humidity Indicator in Foil
Desiccant for up to 24 months.
Spent bags of desiccant must be reactivated in a drying
1.3.3 Desiccant Check and Reactivation oven for 12 hours at 110 _C. If a drying oven is not available,
Upon completion of the shipment, in case of interruptions the contents of the bags must be spread out to a thin layer on
necessitating in-transit storage in excess of one month, or if metal trays and dried for several hours at 110 _C -- 130 _C until
components require storage for any other duration (cf. Sec- the weight remains constant. The dry desiccant can then be
refilled into the bags, and the bags sealed dusttight. The bags
should then be re-inserted in the package without any undue
delay. Any direct contact with metal parts must be avoided.
When pink: danger of corrosion The opening in the foil can then be resealed with a heat-
sealing unit.
2 Packaging
When pink: replace desiccant
2.1 Wooden and Steel Crates or Containers
All packing crates must have stable bases with skids
capable of supporting the weight of the components to be
packed. Components packed in crates must be securely and
When pink: caution
adequately bolted down or otherwise held in position to
prevent any shifting during shipment. The measures taken
must account for the fact that crates may be tilted up to 30_.
Fig. 1 Humidity Indicator Crates for sea freight (with the exception of plywood boxes
(exact location to be indicated) or crates with airtight wrappings) must be lined with poly-
Siemens
BHEL,Haridwar AG 2.5--0030--0003 / 2
Energy Sector 0710E
0114E
Fig. 3 Rotor in Tightpack on Skid
ethylene sheeting. Only the bottom of the crate must remain secured to pallets for dustfree transportation. Be sure to pro-
unlined. Instead the bottom of the packing crate must be vide adequate cushioning on all sharp edges and corners of
provided with holes of sufficient size and number to ensure the items in question.
good drainage of any water and to ventilate the interior of the
case.
Crates with interior airtight wrappings of polyethylene 2.4 Cushioning Material
sheeting must have inspection openings with covers at those Suitable cushioning materials include high-air-content
locations where the inspection windows and the humidity indi- expanded plastic, expanded rubber, expanded-plastic strip-
cators are situated in the wrapping. If long-term storage is ping, sheet rubber and styrofoam. The cargo, its cushioning
planned, additional openings must be provided to enable and the packaging materials should form a strong, stable unit
replacement of desiccant. with the capacity to effectively absorb mechanical impact and
Crate covers must be reinforced with a sufficient number of vibrations.
square-timber braces to withstand the lateral compressive Consequently, and due to the fact that they tend to plug up
forces resulting from hook and rope attachments. cooling ducts and ports, styrofoam chips are unsuitable for
Packages in which the center of gravity is off-center or use as cushioning material. If at all, they should only be used
situated in the upper half of the package must be marked with for very light items with large surface areas.
a center of gravity symbol.
Crates with maximum dimensions of
5000 x 2500 x 3500 mm (L x W x H ) and a weight of 15000 kg or 2.5 Marking
less must have a base structure designed to permit handling To ensure correct and careful handling of goods during
by means of a forklift truck. shipment, each package should be marked appropriately on
at least two diagonally opposite sides.
The packages should also be marked to indicate the sensi-
tivity of the cargo. The symbols indicating Keep dry and This
CAUTION side up must be applied to every package. Any package in
Do NOT use forklift trucks for handling cases containing which the center of gravity is off-center must also be marked
stator winding bars. with the Center of gravity symbol in such a manner that the
actual location of the packages center of gravity can be clearly
2.2 Skids identified. Cases containing airtight-wrapped items must also
Heavy components should be transported on skids, the carry on orange Roof symbol. All packages weighing more
dimensions of which depend on the size and weight of the than 1000 kg must be marked with the symbol Attach lifting
component and on the planned mode of transport (railway car, gear here to identify the rope attachment points. The symbol
truck or ship). denoting Do not use forklift trucks must be stamped on
In case of extreme shipment conditions, very heavy crates that are unsuitable for forklift handling.
weights, or at the Customers request, skids for rotor and
stator can be made of steel. Example:
2.3 Tightpacks
Tightpacks, i.e., packages employing a shrink film system,
should be used whenever small, light items are to be efficiency
Siemens
BHEL,Haridwar AG 2.5--0030--0003 / 3
Energy Sector 0710E
0114E
3 Shipping corresponding notice must be displayed both on the transport
vehicle and in the shipping documents.
Upon arrival at their place of destination, the components
WARNING
WARNUNG and their protective packaging must be examined for damage.
Any damage discovered must be recorded, and the necessary
Risk of personal injury. Lifting trunnions can shear off during
repairs initiated without delay.
transport. The generator can fall down and cause personal in-
jury. Ensure compliance with the handling procedures for the
lifting beam. Do not stand, walk or work under suspended
loads and wear suitable personal protective equipment and WARNING
WARNUNG
clothes. Risk of personal injury. Any rotor shipping braces acci-
dentally left on the rotor can cause damage to the generator.
The mode of transportation (truck, railway car, ship, air- Risk of personal injury due to ejected parts. When assembling
craft) should be selected according to the nature, size and the generator, check and ensure that all rotor shipping braces
weight of the cargo, the traffic conditions anticipated for the have been removed.
chosen route, and the urgency of the shipment.
It should be ensured that only vehicles are selected which
feature the necessary structures and equipment for safety 4 Storage and Long-Term Storage
withstanding the loads generated by the cargo.
The cargo should be loaded and secured such that it will Any period of storage exceeding 12 months is referred to
not, under normal conditions of transportation, move, roll, tip as long-term storage. Storage must not impair the function or
over, fall down or cause the vehicle to overturn. Tie-down the quality of the goods.
chains and straps, and anti-skid plates are the preferred types In cases where open-air storage is unavoidable, the stored
of constraint and should be used in accordance with the goods must be protected by either a durable outer packing or
manufacturers instructions. an equivalent form of surface protection.
All components on skids should be slid into position on the The outdoor storage area must offer adequate protection
transport vehicle with the aid of guide timbers. A slipway length for the stored goods against precipitation, standing water,
of at least 1.5 m must be provided for this purpose. If several ground moisture, dirt, vermin and unauthorized access. The
units are to be formed, they must be spaced at least 50 cm goods must be covered with waterproof tarpaulins or located
apart. If this method of loading is used, the weight of the load under protective roofing, and must be adequately ventilated.
must not exceed 75 % of the relevant load limit of the vehicle Components in storage, including long-term storage, must
in question. be inspected at monthly intervals with regard to surface
Tarpaulins should be used to protect packing crates, protection, nitrogen pressure and humidity indicator colors.
unpackaged and/or sensitive components against moisture Any damage to the surface protection, loss of nitrogen
and soiling. pressure or changes in the color of humidity indicators of air-
Large, heavy and sensitive components and items packed tight packages during these inspections must be recorded by
in crates for rail transport must not be loaded via humps. A the responsible personnel.
Siemens
BHEL,Haridwar AG 2.5--0030--0003 / 4
Energy Sector 0710E
0114E
Turbogenerators
Checking Desiccant in Packing of Components
Maintenance
Desiccant Checking Requirements should be recorded in the table below. The desiccant must be
The absorbent capacity of the desiccant must be checked removed and replaced or reactived by drying when a change
after shipment has been completed and at intervals of one in the color of the 40 % moisture indicator is observed.
month during any subsequent storage period. The results
Job name: Sl. No.: Type:

Moisture indicator Weight of
Shipping outer packing Location blue or pink? desiccant Replacement
Condition of
Condition of
component
or identification in packing or
Company
storage of moisture Bottom Center Top in kg reactivation

phase indicator circle circle circle of desiccant
Name
Date
(30 %) (40 %) (50 %) (1 kg = 2.2 lb.)
Prior to TE
shipment
TE
TE
EE
EE
EE
All Rights Reserved
TE
TE
TE
EE
EE
EE
TE
Copyright
TE
TE
EE
EE
EE
TE
TE
TE
EE
EE
EE
TE
TE
TE
EE
EE
EE
Siemens AG
Energy Sector 0109E
0114E
Insulation Resistance Measurements
Turbogenerators
on Rotor Windings
Maintenance
Test Report
Checking the Insulation Resistances of Rotor Windings

in Sealed Packing
The insulation resistance of the rotor winding should be of one month during any subsequent storage period. The
checked after shipment has been completed and at intervals results should be recorded in the table below.
Job name: SI. No.: Type: Component:

Shipping or Prior to
storage phase shipment
Date
Name
Company
Storage area
Temperature in
storage area in qC
Rel. humidity of ambient
air in storage area in %
Rotor temperature in qC
50
Moisture TE1 40
indicator in 30
packing
blue or 50
pink? EE1 40
30
Pressure of nitrogen
blanket in bar
Applied voltage in V
15 s
30 s
Copyright
45 s
Insulation resistance in M 8
01 min
02 min
03 min
04 min
05 min
06 min
07 min
08 min
09 min
10 min
NOTES: 3. The connection to the rotor winding should be made at a

specially indentified bolt on the exciter-end end cover.
4. The connection to the rotor body should be made at a
1. The insulation resistance should be measured with an second bolt on the exciter-end end cover.
insulation measuring device (% 500 V). 5. After each measurement, any static charges should be
2. Prior to each measurement, any static charges should be removed by short-circuiting the winding through the rotor
removed by grounding the windings as a precautionary body (not less than 20 minutes)
measure (10 minutes).
Siemens AG
Energy Sector MKC36 0909E
0114E
Turbogenerators
Preparation of Machinery Parts
Maintenance
1 General Cleaning of internal and external threads should be done

The machinery parts to be assembled are delivered ready by chasing, using suitable taps or cutting dies. The dimensions
for mounting, unless certain portions must be protected during of the external and internal threads may be taken from the
transport against corrosion or damage. respective drawings. Use dry compressed air to blow out the
In case of orders for delivery to European countries, all rethreaded tapped holes.
sensitive portions of the machinery parts, e.g. journals, are Where no taps are available cleaning of the tapped holes
provided with a protective coating and protected against may also be carried out with the aid of the original screws. At
damage. first, the screws should be cleaned by means of solvent and
In case of orders for delivery to overseas countries, all a brush. The cleaned screws should then be dipped into a
machined surfaces are provided with a protective coating. In solvent and immediately afterwards be screwed into the holes
addition, complete assemblies are sealed in plastic sheeting. for thread cleaning.
If required, this procedure should be repeated several
2 Removal of Protective Coating times until the threads are free from protective coating.
The protective coating applied at the manufacturers work
should be carefully removed prior to installation. The surfaces
to be cleaned should be washed with petroleum or a similar
3 Remedying of Minor Damage
agent. When using trichlorethylene, the cleaned surfaces
Damaged machinery parts should be reconditioned as
should be carefully dried and afterwards a thin oil film should
dictated by the extent of the damage and the operational
be applied. Non-observance of this requirement implies the
requirements unless the nature of the damage does not
danger of corrosion.
warrant such remedying.
All Rights Reserved
Particularly thick layers of protective coating should be

Seriously damaged parts should be returned to the
softened by applying one of the above-mentioned cleaning
manufacturers works together with a damage or failure report.
agents and then be removed by means of a hardwood board
The machinery parts and the fixing and locating elements
(approximately 10 cm u 10 cm u 1 cm, 3.94 in. u 3.94 in. u0.4 in.).
should be checked for burrs and compression marks, and
such imperfections should be removed by means of a
CAUTION smooth-cut file. Fine-finished surfaces should only be

polished by means of an oilstone.
Never use scrapers, finishing trowels or sheet metal strips
for removing the protective coating from
highly sensitive machinery parts (journals, etc.).The cov-
Copyright
ers protecting the components of the d.c. plug-in contact CAUTION

assembly should only be removed shortly before cou-
pling the rotors.Make sure that the sleeves and bolts of Burrs and compression marks on bearing metal surfaces
the d.c. plug-in contact assembly of the exciter rotor will should only be removed by means of a spoon scraper or
not come into contact with any solvent. flat scraper.
Siemens AG
Energy Sector 0210E
0114E
Turbogeneratoren Checking the Insulation for
Maintenance Protection From Shaft Currents
1 General as outlined for the labyrinth rings. It is to be expected that the

total resistance will likewise be lower than the lowest inividual
During operation of a generator, voltages are set up along resistance measured before.
the rotor due to magnetic unbaIances. This shaft voltage would
cause a destructive current to flow through the bearing, shaft 2.4 Pedestal Bearing of Slipring Assembly
seal and other components if the rotor were not insulated from The insulation resistance between the bearing pedestal
ground at least at the exciter end. For reasons of and base frame should be measured immediately after
interchangeability, all stator components coming into contact mounting of the pedestal. With satisfactory insulation, a value
with the generator rotor are insulated. The bearing at the in excess of 10 megohms is to be expected.
slipring shaft is insulated. Following this, bolt the associated oil pipe to the bearing
pedestal being careful to insulate it. It is also recommended to
repeat the insulation resistance measurement after fitting of
2 Checking the Shaft Seal and Bearing each individual pipe. If a sufficiently high resistance value is
Insulation During Installation measured (0.5 megohms) proceed with fitting of the next pipe.
Finally, measure the insulation resistance to the base frame of
the bearing with the connected pipework. If this value is higher
2.1 Bearing Saddle
than 0.3 megohms, proceed with mounting of the slipring shaft.
Prior to inserting the rotor and supporting it on the bearings,
the insulation resistance of the built-in bearing saddle should
be measured separately by means of a 100 V megger applied 2.5 Final Checking
between the bearing saddle and the lower part of the stator After the slipring shaft has been coupled to the generator
frame. The values measured should be recorded. rotor and insulated from the bearing pedestal, a final insulation
All Rights Reserved
With satisfactory insulation, a value in excess of check should be performed. The total insulation resistance
10 megohms is to be expected. If an insulation resistance must not be less than 0.1 megohm. Due to contact with the
value below 0.3 megohms is measured, the insulating parts shaft, the measuring curcuit covers in parallel:
should be checked for moisture, contamination or metallic
contacts. If required, the insulation should be dried at 80 _C TE/EE bearings
(176 _F) maximum. TE/EE shaft seals

The measurement should be repeated immediately after Slipring bearing pedestal with pipework
the rotor has been supported on the bearings.
The specified insulation values apply solely for the dry
IMPORTANT: condition., i.e. prior to operation of the oil supply systems (lifting
Copyright
With this measurement and the following oil, bearing lube oil and seal oil).
checks both rotor bearings must be insulated,
and the generator rotor must not come into contact with
the turbine shaft through measuring devices or similar 3 Checking the Shaft Seal and Bearing
parts, to prevent the generator rotor from being grounded. Insulation of the Assembled Unit
Since, with the rotor inserted, all individual resistances
measured previously are now in parallel in the measuring Checking the shaft seal and bearing insulation during
circuit, the total resistance will be slightly lower than the operation may be done by way of the shaft voltage prevailing
lowest individual resistance value measured before. with the generator running in an excited condition. For this
purpose, the potential of the insulated shaft seals and bearings
2.2 Inner and Outer Labyrinth Rings is accessible external to the generator. With the generator
Inner and outer labyrinth rings are insulated from other running, the components coming into contact with the shaft are
components. The insulation resistance of each individual separated from the shaft by an oil film, which has insulating
labyrinth ring should be measured after installation in order to properties. Consequently, a non-defined resistance value is
preclude any lengthly search for faulty mounting on set up at the potential measuring points of the shaft seals and
measurement of a poor insulation resistance. Proceed with bearing sleeves which is dictated by the magnitude of the
mounting of the next component only after having indentified resistances of the oil film and insulating parts. The following
and removed the cause of a poor insulation resistance. After method permits the insulation to be checked without
installation of all insulated components the total resistance will disassembly of components being required.
be slightly lower than the lowest individual resistance valvue Useful results are, however, to be excepted only if the
measured before. turbine end of the generator rotor and the turbine shaft are
grounded properly during the measurements. Grounding must
2.3 Shaft Seals be maintained to discharge to ground any static charges
Both shaft seals are mounted such that they are insulated. occurring continuously during operation due to steam and oil
To check the insulation resistance, follow the same procedure film friction.
Siemens AG
BHEL,Haridwar MKD &MDC 2.5--0300--0002 / 1
Energy Sector 0210E
0114E
3.1 Checking the Insulation With the Generator satisfactory insulation, the instrument will continue to indicate
in an Excited Condition a shaft voltage of the original magnitude. In the event of
Due to the rotor grounding arrangement at the turbine end, insufficient insulation resistance, a current will flow through the
the shaft voltage should be measured at the exciter end. Since insulation, which may be read at the ammeter into the circuit.
the result depends, however, on the function of the rotor Bridging of the oil film results in a reduction of the original shaft
grounding system (carbon brush sliding on shaft), the shaft voltage or in its complete collapse.
voltage should first be measured according to Fig. 1 with the
generator running and excited. Normally, this will be an
ac voltage of a few volts on which a small dc component is
superimposed. Measurement should be performed by means Roil
of a voltmeter in the ac range. The voltage should be picked off
the shaft through a sliding contact with an insulated handle,
which is connected to the meter by a cable.
TE EE
A
Roil Roil
Rins Rins 2 1 V
Rins
1
V
1 Voltmeter (ac range)
2 Ammeter
1 Voltmeter (ac range)
Fig. 3 Measurement of Shaft Current With the Generator
Fig. 1 Measurement of Shaft Voltage With the Generator in Excited Condition
in Excited Condition
The resulting current can be measured for a brief moment
The shaft voltage measured in this way should then be by means of an ammeter connected into the circuit between
compared with the voltage measured according to Fig. 2. If the the measuring brush and the potential measuring terminal.
two readings are not identical, the rotor grounding system
should be rectified first before taking any further readings to
check the insulation for shaft currents. Roil
EE
Roil
1
Rins
V 1
Rins
1 Bridge instrument
1 Voltmeter (ac range) Fig. 4 Measurement of Insulation Resistance With the Generator
in Non-Excited Condition
Fig. 2 Measurement of Shaft Voltage at Exciter End With the
Generator in Excited Condition
If the shaft voltage can be accurately measured according 3.2 Checking the Insulation With the Generator
to Fig. 2, the measuring brush on the shaft should first be in Non-Excited Condition
connected to the potential measuring terminal on the insulated If the previous tests are inconclusive, additional tests may
component (bearing sleeve of shaft seal) at the exciter end by be performed in consultation with the manufacturer to locate
means of a cable. The oil film of the component is thus bridged, insulation defects with the generator running and in
with the component assuming the shaft potential. With non-excited condition. A bridge instrument must be used. To
Siemens AG
BHEL,Haridwar 2.5--0300--0002 / 2
Energy Sector 0114E
0210E
measure the resistance of the insulated component with standstill, since a stable oil film providing for full insulation can
respect to the shaft and ground, the bridge instrument should only be formed above a speed of approximately 3.33 to
be connected between this component and ground. 6,66 s-1.
The resistances (Roil and Rins in series) of the parts in In case of a low insulation resistance, it must be assumed
contact with the shaft are then connected in parallel with the that the insulation is defective, requiring detailed checking of
measuring voltage. the insulating parts (Contact the manufactorer).
This measurement is not practicable with the generator at
Siemens AG
BHEL,Haridwar 2.5--0300--0002 / 3
Energy Sector 0210E
0114E
Turbogenerators
Flushing the Oil Piping
Maintenance
1 Measures to be Taken at lnspections, 4 Flushing Oil

Repairs or Checks The oil used for flushing must be provided by the user and
When opening parts of the oil systems for inspection, repair oil supplier as laid down in the generator manufacturers oil
or checking, make sure that no dirt is introduced into the oil specification. In this connection, it may become necessary to
circuits. In the event of a contamination being unavoidable due consult the turbine manufacturer too.
to the work to be performed, take care to reduce such The following methods are possible:
contamination to a minimum and perform a thorough cleaning
afterwards. J Use of the same oil grade for both flushing and operation.
In case of more extensive inspections, it is recommended On completion of the flushing procedure, oil samples
to drain the oil, to clean the oil coolers, the oil tank and the should be taken and analyzed to decide whether the
bearing compartments in the same way as for initial operation flushing oil charge can be used as service oil change after
of new plant, and refill the oil via filters. After each inspection, treatment by the oil supplier.
the oil system should be subjected to a short flush. lt is J Use of an oil grade intended for use as flushing oil only. Its
recommended to install screens in the throttle valves and to properties, particularly its viscosity, are matched to the
perform flushing for 12 hours. On completion of this flushing special application. This oil charge is completely drained on
procedure, all filters and screens should be cleaned again. completion of the flushing procedure and replaced by a
lf the oil piping must be flushed the following procedure new service oil charge. The properties of the service oil and
should be used. flushing oil must be suitably matched.
2 Preparation of Bearing Compartments

All Rights Reserved
Prior to commencement of the flushing procedure, the

bearing compartments should be cleaned carefully. lf any
reworking has been done in the bearing compartments
(e.g.drilling), the chips should be removed by means of a
magnet. In addition, the bearing compartments should be

cleaned with lint-free rags (never use cotton waste). The
cleaning agents used should leave no residue. After cleaning,
the bearing compartments should be subjected to a thorough
visual inspection.
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3 Preparing the Lube Oil System for Flushing

During flushing, the highest possible oil velocity is to be
maintained in the pipes.
When the bearings are installed, make sure that no
contaminated oil is introduced between shaft and babbitt. To
do this, remove the upper half bearing sleeves and fit
temporary oil drain pipes to the inlet openings of the lower half
sleeves. Remove the valve cones from the permanently
adjustable throttle valves before the bearings and insert the
flushing fittings instead. Do not yet install the flushing screens
supplied with the throttle valves. Make sure that the hoses of
the shaft lift oil system are not connected to the bearings, as 1 2 3 4
otherwise contaminated oil will be admitted to the bearing
1 Oil drain
journal. 2 Bearing saddle
3 Seal
4 Bearing sleeve
Fig. 1 Oil Drain at Generator Bearing
CAUTION
Valve blocks and bearing journals must not be part of the

flushing process of the hydr. shaft lifting device. Disas-
semble the conn. pipe to the valve block or seal the conn. 5 Flushing Procedure
pipe on the block end. Flush the piping of the hydr. shaft Flushing all bearing oil lines and all shaft lift oil pipes of the
lifting device with a suitable hose or via a bypass-line dis- generator should be performed in conjunction with the turbine
charging to the bearing oil return line. according to the instructions issued for the turbine.
MKD
Siemens AG
BHEL,Haridwar MKW &MDC 2.5--0320--0001 / 1
Energy Sector 0310E
0114E
During flushing, the oil lines should be hammered regularly shaft lift oil system should be connected to the bearings and
to remove dirt particles from the walls. During the last third of checked for tightness.
the entire flushing period, the screens should be temporarily
installed in the throttle valves upstream of the bearings for
checking the dirt accumulation. 6 Supervision of Oil Circuits
After draining of the flushing oil, remove any dirt deposits After recommissioning, all screens and filters should be
from the bearing compartments. Remove and clean all filters replaced and/or cleaned as frequently as possible. During
and screens. Remove all bypasses, orifice plates or blank commissioning, the oil should be checked for contamination,
flanges as weIl as the additionally installed filters. Refit the e.g. via vent ports. In case of an extremely high dirt content due
valve cones in the throttle valves before the bearings. to carbon dust, construction work, etc., special precautionary
Assemble the bearings ready for operation. The hoses of the measures should be taken.
Siemens AG
BHEL,Haridwar 2.5--0320--0001 / 2
Energy Sector 0310E
0114E
Turbogenerators Measures to Prevent Corrosion
Maintenance During Inspections
During an inspection, the individual components of the ally the retaining ring area can be kept dry and above ambient
generator are exposed to the ambient conditions which may temperature level. The air dryer or fan-forced heater should be
result in hazards to these components. It is therefore strongly arranged so that the air will circulate in a closed circuit.
recommended to take suitable measures for preventing any If possible, the primary cooling water should be circulated
exposure to moisture, especially rain, snow, liquids of any kind through the system during the inspection. The heat dissipated
and condensation. Covering the components will not afford by the pump is sufficient to maintain the temperature of the pri-
sufficient protection. mary water and the stator winding above ambient tempera-
To avoid the above-mentioned hazards, the assembly work ture.
during an inspection should be accomplished under protection The cooling water should be drained from the hydrogen
from weather conditions. The generator should only be and the seal oil coolers, and the secondary cooling water
opened if an uninterrupted execution of the work will be should be drained from the primary water coolers. The coolers
ensured and provided that the necessary protective measures should cleaned, dried and then be kept dry by means of suit-
can be taken. After opening of the unit and withdrawal of the able measures.
rotor, the stator openings should be promptly reclosed. The Normally, a condensation hazard can be recognized with
stator should be dried by means of a portable air dryer or the help of a dewpoint measuring device. In case of doubt,
fan-forced heater and kept above ambient temperature level. however, it is recommended to dry the components on a
The air dryer or fan-forced heater should be arranged so that continuous basis in order to achieve a markedly low dew-point
the air will circulate through the stator interior in a closed circuit temperature on these components, i.e. to maintain their
for ventilation of the entire internal space. temperature above ambient temperature level.
The rotor should be protected in such a manner that especi-
All Rights Reserved
Copyright
Siemens AG
Energy Sector 0504E
0114E
Preventive Measures
Turbogenerators
to Avoid Moisture Condensation
Maintenance
Survey
Phase Keyword Precautionary Measures and Checks

Transport Packing: 01 Dry rotor retaining rings by blowing dry air into rotor end windings from portable air
dryers (e.g. Munters dryer) shortly before packing. Multiple dry packing in sheet-
ings with desiccant added.
Accompanying 02 Reference to special packing and request for restoration after opening due to
documents: customs or in-transit damage.
Damage to 03 Restore proper condition of dry packing immediately. For details, see description
packing: accompanying the cargo.
Receiving: 04 Check effectiveness of dry packing and desiccant. Record condition in checklist.
Request for repeat checks according to checklist during subsequent storage.
Storage Condition: 05 Maintain dry packing until immediately before assembly.
Check: 06 Monthly functional check of dry packing and desiccant according checklist.
Storage area: 07 Indoor storage in dry building; outdoor storage in seaworthy packing, under
shelter, protected against precipitation/ground moisture.
Installation Outdoor 08 Transport to jobsite in dry packing. Acclimatization in dry packing to avoid
installation: condensation after unpacking.
09 Installation under shelter. Removal of dry packing from retaining rings (1st layer)
as late as possible.
All Rights Reserved
Open generator, 10 With danger of condensation (outdoor installations and open power house), blow
rotor installed dry air from portable air dryers into rotor end windings and slipring assembly.
Ready for 11 H2 cooled generators:
operation Pass small cooling water flow through H2 cooler to ensure that cooler is coldest
Generator closed,
(standstill component in the generator (condensation hazard!).
filled with
or turning
H2 gas:
gear
operation)
Scheduled Outdoor 12 Generator closed: Measures as under Ready for operation.
mainten. installation:
without
13 Generator open: Shelters must prevent precipitation from entering the generator;
Copyright
rotor
removal the retaining rings areas must be covered and kept dry by supplying dry air.
Scheduled Indoor 14 If rotor is set down in dry power house with even temperature, it is sufficient if the
mainten. installation: entire rotor is covered against dirt and wetness. If danger of condensation, the
with rotor rotor area between the bearing journals must be provided with dry packing.
removal
Outdoor 15 Set down rotor under shelter and provide rotor areas between bearing journals
installation: with dry packing.
BHEL,Haridwar
Energy Sector 0109E
0114E
Turbogeneratoren Inspection
Maintenance Foreword
Preventive maintenance of generators serves to avoid equivalent operation time under consideration of the machine
major problems or damage while the unit is in service. output in four performance groups.
Apart from its scope, the timing of an inspection is
Tequiv = K1 T1 + K2 T2 + n T3
important. To account for the deterioration and stresses due to
different modes of operation, the number of operating hours, Tequiv t, Tequiv r = Equivalent operating hours Subscript t
the number of starts and the turning times are used as criteria K1 = Weighting factor for stress refers to total
in determinating the intervals between the inspections. impact during normal operat. hours
The intervals recommended in the following are the same operation since initial
as those indicated in the VDEW Recommendations for T1t ,T1r = Operating time in hours commissioning
Intervals Between Generator lnspections [1] which are based K2 = Weighting factor for turning
on the accumulated experience of the German public utilities, gear operation
machine insurance companies and manufacturers. This T2t ,T2r = Turning gear operation time Subscript r
Foreword contains a large number of extracts from the VDE in hours refers to
Recommendations. n t ,n r = Number of starts operat. hours
The guiding values given in the VDEW Recommendations T3 = Weighted time equivalent between two
are to assist the power plant owners/operators in scheduling in hours per start main inspect.
inspections, taking into account also own experience on the
performance of their generators and that of sister machines. Table 2: Weighting Factors for the Different Power
Output Ranges
Types of lnspection Power
Depending on the scope, date and duration of the Rating K1 K2 T3
Output Range
All Rights Reserved
inspections, a differentiation is made between

1 SN > 600 MVA 1.0 0.5 20
J lnitial lnspection (ll)
2 250 < SN < 600 MVA 0.9 0.3 10
J Short lnspection (Sl) (or Minor lnspection)
J Intermediate lnspection (Inl) (or Medium lnspection) 3 50 < SN < 250 MVA 0.8 0.1 10
J Main lnspection (Ml) (or Major lnspection) 4 SN < 50 MVA 0.7 0.1 05
Table 1: Types of Inspection, Features and Duration The recommendations given in the following apply to
normal operation without major disturbances. Abnormal
Type Features Duration disturbances, such as close-in system faults, faulty
Copyright
II Maximal as Up to several synchronizing, asynchronous running and inadmissibly high

Main Inspection weeks unbalanced load, may necessitate shortening of the
SI Checks and measures required Days respective inspection interval or an immediate check.
based on observations during When scheduling inspections, also consider the following
operation and checks factors:
Inl Like Short Inspections including A few weeks
partial disassembly but without J Wear and deterioration of components
removal of rotor J Deterioration of running behaviour
MI Like Intermediate Inspection but Several weeks J Frequency of load rejections associated with overspeed
with removal of rotor J Earth faults or interturn faults in generator field circuit
J Hydrogen, water or cooler leaks
The scope of work and checks to be performed should be
J Change in coolant flow rates
agreed upon with the manufacturer in good time. The date of
J Fouling of air-cooled generators
the Initial Inspection should be determined under due
J Deterioration of shaft insulation
consideration of changes that are likely to occur after a
J Type specific experience.
relatively short service period.
The time periods given are guiding values. Depending on
With proper performance of the generator and provided
the scope of the planned work or inspection findings, the
that the inspection findings obtained by the preceding
inspection period is either shortened or lengthened.
inspections (s) have been favourable, the intervals between

inspections may be lengthened within reasonable limits.
Influences
Scheduling of the Initial Inspection and of the subsequent
inspections mainly depends on the number of operating hours, Recommendation for Inspection Intervals
The Initial Inspection (ll) after an equivalent operation time
the number of starts and the turning times. The influences are
considered according VDEW Recommendation for an 10 000 h Tequiv t 20 000 h
Siemens AG
Energy Sector 1110E
0114E
The Main Inspection (MI) after an equivalent operating time (power output range 2) at peak load (operating mode D) will
40 000 h Tequiv r 60 000 h result in an interval of 6 to 10 years.
lt is recommended that one or more Short and Intermediate

Inspections are performed between Main Inspections. This Table 4: Determination of the Equivalent Operating
result in a sequence of Short, Intermediate and Main Hours for One Calendar Year with Differing
Inspections which can be selected flexibly at different Operating Modes and Ratings
intervals.
This point of time is not dependance to the technical
Power Output 1 SN 600 MVA
requirements of the generator, but also to the most generator
Operat.
dependend moments of shut down periods of the machine set. T1 T2 n T1uK1 T2uK2 nuT3 Tequiv
mode
A+E 7000 0500 010 7000 0250 0200 07450
Recommendations
B 5000 2500 050 5000 1250 1000 07250
By the mathematical calculation of inspection intervals
C 3000 5500 150 3000 2750 3000 08750
based on the equivalent operating time
Tequiv = K1 T1 + K2 T2 + n T3 (from Table 2) will be included D 1000 7500 300 1000 3750 6000 10750
the turning gear operation hours in addition to the number of
starts and by classifying four groups of power output ranges Power Output 2 250 MVA SN 600 MVA
with different weighting factors. Operat.
T1 T2 n T1uK1 T2uK2 nuT3 Tequiv
mode
In this way an equivalent operating time is determined for
the various operating modes. lt reflects the diverse operating A+E 7000 0500 010 6300 0150 0100 6550
influence and corresponds weIl with experience. The B 5000 2500 050 4500 0750 0500 5250
equivalent operating times are determined and compared for C 3000 5500 150 2700 1650 1500 5850
one calendar year considering different operational modes in D 1000 7500 300 0900 2250 3000 6150
the four power output ranges.
Regardless of the four power output ranges, in principle five Power Output 3 50 MVA SN 250 MVA
operating modes can typify turbogenerators (Table 3). For Operat.
T1 T2 n T1uK1 T2uK2 nuT3 Tequiv
each operating mode typical values are given for the load mode
ranges, the annual operatiog time, load variations and the A+E 7000 0500 010 5600 050 0100 5750
annual number of starts providing such a characteristic order. B 5000 2500 050 4000 250 0500 4750
C 3000 5500 150 2400 550 1500 4450
Table 3: Typical Operating Modes
D 1000 7500 300 0800 750 3000 4550
Annual
Oper- Annual
Operating Load
ating Load Ranges No. Power Output 4 SN 50 MVA
Time Variation
Mode of Starts Operat.
in h T1 T2 n T1uK1 T2uK2 nuT3 Tequiv
mode
A base load 7000 small 10 A+E 7000 0500 010 4900 050 0050 5000
B lower B 5000 2500 050 3500 250 0250 4000
4000-6000 large 50
medium load
C 3000 5500 150 2100 550 0750 3400
C upper D 1000 7500 300 0700 750 1500 2950
2000-4000 large 100-200
medium load
D peak load 2000 small 300
E operation in Regardless of the above recommendations to perform the
industrial 7000 large 10 Initial and the Main Inspections after having reached
power plants equivalent operating hours totals of Tequiv t or Tequiv r , the
maximum time (operating time + turning gear time + standstill
Examples of the equivalent operating hours in a calendar time) between two Main Inspections, and also between Short
year for each of the five typical operating modes are shown in and Intermediate Inspections, should not exceed the period
Table 4 for the four power output ranges. The turning gear time specified in Table 5 because of harmful long-term factors
in the Table has been taken as 50 hours per shutdown, but
subject to an annual maximum of the difference between Table 5: Maximum Total Time for Inspection Intervals
8 500 h/year and the operatiog time. In some circumstances
this may result in shutdown times of 1 000 hours per year for Power Output Range 1 + 2 Power Output Range 3 + 4
operating modes A, B and E. SI 02 years 03 years
The recommendation of a generally binding inspection
InI 05 years 06 years
interval of 40 000 to 60 000 equivalent operating hours
between Main Inspections for a medium-sized turbogenerator MI 10 years 12 years
Also refer to the following information

[1] Recommendations for Intervals between Turbogenerator Inspections, VDEW-Publication, Edition 1991,ISBN 3--8022--0352--6
Siemens AG
BHEL,Haridwar 2.5--1010--0005 / 2
Energy Sector 1110E
0114E
Turbogenerators Inspection Schedule
Maintenance Stator
Major Inspection
Minor Inspection
Initial Inspection
Work required
Measure insulation resistance of stator winding u u u
Subject stator winding to insulation resistance testing1) u
Remove TE and EE end shields. Replace seals and gaskets prior to re-assembly u u
Remove terminal box and replace gaskets u
Dismantle bushings and replace gaskets u
Check condition of stator core u u
Check seat of stator winding in slot section and end-winding section u u
Check bar connections (spring tension, voltage-drop measurement) u u
Replace all seals and gaskets for generator connection flanges and terminal bushings u
All Rights Reserved
Replace all seals and gaskets for components carrying water u
Replace seals and gaskets for PTFE hoses connected to stator winding u
Check PTFE expansion joints u

Clean strainers in primary water system u u
Check orifice plates in hoses u
Check strainers in phase connector flanges u
Perform leaktest on generator primary water system u u u

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Perform H2 leaktest on generator u u u

1) Dissipation factor measurement charging and leakage current measurement, and, in particular cases, high-potential test.
Siemens AG
Energy Sector 0302E
0114E
Maintenance Rotor
Major Inspection
Minor Inspection
Initial Inspection
Work required
Perform runout check u u
Withdraw and check rotor visuell u u
Check rotor wedges and retaining rings u u
Check end windings and gas outlet ducts u u
Measure insulation resistance of rotor winding u u u
Check bearing surfaces u u
Check shaft seal contact faces u u
Check rotor fan u u
Check coupling flanges u u

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Check rotor alignment u u
Perform visual examination of air side of axial bolts u
Remove radial bolts, check and replace if necessary. Replace multicontact band u
Replace H2 seals in EE coupling u

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Siemens AG
Energy Sector 0408E
0114E
Maintenance Cooler
Minor Inspection
Major Inspection
Initial Inspection
Work required
General
Check cooling water inlet and outlet pipes, vent pipes, drain pipes and valves on all coolers u u u
Check condition and function of temperature and pressure measuring instruments at all coolers u u u
Replace all flange gaskets and O-rings in coolers and pipes u
Replace all ball valves (including the O-rings in the AVIT joints) u
H2 -Cooler
Clean H2 cooler on water side u u u
Check condition and, if required, recondition H2 cooler water channnels u u u

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Dismantle H2 cooler, check on water and gas sides; clean and perform leakage tests u
Seal oil cooler
Remove seal oil cooler, check for fouling and clean if necessary
u u u
Replace any gaskets if damaged, and perform pressure test following re-assembly
Primary water cooler
Remove primary water cooler, check for fouling and clean if necessary
u u u
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Replace any gaskets if damaged, and perform pressure test following re-assembly
Note: No cleaning on water side is required on coolers supplied with condensate.
MKA
Siemens AG
BHEL,Haridwar MKF &MDC 2.5--1040--0016
Energy Sector MKW 0109E
0114E
Maintenance Bearings
Major inspection
Minor inspection
Initial inspection
Work required
Check and, if required, replace bearing insulation u u
Check bearing surfaces and babbitt bonding (dye penetrant and US*-test) u u
Check bearing clearances u u
Check seating of bearing sleeves on bearing saddles u u
Check labyrinth rings, and if required, replace seal strips u u
Check condition and performance of bearing temperature monitoring system u u
Check condition and performance of shaft lift oil system u u
Check condition of potential instrument wires u u
Clean hose between slipring bearing compartment and fan casing u u u

All Rights Reserved
Copyright
* US = ultrasonic test
MKC
Siemens AG
BHEL,Haridwar MKD &MDC 2.5--1050--0005
Energy Sector 0109E
0114E
Maintenance Shaft Seals
Major inspection
Minor inspection
Initial inspection
Work required
Check shaft seal insulation u u
Replace shaft seal insulation and gaskets u u
Check sliding contact faces of seal rings and seal ring carriers u u
Check contact faces of seal rings (dye penetrant test) u u
Check seal ring clearances u u
Check inner labyrinth rings and, if required, replace seal strips u u

All Rights Reserved
Copyright
MKA06
Siemens AG
BHEL,Haridwar
MKA07 &MDC 2.5--1060--0002
Energy Sector 0109E
0114E
Maintenance Generator Supervisory Equipment
Major inspection
Minor inspection
Initial inspection
Work required
Check condition and performance of temperature gauges and alarms u u u
Replace gaskets at temperature measuring points u
Check condition and performance of level meter system (liquid level alarm switches) u u u
Check condition and performance of grounding brush u u u

All Rights Reserved
Copyright
BHEL,Haridwar
Siemens AG MKY &MDC 2.5--1080--0005
Energy Sector 0114E
0109E
Turbogenerators
Measures for Preservation of Generator
Maintenance
During Standstill
Preservation measures will have to be taken when a The supply of water to the bearing oil and seal oil coolers
water-cooled generator is to be shut down. is not required during this period.
The scope of the preservation work required depends on
the duration of the shutdown, on the overall conditions in the 3 Coolers
vicinity of the unit and on the extent to which checks and All coolers should be drained on their cooling water sides
maintenance are possible during such period. and dried in a suitable measures. During the outage, the drains
The preservation measures recommended in the following and vents should be kept open.
are sufficient under normal conditions. High relative humidity Caution: Never leave water-filled coolers standing idle for
in combination with severe temperature changes involves the several weeks.
risk that the temperature of certain surfaces in the generator For cooler drying, hot air or dry ambient air may be used
may drop below the dew point, resulting in the possible which should be admitted by means of blowers via the cooling
formation of a moisture film due to condensation on these water inlet/outlet flanges. A fan-forced heater with a rating of
generator components. In such a case, special measures may 1 to 2 kW has proved satisfactory for this purpose.
be required for preservation of the rotor retaining rings (see
also 2.5--0030, Packing, Transport and Storage of Generator
4 Slipring Assembly
Rotors). The slipring assembly should be protected against
moisture by maintaining the space below the enclosure at a
1 Generator Interior
moderate temperature by suitable means. This may be
The hydrogen gas should be removed from the generator.
achieved with a hot air blower installed inside the enclosure.
The stator and rotor windings should then be protected against
The carbon brushes should be removed and the sliprings
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moisture by maintaining the generator interior at a moderate

covered with oiled paper.
temperature or in dry condition by suitable means. This may,
for instance, be achieved by the provision of a hot air blower
5 Bright Components
or dryer. The generator interior can also be maintained in a
All accessible bright components, e.g. exposed shaft
sufficient dry condition by keeping the primary water system in
portions, should be protected with a suitable corrosion
operation as mentioned under item 7 with activated primary

inhibiting oil or grease, e.g. Tectyl.
water heating system, if provided. No additional blowers are
the required.
If additional blowers are used for drying, the air should be 6 Seal Oil and Gas Systems
admitted and discharged via branches at the exciter end and Except for the work already mentioned, no preservation
measures are required on the coolers of the seal oil system.
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turbine end manhole covers.

Prior to recommissioning the generator, the insulation During the weekly activation of the seal oil system for
resistances of the stator and rotor windings should be turning the shaft, the system should be inspected for proper
measured and the windings dried, if required. functioning by checking all operation values.
All valves in the gas system should be closed. No additional
2 Bearing and Shaft Seals measures are required.
No preservation measures are required on the bearings of
the turbogenerator and on the H2 shaft seals. 7 Primary Water System
However, the bearing and seal oil systems should be After completion of the assembly or following a prolonged
placed into operation once a week and the entire system shutdown of the unit, the primary water system should be
adequately flushed with water-free oil. After activation of the oil placed into operation or kept in service, with monitoring and
systems, the shaft should be operated on the turning gear for maintenance to be performed in accordance with the
approximately three to four hours. information igiven n the turbogenerator manual.
Siemens AG
Energy Sector 0114E
0109E
Turbogenerators
Shaft Seal
Maintenance
The inspection of shaft seal rings and seal ring carriers is wear shall be replaced or reworked.
performed as follows: In addition, the contact surfaces shall be examined for
fractures and scoring marks. This is particularly required if
J If the components are not dismantled for the inspection, the parameters such as seal oil pressure, seal oil volume, H2
insulating effect of the shaft seal with regard to the side seal oil temperature, etc. displayed fluctuations in the
generator casing can only be measured via the shaft operating period prior to the inspection. Liquid penetrant
current. testing may be performed to obtain more accurate results.
J If the seal ring is removed, the clearances between seal
strips of the labyrinth rings and the shaft must be recorded Reassembly of the shaft seals should be performed with
prior to removing the seal ring. During the removal, the utmost care.
condition of all shaft seal components and particularly that During each inspection, a check should be made to ensure
of insulating elements such as flange insulation and that the seal rings are still sufficiently insulated from the stator
insulation barriers shall be checked. frame.
Following removal of the shaft seal, all components shall be
cleaned thoroughly. Any components displaying signs of
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Copyright
Siemens AG
BHEL,Haridwar MKA06/07 &MDC 2.5--6000--0005
Energy Sector 0109E
0114E
Turbogenerators
Maintenance Insulation and Sealing of Shaft Seals
1 Introduction must be dry to provide a sufficient insulating resistance. Moist

Due to their potential contact with the shaft, labyrinth rings insulating material must be dried in an oven at approx.
and seal ring carriers must be insulated from the end-shield 80 --100 _C (176 through 212 _F).
bearings to prevent any current from flowing across these
components.
This requires the use of specially-designed seals and insu-
lating material.
Prior to installing the components, the seals and insulating
material must be checked, adapted and replaced if necessary.
2 Seal Rubber
In terms of its shape and quality, the rubber material used
for the seals is a special design which is characterized by its Fig. 2 Cut in Insulating Rings
resistance to gas and oil, and its high insulation resistance.
Each ring is cut radially to enable the rings to be installed
The rubber material is produced and supplied by Siemens,
on the shaft. Following installation, the cuts must be offset by
and it must be ensured that no other material is used for this
90q.
purpose. Any additional rubber must be ordered from Sie-
mens.
6 Check and Installation of Insulation
3 Cutting the Rubber to Length Before installing the labyrinth ring and the seal ring carrier,
Prior to installing the labyrinth rings and seal ring carriers in the insulating rings must be checked thoroughly, and be
All Rights Reserved
the generator, these must be assembled provisionally, and the replaced if necessary. When preparing new insulating rings,
required length of rubber must be determined by inserting this care must be taken to ensure that one cut is at the 12 oclock
in the groove. The position of the rubber (round side facing out- position and the other offset by 90_ (i.e. at the 3 oclock or
ward) and the chamfered joint must be taken into account. 9 oclock position), and that the holes for the bolts are smaller
The rubber should be cut so that the ring only has one joint. than the holes in the end-shield bearing and the seal ring
carrier.
With regard to the insulating rings for the seal ring carrier,
particular attention must also be paid to the holes for the
Seal oil supply

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J
J Seal ring oil supply.
These holes must exactly match the bores in the seal ring
carrier.
The outside diameter of the insulating rings must exactly
match the outside diameter of the flange face of the end-shield
bearings. This ensures that the seals are centered around the
center of the shaft and cannot move when the seal ring carrier
* Apply pressure in direction of arrow
is installed.
Fig. 1 Joining the Seal Rubber The inside diameter of the insulating ring is shown in the
corresponding drawing. Strict compliance must be ensured
4 Inserting the Seal Rubber with the specified dimensions because an insufficient inside
After cutting the rubber to length, and after both ends have diameter would prevent the rubber from fitting snug to the seal
been prepared for application of the adhesive, the rubber must face of the end-shield bearing.
be placed round the shaft and joined together (cf. 2.5--2120) The closed insulating rings must be cut fully at the prepared
before placing it in the groove. It must be ensured that the positions and placed round the shaft. Thinly apply Ramsey
round side of the rubber faces toward the end-shield bearing, grease to the side of the insulating rings facing toward the end-
and that the joint is arranged as shown in Fig. 1 above so that shield bearing, and press the insulating rings against the con-
the chamfered joint is firmly pressed together when the compo- tact surface of the end-shield bearing. Close the cut rings by
nent is bolted to the end-shield bearing. pressing the two ends together. The Ramsey grease prevents
Handhabung: OFFEN
the insulating rings from moving during the remaining assem-

5 Insulation bly activities.
The insulation comprises two insulating rings each measur- If Ramsey grease is not available it is possible to use non-
ing 1 mm (0.04 in.) thickness. The material is hygroscopic and conductive vaseline.
Siemens AG
BHEL,Haridwar MKA &MDC 2.5--6110--0002 / 1
Energy Sector 0114E
1010E
NOTE:
Do not use electrically conductive vaseline.
The procedure for handling the insulation of the labyrinth

rings is identical to that used for the insulating rings of the seal-
ring carriers.
Siemens AG
BHEL,Haridwar 2.5--6110--0002 / 2
Energy Sector 1010E
0114E
Turbogenerators
Stator
Maintenance
1 Insulation Resistance Measurement

Attention
After each shutdown, the insulation resistances should be
measured prior to carrying out the inspection (see also Even minimal-size metallic particles left inside after
2.5--2300, 2.5--3300 and 2.5--2310). work on the generator can lead to large-scale damage
during generator operation. To prevent such damage
2 Stator Winding to the generator and the stator winding, the following
Depending on the scope of the inspection, the slot wedges precautionary measures must be taken.
should be checked for tight fit, and the end windings should be
inspected for proper support. 01 Only persons assigned to such work may enter
After opening the generator, the interior should always be the interior of the generator.
inspected for contamination of any kind. If contaminations are 02 Persons assigned to such work must be in the
detected, its cause should be determined and corrected in possession of clear work procedures and have
order to preclude any new contamination. The generator been informed of special features of the work
interior should be cleaned thoroughly. scope involved and of the associated potential
dangers.
3 Terminal Bushings
The bushings and expansion joints should be inspected to 03 All persons entering the interior of the generator
ensure a proper connection between the bushings and the must wear clean overshoes.
phase connectors. The bushings should also be checked for
proper connection to the bus bars arranged external to the 04 Before entering the generator interior, all
generator. persons must empty their pockets and remove all
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metallic objects worn (such as watches, chains,

4 Primary Water Tubes and Hoses in Stator earrings etc.).
All primary water hoses and tubes must be checked. If
05 Tools required for work inside the generator may
possible, this should be performed without draining the
only be transported within boxes, and must be
primary water from the generator.

returned to these boxes after use.
5 Cooler Wells 06 After completion of work inside the generator, the

When dismantling of the hydrogen cooler sections is completeness of tool kits should be verified
required for inspection, the cooler wells in the cooling header against tool lists and the results of this check
should be checked for cleanliness.
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logged.
6 Flanged Joints and Metering Connections 07 All winding areas on which work is to be
All stator flanges should be checked for proper alignment performed must be covered off carefully before
and seating. The stator should be checked for tight anchoring work is started.
to the foundation.
08 All parts to be installed or removed should be
All metering connections should be checked for proper
listed, with details of their exact whereabouts.
mounting and condition as far as practicable. This should
include both the electrical metering connections and the pipe 09 Should a part be dropped despite all the above
connections to the measuring instruments. precautionary measures, it is imperative that it be
Prior to recommissioning, the insulation resistance of the located and removed. Site management should
stator winding should be measured and, if necessary, be informed in the case of any problems in this
improved. context.
10 Generator openings should be closed off with the

original covers for the duration of any work
breaks.
11 The use of the attached check list (2.5- 2001) for

works at the generator is strictly required.
Table 1 Precautionary Measures During Work Inside the Generator
Siemens AG
Energy Sector 0409E
0114E
Turbogenerators Check List for Works on Generator
Maintenance
Description of work to be carried out to be checked by Date Name / Signature
1 Work permit for works on generator
Area around generator to be barriered off (work passes to

be issued to individual workers) and supervisor to be nom-
2
inated for the period the generator is open. Closing during
breaks and process interruptions to be assured.
3 Cleanness check of area around generator
Instruction of workers regarding working inside and around

4
the generator
Listing of all tools used for repairwork inside of generator.

5
Tools to be marked
Checking of inside of generator immediately after

6
manholes are opened (first man inside generator)
All opening of generator, pipework and bearings to be

7
temporarily covered
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Listing of all material removed from the generator parts to

8
be collected in separate boxes
Checking of complete generator inside prior to closing of

9
manholes (last man inside generator)
10 Check of whereabout of tools used inside of generator
11 Checking the material removed from generator
12 Release of generator for start-up

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13 Return of work permit

BHEL,Haridwar
Siemens AG 2.5--2001--0001
MKA &MDC
Energy Sector 0109E
0114E
Turbogenerators
Cementing the Joints of Profiled Gaskets
Maintenance
1 Sicomet 50 Adhesive take care that the profile does not suffer any visible distortion
and that the pressure applied after pulling together the parts to
Profiled gaskets should preferably be cemented together be mounted is exerted on the area of cut (see arrow in Fig. 1).
by means of Sicomet one-component adhesive. This adhesive The faces to be cemented together should be well roughened.
meets all requirements, its only disadvantage being the
difficulties encountered in storage. 2.2 Cementing the Joint
Sicomet should be protected from moisture, heat and sun- The adhesive should be applied in drops on the joint areas
light and should therefore be stored in a dry, cool and dark to be cemented together, using a plastic or metal spreader for
place. To prevent an increase in viscosity and discoloring of the obtaining a thin film. Immediately afterwards the joint faces
adhesive Sicomet is best stored at a temperature of -10 _C should be assembled and located in position. Because of the
(14 _F). If stored under these conditions, Sicomet has an unlim- short curing time of 10 to 30 s any readjustment will be almost
ited working life. Defrost Sicomet prior to use and bring to room impossible. After curing, any cement residue should be
temperature. removed from the outer surface of the bonded joint by means
Repeated freezing and defrosting does not affect the bond- of emery paper.
ing properties. The maximum storage time at room tempera-
ture is six months. The adhesive not used up must be stored WARNING:
at a temperature of -10 _C immediately. Sicomet should only be used in well ventilated work areas.
Care must be taken to avoid body contact. In the event of
contact with the eye, rinse immediately with ample
2 Preparatory Work and Application of Adhesive amounts of distilled or drinking water to dilute the adhe-
sive. The eye should then be treated to soothe any in-
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2.1 Preparatory Work flammation and a physician immediately consulted.

The exact length of the profiled gasket is determined by
inserting it in the center of the sealing groove, allowing 30 to 2.3 Breaking the Cemented Joints
40 mm (1.12 to 1.57 in.)in length for overlapping at the joint. The Cemented joints which are to be broken should be placed
joint faces could be cut so that the overlapping portion to be in a bath of either dimethyl-formamide for a brief period or of
cemented is approximately 30 to 40 mm long. When cutting ethylacetate for a longer time, resulting in swelling.
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30 to 40 mm
Fig. 1 Cementing of a Profiled Gasket
Siemens AG
Energy Sector 0109E
0114E
Turbogenerators
Generator Drying System
Maintenance
1 General The tubular ducts are dimensioned so that a laminar flow

A dryer (dehumidifier) should be connected to the with low pressure loss is obtained even at high air velocity.
generator to avoid the formation of moisture condensate The moisture adsorbed by the dryer wheel is removed in a
inside the stator frame housing with the turbine-generator at regeneration section by a stream of hot air directed through the
rest after removal of the hydrogen gas or during overhauls. wheel in the opposite direction of the inlet air and then
The dry air inlet and outlet connections are located in the stator discharged to the atmosphere.
end shields. After regeneration, the dryer wheel material is again
For connection of the dryer, the covers in the upper half end capable of absorbing moisture.
shields should be removed and replaced by the covers The adsorption of moisture and regeneration of the dryer
comprising the dryer connection branches. The dryer should wheel material take place simultaneously, using separate air
be connected with flexible hoses and then placed into streams, which ensures a continuous drying of the air.
operation.
1 2 3 3 Operating Principle of Adsorption Dryers

Dehumidification takes place in a slowly rotating dryer
wheel (approximately 7 revolutions per hour). The honeycomb
dryer wheel consists of a magnesium silica alloy containing
crystalline lithium chloride. The inlet side of the dryer wheel is
subdivided so that 1/4 is available for regeneration and 3/4 for
the adsorption section.
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1 2 3 4 5
5 4 7 6
1 Regeneration air outlet 5 Filter

2 Dryer wheel 6 Dry air outlet
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3 Heater 7 Shutoff valve, motor driven

4 Ventilator
Fig. 2 Schematic Diagram
4 Adsorption Section of Dryer

The air to be dehumidified passes through the adsorption
section of the dryer wheel, with part of the moisture contained
in the air being removed by the adsorbent material, i.e. lithium
1 Stator frame 3 End shield chloride. The moisture is removed as a result of the partial
2 Cover pressure drop existing between the air and the adsorbent
Fig. 1 End Shields material.
2 Mode of Operation of Dryer 5 Regeneration Section of Dryer

The dryer dehumidifies the air within the stator frame In the regeneration section of the dryer wheel, the
housing. The dryer wheel is made of a nonflammable material. accumulated moisture is removed from the dryer wheel by the
On its inlet side, the wheel is provided with a system of tubular heated regeneration air.
ducts, the surfaces of which are impregnated with a highly Continuous rotation of the dryer wheel ensures continuous
hygroscopic material. dehumidification of the air.
Siemens AG
Energy Sector 0109E
0114E
Turbogenerators
Mounting of Inner Labyrinth Rings
Maintenance
1 General 3 Installing Labyrinth Rings

The purpose of inner labyrinth rings is to prevent the seal (If labyrinth rings are assembled after rotor installation)
oil escaping from the shaft seals on the hydrogen side from Place lower half labyrinth rings on rotor in their proper axial
entering the generator interior. positions for normal operation. lf required, use appropriate
For this reason, these components should be assembled hoisting gear.
with utmost care. The bracket which protects the labyrinth ring from dropping
while this is being rotated into position should be assembled
from below. Then move the labyrinth ring into position by
rotating it through 180_ around the circumference of the rotor.
1 Lower half labyrinth ring

2 Bolted joint
3 Fitting device
Fig. 1 Labyrinth Ring
3
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The labyrinth rings must be mounted after installation of the

Fig. 2 Moving Lower Half Labyrinth Ring into Position
generator rotor and installation of the lower half bearings, but
before the upper half end-shield bearings are installed. At first,
the ring should be attached to the lower half end-shield bearing Push the lower half labyrinth ring in axial direction against
only. After complete assembly of the upper half end-shield the flange of the end-shield bearing. Attach it provisionally by
bearing, the inner labyrinth ring should be bolted in position. means of the two bolts at joint level so that the fitting device can
At this stage, the generator rotor must not be coupled to the be detached afterwards.
turbine rotor. When placing the upper half labyrinth ring in position, make
Mounting of the inner labyrinth rings is facilitated if the rings sure that the joints are aligned and that the taper pins can be
are already assembled on the rotor prior to rotor installation easily inserted.
Copyright
and the joint bolts tightened from outside. The labyrinth rings The joint bolts, nuts and lockplates should then be inserted
are then installed in the stator together with the rotor. and uniformly tightened.
To avoid contact with the shaft and the resulting flow of shaft Remove the two bolts provisionally inserted at the labyrinth
currents the labyrinth rings must be insulated from the end ring-to-end-shield bearing joint and move labyrinth ring in axial
shields at the flanged points. Attention should be given to direction away from the flange up to the shaft collar. With the
careful fitting of the insulation. After completion of the labyrinth ring in this position, insert the gasket and the
assembly work, the insulation of the labyrinth rings should be insulation.
checked (see also 2.5--0300, Checking the Bearing and Seal
Insulation).
4 Installation of Gaskets and lnsulation
Prior to connecting the labyrinth ring to the end-shield
2 Preparatory Work bearing, the insulation and gasket should be checked,
The labyrinth rings should be cleaned with a suitable replaced (if necessary), and placed in the proper position.
solvent. Clean the groove for the gasket and all fixing holes
and oil drain holes in the lower half labyrinth rings with
compressed air. Check flange surfaces facing the end-shield 5 Assembling Labyrinth Rings
bearings and perform a bluing check. Correct any unevenness Shift Iabyrinth rings up to the flange of the end shield
by local rescraping. bearing. Provide mounting bolts with insulating sleeves,
The mating upper and lower half labyrinth rings are marked insulating washers, washers and lockplates. Insert bolts from
TE or EE close to the joints and should be mounted the bearing compartment side via the through holes of the end-
accordingly. shield bearing and screw them into the tapped holes of the
The labyrinth rings should be provisionally assembled and labyrinth ring.
the length of the gasket (seal rubber) determined and Measure the insulation resistance and compare with the
prepared. value measured previously (see also 2.5--0300, Checking the
Following this, the insulating rings should be matched. Bearing and Seal Insulation).
BHEL,Haridwar
Siemens AG MKA &MDC 2.5--2162--0004 / 1
Energy Sector 0109E
0114E
6 Checking Labyrinth Ring Clearances Labyrinth Rings). New seal strips are available from Siemens
The labyrinth rings are adjusted. Mlheim Manufacturing Plant.
To check the radial clearances, measure the gap between
the caulked seal strips and the shaft at two opposite points 10 Final Assembly of Labyrinth Rings
each of the horizontal and vertical centerlines. After assembly of the labyrinth rings with the specified
Use air gap gauges or feeler gauges (0.02 mm clearances, check the insulation and compare the results with
increments) for making the measurements. The clearances those of previous measurements. lf the results correspond to
measured should be plotted in a coordinate system and the specified minimum values, place the upper half end-shield
compared with the reference dimensions. bearing in position.
The clearances are specified in the shop records, and are Bolt the labyrinth ring to the upper half end shield bearing
typically determined as follows: only after the upper half end-shield bearing has been
completely attached to the stator frame and bolted to the lower
Top clearance half at the joint. When bolting the labyrinth ring, check that the
insulating sleeves, insulating washers, washers and
lockplates are positioned correctly.
Finally, check all flange bolts again for uniform tightening.
1/2 lateral clearance 1/2 lateral clearance Then check again the insulation resistance of the labyrinth
ring insulation.
With satisfactory insulation, secure all bolts on the
circumference as weIl as the joint bolts and nuts. Check the
insulation resistance again.
1
0.05 mm
(0.1 mm for shafts measuring 500 mm in diameter)
Fig. 3 Labyrinth Ring Clearances Around Circumference
ln case the clearance distribution should not correspond to

Fig. 3, a readjustment should be made in order to obtain the
specified clearances.
lf the actual clearances do not correspond to the specified
clearances, reworking of the Iabyrinth ring will be necessary.
In case of excessive clearances, new seal strips will have to
be fitted (see also 2.5--2163, Fitting New Seal Strips to
Labyrinth Rings).
7 Readjusting Labyrinth Rings

The mounting bolts of the labyrinth ring should then be
slightly loosened and the labyrinth ring shifted by means of a
mounting iron and wooden block in order to obtain the
specified clearance distribution. When inserting the mounting
iron be sure not to damage any parts.
Retighten the mounting bolts when the specified clearance
distribution has been obtained and check the clearances
again after tightening.
2
8 Reworking Labyrinth Rings
The labyrinth rings must be removed for performing this
work.
9 Fitting New Seal Strips 1 End shield bearing

2 Inner labyrinth ring
ln case of excessive actual clearances, new seal strips
must be fitted. To do this, remove the old seal strips and insert Fig. 4 Assembled Inner Labyrinth Ring
new seal strips (see also 2.5--2163, Fitting New Seal Strips to
Siemens AG
BHEL,Haridwar 2.5--2162--0004 / 2
Energy Sector 0109E
0114E
Turbogenerators
Fitting New Seal Strips to Labyrinth Rings
Maintenance
1 General labyrinth ring groove. Apply auxiliary tool to the seal strip at the
During initial installation or inspection of the unit the radial labyrinth ring joint and drive out seal strip by light hammer
clearances between the caulked-in seal strips of the labyrinth blows until the turn-out tool can be applied. The machined slot
rings and the shaft should be measured. For required labyrinth in the turn-out tool should be pushed over the caulked seal strip
ring clearances, see the binding drawing Rotor Clearances. and the seal strip pulled out by turning the turn-out tool.
If the actual clearances are excessive, new seal strips should
be fitted to the labyrinth rings. To do this, the old seal strips
should be removed and replaced by new ones. New seal strips
are available from stock at KWU Mlheim Works.
WARNUNG
WARNING
Risk of fire and personal injury. Excessive clearance at the
oil wiper rings and bearing can cause oil to escape. Risk of per-
sonal injury due to fire or slipping. Replace the seal strips of the
oil wiper rings as per the corresponding maintenance sched-
ule. Check the oil wiper rings and bearings for signs of oil leaks
and clearances as per the maintenance schedule. Record the
parameters in the assembly record.
2010 -- All Rights Reserved
2 Tools
The tools shown below are required for removal and fitting
of seal strips.
Fig. 2 Driving Out Seal Strip

e Siemens AG
Copyright
1 2 3 4 5 6 7 8
Fig. 3 Pulling Out Seal Strip
1 Scraper
2 Sharpening tool 4 Cutting New Seal Strips to Length
3 Smooth file The new seal strips to be fitted are delivered in the form of
4 Caulking tool
5 Pincers a coil approximately 300 mm (11.8 in.) in diameter. From this
6 Turn-out tool coil the required length including a sufficient allowance for one
7 Drift key
8 Hammer groove of the half labyrinth ring should be cut by means of pin-
Fig. 1 Tools Required for Fitting New Seal Strips to cers. Bend seal strip by hand so that its diameter matches the
Labyrinth Rings diameter of the labyrinth ring. Cut seal strip to required length
with an allowance of 2 to 3 cm (0.8 - 1.2 in.). Using this strip as
3 Removing Seal Strips a sample, the half rings required for the remaining number of
For removal of the old seal strips, a chisel, screwdriver or grooves should be cut from the coil and bent as described
similar device should be sharpened so that it fits into the above.
Siemens AG
BHEL,Haridwar
MKA &MDC 2.5--2163--0001 / 1
Energy Sector 0710E
0114E
Fig. 4 Seal Strip, Pulled Out
Fig. 6 Cutting Projecting Seal Strip Ends
5 Caulking New Seal Strips
Insert seal strip into groove at bottom center of labyrinth ring
and gradually drive seal strip into the groove over its full length
by applying light hammer blows to the caulking tool.
Fig. 7 Finishing Seal Strip Ends by Means of a Smooth File
Join surface is super-finished and must not be damaged.

Fig. 5 Driving in Seal Strips
Never drive home seal strip to slot bottom immediately as

this may result in lateral distortions of the seal strip.
Starting again at the bottom center, proceed to drive in the
seal strip lightly in direction towards the labyrinth ring joint. It
is recommended to move the caulking tool along the seal strip
several times in opposite directions, applying light hammer
blows until the seal strip beds against the groove bottom. With
the strip in this position, the caulking tool touches the inner
diameter of the labyrinth ring. Avoid hard hammer blows, as
otherwise the caulked-in seal strip will be unduly squeezed. In
addition, this would necessitate remachining of the groove
prior to inserting a new seal strip.
6 Finishing Seal Strips at Labyrinth Ring Joint

Fig. 8 Checking the Joint with a Bar for Color Print Control
After caulking of each seal strip, the strip end projecting
from the joint should be cut by means of pincers. The remain- After all seal strips have been caulked in and finished at the
ing 1 to 2 mm (0.04 - 0.08 in.) hould be carefully removed by joint, the joint surface should be checked by means of a bar for
means of a smooth fiIe after caulking of all seal strips. color print control and, if required, reworked with a scraper.
BHEL,Haridwar
Siemens AG 2.5--2163--0001 / 2
Energy Sector 0710E
0114E
7 Turning lnside Diameter of Labyrinth Ring
After color print control, the half labyrinth rings should be
assembled according to the marks and then turned on a lathe
to suit the shaft dimensions and clearances specified on the
drawing Rotor Clearances.
Fig. 10 Sharpening Seal Strips
8 Sharpening Seal Strips

Turning the inside diameter of the labyrinth rings results in
blunt seal strips The seal strips must therefore be sharpened
by means of a special sharpening tool prior to assembly. After
completion of this work, the half labyrinth rings should be
bolted together again.
CAUTION
Fig. 9 Rescraping Joint Surfaces Risk of personal injury due to sharp edges. Be sure to wear
suitable protective gloves when sharpening the seal strips.
Siemens AG
BHEL,Haridwar 2.5--2163--0001 / 3
Energy Sector 0710E
0114E
Turbogenerators Insulation Resistance Measurements
Inspection on Stator Winding
During manufacture and transport, the insulation of the lf the insulation resistance measured is lower than the
stator winding may have been exposed to moisture which specified minimum value, the neutral connections must be
would reduce the insulation resistance of the windings. The separated and the insulation resistances of the individual
insulation resistance should therefore be measured prior to winding phases measured. During the test, the other two
initial startup, after prolonged shutdowns and after work on the phases which are not involved should be grounded. lf the
windings. lf required, the generator should be dried until a insulation resistances of the individual phases are likewise
sufficient insulation resistance is obtained. Iower than the required limit value, drying of the windings will
be indispensable. Great differences in the insulation
resistance values are indicative of local contaminations, e.g.
1 Required Insulation Resistance of Stator Winding insulators at bus duct or terminal bushings. lf practicable,
The insulation resistance measured is dependent on the additional connections should be separated.
temperature. To permit a proper assessment, a correction to an If this measure does not result in an improvement, it is
agreed reference temperature (formerly 75 _C) must be made. recommended to obtain the services of a specialist from the
An insulation resistance of 1 megohm per each kilovolt of manufacturers works.
rated voltage at 75 _C is normally attainable without any
difficulties. 2 Measurement of Insulation Resistance
New international standards specify an insulation Prior to each measurement, the generator must be
resistance of not less than 1 megohm per each kilovolt of rated deexcited and any static charges removed by grounding the
generator voltage at 40 _C. windings. The windings should also be grounded after each
A correction of the insulation resistance measured at the measurement for the duration of the recharging period.
All Rights Reserved
winding temperature prevailing during the measurement to the The insulation resistance of the stator is measured between
above reference temperature can be made using the diagram the winding copper and the stator core.
in Fig. 1. Prior to primary water filling, the insulation resistances of the
individual stator winding phases with respect to the steel part
should be measured by means of a 2.5 to 5 kV megger.
10000
During normal operation, the winding bars are electrically
connected to the grounded cooling water manifolds through
Insulation resistance R in megohm
5000
the water in the water inlet and outlet hoses.
3000 Because of the considerably Iower resistance in the hoses,
2000 a determination of the insulation resistance according to the
Copyright
known methods is no longer practicable.

1000
To enable, nevertheless, a measurement of the insulation
500 resistance, this turbogenerator with water-cooled stator
winding incorporates the following design features:
300
200 J The water manifolds for the cooling water are insulated for
100 5 kV against the frame and connected outside the generator
via cables to the insulated contacts. During normal
50 operation, these contacts are connected to the frame, and
thus grounded.
30
J The bushing hoses are provided with contact sleeves.
20
10 During the measurements, the primary cooling water must

be flowing, the required conductivity being $ 1 mmho/cm.
5 To measure the leakage current according to Fig. 2, the
water manifolds should be disconnected from ground, joined
3
to the contact sleeves and connected to the same power
2
source as the windings. A micro ammeter should be inserted
1 in the connection to the windings. Since, in addition to the very
0 20 40 60 80 100 120 140 160 low leakage current, the power source is now also required to
supply the possibly very high partial currents via the cooling
Temperature t in _C
water connections, batteries are not suitable for this purpose.
Fig. 1 Diagram for Correction of Insulation Resistance The dc voltage should therefore be obtained from a stabilized
Measured to a Temperature of 40 _C power supply.
Siemens AG
BHEL,Haridwar 2.5--2300--0004 / 1
Energy Sector 1194E
The measuring circuit is shown in Fig. 2. U(kV)
R10 = = 103 M8
To determine the insulation resistance of water-cooled I (mA)
windings, the currents due to any cells resulting from the
cooling water in the hoses between the winding copper and the Note: When the generator is filled with hydrogen, make
water manifolds of steel must be taken into consideration. For sure that the rotor shaft ends are properly grounded
this reason, the insulation resistance of the complete winding during measurement and discharging.
should first be measured by applying a positive voltage. After During measurement the movement of ammeter AN is
discharging, the measurement should be repeated with a connected to the positive pole of the stabilized power
negative voltage. supply (approximately 1000 V to ground).
Note: Current may pass through zero. In such a case, the Temperature detectors may be installed in the
ammeter should be changed over and the current read and ring-shaped water manifold. To protect the connected
recorded, observing the negative sign. The recharging metering leads and measuring instruments, the metering
current is the mean value of the tests performed with leads should be disconnected at the generator terminal
positive and negative voltage. strip (at stator frame) during the above test.
lndividual phases can be tested by a similar procedure. After completion of the measurements the measuring circuit
The insulation resistance (R10) is calculated from the should be removed.
applied voltage and the 10-minute recharging current.
1 = Stator
Stator winding connection and terminal arrangement 2 = Rotor
2 3 = Terminal bushing
as shown in this diagram were arbitrarily selected; not 4 = Water manifold ground contact
identical with machine described herein. 5 = Generator ground connection
6 = Hose with contact sleeve
7 = Ground connection for manifolds
G1 = Grounding of generator frame
G2 = Grounding of TE shaft end
G3 = Grounding of EE shaft end
G2 G3 B = Stabilized power supply
UB = Voltmeter
Z Y X W V U AN = Ammeter
IUVW = Current to winding
S = Switch
3 4 5
7 G1 7 4
-- Note:
B V UB J The primary water must flow through
IUVW the winding during the measurement.
S AN J After measurement, the water manifolds
A
should be grounded again via the
ground contacts.
Fig. 2 Circuit Arrangement for Measuring the Insulation Resistance R10
BHEL,Haridwar
Siemens AG 2.5--2300--0004 / 2
Energy Sector 1194E
0114E
Turbogenerators
Drying the Windings
Maintenance
The epoxy resin mica insulation applied to the stator Run up the turbine-generator to rated speed and excite
winding by mean of the VPI process absorbs practically no generator. As a result of this, a current in accordance with the
moisture. Any reduction of the insulation resistance during short-circuit characteristic will flow in the stator winding. The
transport, erection or a prolonged shutdown is mostly caused currents in the three phases should be of identical magnitude.
by a moisture film on the surface of the insulation. To prevent Should this not be the case, the generator will have to be de-
damage to the insulation, it will be necessary to check the in- excited and the cause of the non-uniformity (e.g. poor contact
sulation resistance of the stator and rotor windings prior to of buses) removed.
running up the unit to full voltage. Please refer to Section The stator winding temperature and the hot and cold gas
2.5--2300 for details on performing insulation resistance temperatures should be brought to the maximum operating
measurements on the stator winding particularly for level by slowly raising the field current.
applications with direct water cooling. In case of an insufficient During drying, the absorbent material in the gas dryer
insulation resistance being detected, the winding must be should be carefully observed. When the gas dryer filling is no
dried first. longer active, reactivation should be carried out.
The drying process for hydrogen-cooled generators should During drying, the generator must be occasionally de-
preferably be carried out with the generator filled with excited and run down, and the insualtion resistances must be
hydrogen, making sure that the gas dryer is in operation and measured. In the event of sufficient insulation resistances
that the absorbent material is sufficiently active. being obtained, short-circuit drying may be stopped.
The stator winding should be short-circuited at the Remove the short-circuit at the bushings.
bushings by means of buses. The buses should be fitted so as Following this, the generator may be run up to full voltage.
to permit a measurement of the short-circuit current by means In the event of a prolonged shutdown of the generator, it is
All Rights Reserved
of current transformers. The primary water system for the preferred that the hydrogen filling be retained in the generator,
stator winding must be activated and the conductivity of the thereby eliminating surface moisture on the windings.
water must be reduced to the normal operating level.
Copyright
Siemens AG
Energy Sector 0806E
0114E
Electrical Tests on Stator Winding
Turbogenerators With Vacuum Impregnated
Maintenance Micalastic High-Voltage Insulation
1 The Insulation System of the Stator Winding reasons to be explained in the following sections, not all of
these tests are suitable for checking the insulation of large
The insulation system serves to insulate the generator turbogenerators, especially those with water-cooled windings.
stator bars, which are subjected to a high-voltage potential of
up to 30 kV, from each other and from the grounded stator iron J Insulation resistance measurement (megger)
parts for reliable protection against the additional thermal and J Recharging and leakage current measurement for exact
mechanical stresses arising during operation. determination of insulation resistance
For decades, insulation systems with a high mica content J Dissipation factor measurement
of up to 65 % have been and are still being used most J Partial discharge measurements
successfully. J High-potential proof tests
Since 1960, all generators built by KWU and its parent AC voltage
companies. Siemens Power Generation, respectively, have DC voltage
been equipped with synthetic-resin insulation systems. This
system uses epoxy resin featuring a high resistance to
3 Insulation Resistance Measurement
mechanical, thermal and electric stresses.
The Micalastic insulation consists of mica tapes applied Insulation resistance measurement is by far the simplest
continuously from end to end on the bars, including the involute and easiest of the available tests to perform to determine the
section. Vacuum pressure impregnation with epoxy resin integrity of the insulation. lt is made with an instrument
provides an insulation system which is highly resistant to commonly known as megger and supplying a variable DC
mechanical, thermal and electric stresses and also impervious voltage between 100 V and 5000 V. The instrument is
All Rights Reserved
to moisture. Drying the insulation prior to startup of the calibrated for direct reading of the insulation resistance in
generator will thus only be required to remove any moisture film megohms. The DC voltage for measurement is generated by
on the surface. a hand-operated or motor-operated generator or by electronic
means. This voltage should be applied for not less than one
minute prior to reading the insulation resistance value to allow
2 Purpose and Kind of Electrical Tests
for the decay of the absorption current component with time

The mechanical, thermal and electric strength of the due to a polarization of the dielectric in the electric field. This
insulation system is assured by numerous laboratory tests process, which follows an exponential function, is reflected at
performed prior to using the insulation in actual service on the the instrument by a pointer deflection which is initially fast and
generators and by the results of service experience. The first then gradually slows down. The results of this reading indicate
Copyright
generator provided with the high-grade Micalasticinsulation only the presence or absence of a winding short to ground and
system in 1958 has meanwhile completed 200 000 operating that the insulation resistance is at a level above the accepted
hours without any failure. minimum limit. This test is performed prior to each startup of the
During the manufacturing process until delivery of the unit and prior to each high-potential test on a winding.
generator, a comprehensive quality verification program is On water-cooled generators with water-filled winding, the
performed by subjecting the insulation to electrical tests. relatively low resistance of the water in the hoses between the
Unless the insulated parts in the generator are stressed due to winding and ground potential is connected in parallel to the true
abnormal conditions during transport or during the installation insulation resistance. A megger reading would indicate the
and assembly at the power plant, no electrical testing would be resistance value of the water in the hoses. Depending on the
required prior to placing a new generator into operation. For conductivity of the water and the number of parallel-connected
safety considerations, the insulation resistance should, hoses, this value may be far below 1 megohm and does not
however, be checked by means of a megger prior to each provide any information on the magnitude of the insulation
startup. resistance of the winding. It merely serves to determine that
lt is a known fact that even the best insulation system is there exists no direct short to ground.
subject to aging during service, especially as a result of To determine the insulation resistance of water-filled
operational disturbances, such as voltage surges due to windings by means of megger readings in the usual way, the
sudden short-circuits. etc. water must be drained from the windings, and the surface of the
During overhauls, the degradation of the insulation and any supply hoses requires thorough drying.
damage due to accidental disturbances should therefore be

ascertained by a visual inspection and by means of suitable
4 Recharging and
electrical tests to give assurance of troublefree operation for
Leakage Current Measurement
further years.
There are several methods of electrical testing. All of these To determine the true insulation resistance of an insulation,
are indicated below for the sake of completeness. However, for somewhat larger and more complicated equipment is required,
BHEL,Haridwar
Siemens AG MK &MDB 2.5--2320--0001 / 1
Energy Sector 0409E
0114E
permitting also a determination of the polarization index. For Prolonged exposure to thermal and mechanical stresses
this test, a stabilized DC power source and a micro ammeter and last but not least the effect of partial discharges may result
are required, enabling the current to be measured as a function in new separations and thus in additional discharges.
of the test period under otherwise constant conditions and Measurement of the dissipation factor as a function of the test
allowing the influence of temperature, moisture and dirt to be voltage can therefore provide information on the aging of an
determined and considered. insulation by a relatively simple method.
In hydrogen-cooled generators, the ambient is quite clean, Measuring the dissipation factor on individual winding
and the winding is protected against moisture absorption, components, such as bars, is mostly performed by means of
because, in contrast to air-cooled units, these machines have a guarded electrode to eliminate the effect of leakage currents
a closed cooling circuit. across the coil end. Such a guarded electrode system cannot
In addition, the insulation of Micalastic-insulated be provided for complete windings which are mostly equipped
generators is not subject to moisture absorption. Recharging with an end corona protection. This effect must therefore be
and leakage current behavior and the insulation resistance, taken into consideration when evaluating the variation of the
respectively, may merely be affected by dirt or moisture on the dissipation factor with voltage.
surface of the end windings. The dielectric constant and the dissipation factor are
On windings without water conductor cooling, this test is just measured with a Schering bridge.
as easy to perform as the megger reading. However, to permit
the use of this test also on water-cooled windings with water
circulating in the windings without affecting the recharging
current or the insulation resistance through the water in the
Cxx
C
multiple parallel hoses from the winding to the ground, CN
Siemens Power Generation generators are equipped with Screen
special devices in the water circuit, enabling the water
manifolds to be disconnected from the ground in a simple way.
The bushing hoses are equipped with contact sleeves to
R3 VG
compensate for the leakage current through the water in the R4
hoses.
Since, in addition to the leakage current, the stabilized DC
power source is also required to supply the partial currents via C4
the water in the hoses, i.e. up to 40 mA dependent on the
conductivity of the water, the micro ammeter is inserted in the
circuit through which only the recharging current and the
leakage current of the winding insulation are flowing.
Fig. 1 Schering Bridge
5 Dissipation Factor Measurement At balance, zero current flows through the bridge branch.
The capacitance of the winding is then:
The winding insulation system is primarily a capacitive
setup, with the winding copper constituting one electrode and R4 CN
Cx =
the grounded frame the other electrode. Such circuits are R3
accessible for bridge methods of resistance measurement to
determine the dielectric constant and the dielectric loss factor. and the dissipation factor:
Dielectric loss is defined as the ratio of active power to reactive tan G = R4 Z C4
power. In connection with insulation testing, the dielectric loss
indicates the amount of electrical energy converted into heat To perform dissipation factor measurements on generator
in the insulation. windings, disturbing error capacitances can be eliminated with
The dissipation factor and capacitance of a solid insulating a universal capacitance/dissipation factor bridge using
material are not dependent on the test voltage applied as long ancillary equipment for the initial balancing adjustment. This
as there is no change in the conduction mechanism. A change scheme offers an effective method for measurements on
in the conduction mechanism of insulating materials occurs windings in a directly grounded stator.
due to loss of bond between layers of insulation, with voids
being formed in minute cracks. As the voltage is increased
6 Partial Discharge Measurements
above a certain level (partial discharge start voltage) during the
dissipation factor measurement, partial discharges will occur The dissipation factor measurement described in the
which increase with rising voltage and result in a dissipation preceding section covers the sum of the losses occurring in the
factor tip-up. insulation voids due to partial discharges. Since partial
Micalastic insulation is impregnated with epoxy resin discharge is a radio-frequency phenomenon, this opens up the
under vacuum to be essentially void-free. In new condition, this possibility of using radio-frequency methods for detection.
insulation thus exhibits a dissipation factor tip-up of less than Partial discharge measurements provide useful information
0.001 for each measuring interval of 20 % of rated voltage. for the detection of localized defects in winding components,
Siemens AG
BHEL,Haridwar 2.5--2320--0001 / 2
Energy Sector 0114E
0409E
such as the phase connector insulation system. This method reliability. The application of a high test voltage is especially
is also used for quality assurance during manufacturing.
BHEL,Haridwar recommended in all cases where it is to be expected that the
HV reactor U V W insulation may have suffered localized damage as a result of
extremely high mechanical stresses due to a sudden
Regulating short-circuit or extremely high electric stresses due to
transformer CK Cx transients. A high-potential proof test is also applied in the case
RT of serious aging as identified by a dissipation factor
measurement and if localized weak points in the insulation
cannot be ruled out.
Any breakdown occurring during a proof test indicates that
AKV the winding is approaching the end of its serviceability. After
removal of bars on which a breakdown has occurred, the areas
of the insulation most severely affected by degradation can be
assessed, permitting scheduling of a suitable date for
HV
rewinding. lf no breakdown occurs during the proof test or
transformer
following the removal of already failed bars, this means that
after completion of the test even the weakest area of the
insulation still has a certain life expectancy which will be
PD Plotter
detector XY longer at the field intensity arising during normal operation than
at the test stress level. This enhances the probability of
troublefree operation at least for a certain service period
In the case of generator windings, the partial discharge following the test and avoids the risk of a breakdown occurring
method has so far been applied to detect high-energy during operation together with the consequential damage
discharges, as caused, for instance, by a break in the internal resulting from the high currents arising.
corona shielding system. The measurement is performed in a
manner similar to the dissipation factor measurement by 7.1 AC Voltage Test
recording the maximum apparent discharge magnitude as a This test is normally performed with a power-frequency
function of the voltage for each phase up to 120 % of rated AC voltage of 1.5 times rated voltage. The use of a 50-Hz or
voltage. To do this, a coupling capacitor CK is connected in 60-Hz AC voltage offers the advantage that the field
parallel to the phase capacitance CX. The partial discharge is distribution will be the same as during normal operation,
then detected in the ground connection of the coupling especially at the transition between the straight slot section
capacitor with a suitable partial discharge detector via a four and the end winding, resulting in a proportional stressing of the
terminal coupling network AKV. winding components. As generator sizes increase, the
As with the dissipation factor measurement, the test voltage capacitance of the winding to ground increases accordingly
is applied via a regulating transformer, a high-voltage and thus also the transformer rating required for the test. To test
transformer and a reactor to compensate for the winding and one phase of a large turbogenerator, a test set of 400 kVA or
coupling capacitances. more will fairly often be required. For this reason, resonance
Such a test setup is sensitive to external noise which cannot test circuits are frequently used, permitting a compensation of
be avoided at the power station or in the test field. lf no the high leading reactive power. An exact control of the preset
additional measures for rejection of the external noise are test voltage is accomplished through a high-voltage instrument
taken, background noise levels from 100 pC to more than transformer.
1000 pC are to be expected.
7.2 DC Voltage Test
When utilizing a high DC voltage for proof testing, the field
7 High-Potential Proof Tests
distribution will differ from that described in the preceding
All tests described in the preceding sections are performed section especially at the end windings. As a result of this, DC
with relatively low voltages. Using suitable standards for testing subjects the end turn insulation to considerably higher
comparison, they provide information on the contamination, stresses than AC testing.
surface moisture condition and also on the aging of the The equipment involved in performing a DC high-potential
insulation. They are indicative of the dielectric strength of the test is considerably smaller and easier to transport than the
insulation with a certain probability only. AC test equipment. lf DC testing is used for this reason, it is
A high-voltage test is an indispensable last criterion for necessary to use a multiplication factor to obtain nearly
determining with assurance whether or not the insulation on a equivalent searching ability as an AC test. lt is recommended
winding is suitable for continued operation with sufficient that 1.7 times the AC RMS test voltage be used.
Siemens AG
BHEL,Haridwar 2.5--2320--0001 / 3
Energy Sector 0409E
0114E
Turbogenerators
Treatment of Bolted Contact Surfaces
Maintenance
1 General contact, all contact surfaces must be cleaned with solvent. In

Metallically-bright copper contact surfaces should be cleaning the contacts, make sure that insulating materials
coated with contact grease to provide adequate protection including the insulators of the terminal bushings do not come
against corrosion. into contact with the solvent.
Silver-plated contact surfaces which are exposed to Metallically-bright cooper contact surfaces must be coated
corrosive conditions breaking the contact must also be coated with a sufficient amount of contact grease before closing the
with contact grease. contact again. When bolting the contact faces together,
excess grease should be forced out evenly from the contact
2 Application
point.
The contact surfaces should be coated with contact grease
Use a clean rag to wipe off the excess grease.
immediately after breaking the contact. Prior to re-making the
All Rights Reserved
Copyright
BHEL,HaridwarSiemens AG MKA29 &MDC 2.5--2350--0001

Energy Sector 0109E
0114E
Turbogeneratoren
Rotor
Maintenance
1 Leakage Test of Field Current Lead recommended to make use of the services of our experienced
Before starting overhaul work and H2 purging, check H2 product service personnel who will carefully remove any dirt
seals at the field current lead for leakage. To do this, use a leak accumulations below the retaining rings and within the range
detector and check coupling flange generator rotor/ slip ring of the end windings by means of a special vacuum cleaner.
for gas leakage.
lf no H2 gas leak is detected, the exciter should be
dismantled. The slip ring shaft should be uncoupled from the
generator and a new leakage test of the central field CAUTION
connection performed.
Any inexpert use of compressed air involves the risk of
lf a leak is detected during this leakage test, the
cooling duct clogging and of damage to insulated parts.
manufacturer must be notified. The hydrogen should be
purged from the generator only after completion of the leakage
test.
5 Contact Pins and Plug-in Socket Strips
2 Rotor Wedges and Retaining Rings The contact pins and plug-in socket strips should be
lf the rotor is removed, examine it carefully. The wedges checked for arc erosion and proper contact resistances.
and retaining rings should be inspected for proper condition. Proper seating of the contact pins on the plug-in socket strips
can be verified by visual examination.
3 Shaft Journals and Shaft Seal Contact Faces
The shaft journals and shaft seal contact faces should be 6 Coupling
checked for grooves. lf any irregularities are detected, The coupling flange at the rotor should be checked both at
All Rights Reserved
reconditioning should be carried out according to instructions the guide flanges and at the fitting bolt holes. The coupling
from our service personnel. bolts should be inspected for proper condition.
4 Cleaning the Rotor 7 Insulation Resistance Measurement

After each withdrawal, the rotor should be cleaned Prior to recommissioning, the insulation resistance of the
thoroughly, even if the visual inspection did not reveal any rotor winding should be measured and, if necessary,
contamination. Careful cleaning is important so as not to improved. Details are given elsewhere in this manual (see
damage any of the numerous insulated parts. lt is, therefore, 2.5--3300 and 2.5--2310).
Copyright
BHEL,Haridwar
Siemens AG MKA40 &MDC 2.5--3000--0016
Energy Sector 0114E
0310E
Turbogenerators Insulation Resistance Measurements
Maintenance on Rotor Winding
During manufacture and transport, the insulation of the

rotor winding may have been exposed to moisture which
DANGER
would reduce the insulation resistance of the winding. The
insulation resistance should therefore be measured prior to Fire and explosion hazard due to escaping hydrogen gas.
initial startup, after prolonged shutdowns and after work on the Do not use fire or an open flame in the vicinity of the gene-
winding. If required, the generator should be dried until a rator. Do not perform any activities which causing sparks
sufficient insulation resistance is obtained. Due to a static charging and potential sparking during the
insulation resistance measurement, the rotor shaft must
1 Required Insulation Resistance of Rotor Winding be properly grounded at both ends.
The insulation resistance should amount to 1 megohm at
40 _C (104 _F). 60
At winding temperatures other than 40 _C, a correction can K
40
be made using the curve shown in Fig. 1.
2 Measurement of Insulation Resistance 20

Prior to each measurement, the generator must be
de-excited and any static charges removed by grounding the
10
winding.
8
The insulation resistance should be measured between
6
one slipring and the generator shaft, using a insulation
4
All Rights Reserved
resistance meter with a voltage % 500 V. This voltage will

present no danger to any of the devices in the excitation circuit.
R40_C = Rmeas x K
The duration of the test should be approximately two minutes. 2
After each measurement, the winding capacitance should be
discharged for not less than two minutes.
The insulation resistance of the entire excitation circuit 1

0.8
should be measured with the brushes applied. If an insufficient
0.6
insulation resistance value is obtained, all slipring carbon
brushes should be lifted off and separate measurements 0.4
conducted on the rotor winding and excitation circuit.
Copyright
0.2
0.1
0 10 20 30 40 50 60 70 80 90
Slot temperature in_C
Fig. 1 Correction Curve for Insulation Resistance
Measured (Rmeas) to a Temperature of 40 _C
BHEL,Haridwar
Energy Sector 0310E
0114E
Turbogenerators
Hydrogen Cooler
Maintenance
1 General This does not require the removal of the cooler. Chemical
The intervals at which the coolers should be cleaned cleaning should be applied if scale has formed on the inside
essentially depend on the condition of the cooling water (rf. of the tubes which cannot be removed by brushing.
2.5--5003). If the cooling water is severely contaminated it may Chemical cleaning requires the following equipment:
be necessary to clean the coolers every two months. If, how- -- Pumps
ever, the condition of the cooling water is good (closed cooling -- Vessels
system and use of demineralized water) it may not be neces- -- Piping
sary to clean the coolers for a number of years. Note that the -- Shutoff valves
coolers must be cleaned if the cooler performance deterio- -- Cleaning agents.
rates.
The first inspection of the hydrogen coolers should be The following commercially available cleaning agents are
performed three months after their commissioning. To be able recommended:
to check the level of contamination of the tubes and inlet and
outlet water channels, the top sections of the inlet and outlet Water Side
lines, and the inlet and outlet water channels must be Cleaning Agent Supplier
removed. Depending on the findings, the subsequent
inspections can be performed at intervals of up to 12 months. P3-T288 Henkel KG, Dsseldorf,
Germany
The definitive cleaning intervals can,however, only be reliably
determined after a number of years of operation. SAF-ACID Drew Ameroid GmbH, Hamburg,
Germany
All Rights Reserved
Vecom BA-S Vecom GmbH, Hamburg,

Germany
DANGER
Fire and expolsion hazard due to escaping hydrogen gas. Gas Side
Do not perform any work on the hydrogen coolers until the P3 Grato 90 Henkel KGaA, Dsseldorf,
generator has been shut down and is filled with air at at- Germany
mospheric pressure.
Ameroid ACC9 Drew Ameroid GmbH, Hamburg,
The hydrogen coolers should be cleaned on the water side Germany
if the inspection reveals increasing cold gas temperatures or Vecom B-85 Vecom GmbH, Hamburg, Ger-
the formation of deposits on the inside surfaces of the tubes. many
Copyright
2 Cleaning on the Water Side Connect a circulating pump to the cleaning system via the
It is recommended that the cooler sections be removed for water supply and return lines. Fill the system, close vent valves
this purpose, rf. 2.5--4100. and pump cleaning agent through system. After cleaning,
One of the following procedures can be applied for water- thoroughly flush the system with water.
side cleaning: In the event that the requisite expertise for performing a
J Cleaning the Brushes chemical cleaning procedure is not available, it is recom-
Slightly lower the water level in the cooler and then remove mended that this work be performed by specialist contractors.
the inlet and outlet water channels. Clean the tubes by mov-
NOTE:
ing specially-designed brushes up and down the individual
When performing chemical cleaning work be
tubes. Be sure to avoid any damage to the coating when in-
sure to comply with the instructions for safe
serting the brush in the lower return water channel. The de-
handling of chemicals.
bris removed from the tube surfaces must the be flushed
from the tubes, and the contaminated water completely re-
3 Cleaning on the Gas Side
moved from the cooling system. For this purpose, the cooler sections must be removed, rf.
J Cleaning with High-Pressure Water System 2.5--4100. Following their removal, the cooler sections must
Remove inlet and outlet water channels, connect high- be thoroughly checked on their gas side. To remove minor
pressure water cleaning system and insert nozzle into each contamination, clean the fins and tubes with dry compressed
individual tube. air. If the inspection reveals more severe fouling, clean the
tubes with a high--pressure water system. Recommended
J Chemical Cleaning
pressure: 120 bar with 3 mm spray nozzle. The distance
between the nozzle and the tube bundle should be approx-
imately 2 meters.
Siemens AG
BHEL,Haridwar MKA70 &MDC 2.5--4000-0020
Energy Sector 0909E
0114E
Turbogenerators
Bearings
Maintenance
The insulation resistance of insulated bearings should be damage by cathodic action. Clean the insulation at the bearing
measured prior to each inspection. The bearings should then saddle, as otherwise the insulation properties are affected.
be dismantled and cleaned thoroughly. Bearing sleeves and The inspection procedure described above should be
shaft journals should be checked for proper condition. If performed at all sleeve bearings of the turbine generator.
grooves are detected the manufacturer should be asked for It is also recommended that the hose between the fan
advice whether the bearing may be used further. If a low casing and the labyrinth ring of the insulated slipring bearing
insulation resistance has been previously measured, the compartment be disconnected, cleaned with compressed air
respective bearing should be inspected thoroughly for any and then be reconnected.
All Rights Reserved
Copyright
MKC
BHEL,Haridwar
Siemens AG MKD &MDC 2.5--5000--0009
Energy Sector 0109E
0114E

Exciter

Components Manual

1 General

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cause injury to persons. Before com- ULQJV
mencing with exciter start-up ensure &DUU\RXWDQGUHFRUGUHTXLVLWHFKHFNVGXULQJRS
-
that personnel is not exposed to any HUDWLRQ
hazards during the start-up procedure.
8.5 Repair work during Operation (Mainte-
nance) and at the Standstill (Inspection)
- ,QYROYHHQJLQHHUVIURP6LHPHQV$*
- $OOPHFKDQLFDODQGK\GUDXOLFFRPSRQHQWVDVZHOO 7KH IROORZLQJVDIHW\LQVWUXFWLRQVDSSO\ GXULQJ H[
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BHEL,Haridwar
Siemens AG ELR-1.3-0001-0001 / 3
(QHUJ\6HFWRU 0114E
H


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that this is electrically isolated and can-
not accidentally be reconnected.
10 Special Hazards

Danger: 6HHEHORZIRUVDIHW\LQVWUXFWLRQVZLWKUHJDUG WRH
Do not start turbine-generator set if OHFWULFFXUUHQWKHDWDQGQRLVH
work is being carried out on or near the
Electric Current
generator or exciter.
(QVXUHFRPSOLDQFHZLWKWKHIROORZLQJLQVWUXFWLRQV
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cause injury to persons. Ensure that Danger:
rotor has coasted down. Do not remove Operating noise of exciter may damage

any guards until exciter has come to a hearing. Wear ear plugs at the operat-

full standstill. ing exciter.

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Siemens
BHEL,Haridwar AG ELR-1.3-0001-0001 / 4
(QHUJ\6HFWRU 0114E
H

Exciter

Components Manual

2 Technical Data


Siemens
BHEL,Haridwar AG
(QHUJ\6HFWRU

Exciter

Components Manual

2 Technical Data

2.1 Identification

Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU
Exciter Identification Data
Technical Data
Code word <(5$0$586 800MW
Main exciter type ELR 70/90-30/6-20
Pilot exciter type ELP 50/42-30/16
Year of construction 201
Production number of stator 1201 0209
Production number of rotor 1201 0209
Identification number of exciter shaft E09133

Siemens
BHEL,Haridwar AG ELR-2.1-0001-0209
Energy Sector 1011e
0114E
Exciter Rating plate
Technical Data Main Exciter
SIEMENS
Haupterreger 12000209 2011
ELR 70/90-30/6-20 50s-1 rechts
Generator
600V / 7500A 4500kW S1
820V / 10250A 8405kW S2 10s
Eigenerregung 79 / 112V 151 / 214A
Isolierstoffklasse: F IM 7015 IP 40
Transportgewicht Stnder: 26,5 Mg VDE 0530 T.3

IEC 60034 - 3
Siemens AG Power Generation
Siemens
Energy Sector 1011e
0114E
Exciter Rating plate
Technical Data Pilot exciter
SIEMENS
Hilfserregermaschine 12000209 2011
ELP 50/42-30/16 50s-1 rechts
Generator
220V + 10% 195A S1
65kVA cos=0,6 400 Hz
Permanentmagnetpol
Isolierstoffklasse: F IM 5410 IP 40
VDE 0530 T.3

IEC 60034 - 3
Siemens AG Power Generation
BHEL,Haridwar
Siemens AG ELR-2.1-0002-0209 / 2
Energy Sector 1011e
0114E

Exciter

Components Manual

2 Technical Data

2.2 Mechanical Data

Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU
BHEL,Haridwar
BHEL,Haridwar
Exciter Dimensions and Weights
Technical Data
Weights
Weight Unit of Quantity

Component
Exciter, complete 33241 kg
Stator main exciter 7520 kg
Stator pilot exciter 770 kg
Rotor, complete 8780 kg
Fan cover 2080 kg
RR air guide cover 789 kg
Cover, complete 3500 kg
Bearing pedestal 1700 kg
Base frame 5000 kg
Base frame anchoring 857 kg
Base frame accessories 1045 kg

Cooler without water 1200 kg
Exciter, stator transportation weight 26610 kg
Siemens
Energy Sector 1011
0114E
Exciter Materials
Technical Data
Materials
Component Material Specification/Standard Remarks
TDS 9124 50
Shaft 26NiCrMoV115 -
contains SEW 555*
Rectifier wheel 26NiCrMoV115 TDS 9124 40 -
Armature core M270-50A TDS 13-001 -
Armature winding E-Cu58F20 GEN 754.01 -
Field winding E-Cu57F20 DIN EN 13601 -
Base frame S235JRG2 DIN EN 10025 -
Covers S235JRG2 DIN EN 10025 -
Diodes D690 S26 TT2 TDS 13-033 Manufacturer: EUPEC
Fuses 3NC9 538-2 TDS 13-035 Manufacturer: Siemens
Pole wheel hub 34CrNiMo6 V TDS 9010 07 -
* The TDS 9124 50 contains the SEW 555 and is adapted to rotating rectifier wheels.
26NiCrMoV 11 5 is specified for this scope of application.
BHEL,Haridwar
Energy Sector 1011e
0114E

Exciter

Components Manual

2 Technical Data

2.3 Electrical Data

Siemens
BHEL,Haridwar AG
(QHUJ\6HFWRU
Exciter Design Data
Technical Data
Electrical Data
Main Exciter ELR 70/90-30/6-20

Nominal exciter current, S1 A DC 7500
Nominal exciter voltage, S1 V DC 600
Nominal ceiling voltage, S2 (10 s) A DC 10250
Nominal ceiling voltage, S2 (10 s) V DC 820
Cooling air inlet temperature C 44
Pilot Exciter (PMG) 3-phase ELP 50/42-30/16
No Load Voltage V AC 220 V 10 %
Nominal exciter current, S1 A AC 195
Nominal power, S1 kVA 65 at cosphi 0.6
Nominal ceiling voltage, S2 (10 s) A AC 300
Nominal ceiling voltage, S2 (10 s) kVA 100 at cosphi 0.9
Diode Wheels
A-Wheel (-), B-Wheel (+)

Per wheel
Type of Diodes D 690 S26TT2
Number of Diodes 120
Number of RC Networks 12
Type of Fuses 3 NC 9538-2
Number of Fuses 60
Fuse Data Approx. 150 Ohm, 1000 V / 800 A
Siemens
Energy Sector 1011e
0114E
Exciter Design Data
Technical Data
Breakdown of Fuses
Number of fuses blown per diode 2 Fuses No Ceiling Operation

wheel and bridge arm 3 Fuses Shut down turbine-generator set
Torques
Torque Unit
Moment of inertia of rotor 566 Kgm
Brushes, Brush Holder

(ground fault detection)
Type: Kollectra, 06.08.0297.01

Brush holders
Qty: 4
Type: S13F19
Qty: 4
Carbon Brushes
Orig. size: 20x8x30 mm
Min. size: 20x8x15 mm
BHEL,Haridwar
Siemens AG ELR-2.3-0001-0209 / 2
Energy Sector 1011e
0114E
Exciter Curves and Data
Technical Data
Manufacturer: Siemens AG
Documentation title: Excitation Data Sheet

Main exciter and pilot exciter curves
Amount: 3 pages
BHEL,Haridwar
Energy Sector 1011e
0114E
Siemens AG Excitation Data Sheet Rev. Printed at
Erreger- und Reglerangaben Druck am
E F PR GN ERF EN 3 YERAMARUS
BHEL 800 MW<< A 2009-11-27
Generator SGen5-3000W (125/67) Generator-Number 12580

SN = 941 MVA Generator-Nummer
UN = 27,0 kV +5/-5% Cold Gas Temp. Generator 44 C
IN = 20,122 kA Kaltlufttemperatur Exciter 44 C 1)
f= 50 Hz
n= 3000 min-1 Rotor Resistance 20C 0,061 :
cos M = 0,85 Luferwiderstand warm 0,073 :
Direction of Rotation (view from turbine to generator) Clockwise

Drehrichtung bei Sicht von Turbine auf Generator Im UZS
Main Exciter Type ELR 70/90-30/6-20N No Load Time Constant 1,706 s (T'D0)
Typ der Haupterregermaschine Leerlaufzeitkonstante
Capability at 40 C cold air temperature:
Nenndaten bei 40C Kaltgastemperatur: Load Time Constant 0,944 s (T'DL)
600 V 7500 A 4500 kW S1 Belastungszeitkonstante
820 V 10250 A 8405 kW S2 10 sec.
Field-Resistance 20C 0,423 :
Feldwiderstand warm 0,505 :
Pilot Exciter Type ELP 50/42-30/16
Typ der Hilfserregermaschine 1) Depending on cooling gas circuit;
no-load voltage (Leerlauspannung) : f= 400 Hz Cold gas temperature of exciter can be differ-
220 V 195 A 65 kVA ent from cold gas temperature of generator.
S1
220 V 300 A 100 kVA S2 2 min.
Characteristics (Project Data) Generator Main Exciter

Kennlinien (projektbezogen) Generator Haupterregermaschine
Generator- Load Winding temp. If Uf IE UE

Generator-Belastungszustand Wicklungstemp. [A] [V] [A] [V]
No Load (0,50*UN) Leerlauf (0,50*U N ) 20C 775 47 14,3 6,0
No Load (1,00*UN) Leerlauf (1,00*U N ) warm 1947 143 38,0 19,2
Nominal Load (941 MVA) Max. Last warm 5549 407 108,1 54,6 S1
25% Overcurrent 25% berstrom warm 6722 493 131,0 66,1 S2 60 sec.
Ceiling Excit. (1,6-times) Stoerregung warm 8878 651 173,8 87,7 S2 10 sec.
Load Point A (988 MVA) Lastpunkt A warm 5774 427 112,8 57,2 S1
Load Point B (xxxx MVA) Lastpunkt B warm --- --- --- --- S1
Excitation Response (average): app. 2,0 s-1 at 250 V Controller Voltage
Auferregungsgeschwindigkeit acc. to IEC 34 Reglerausgangsspannung
Voltage rise at sudden discharge and rated excitation 32,9 %

Generatorspannungsberhhung bei Entlastung und Nennerregung
Generated from order data table Erzeugt aus der Auftragsdatentabelle Checked Ka; 2009-11-27
H. Kaluza Geprft
2-pole Turbogenerators Excitation System Voltage vs.
Exciter Field Current
Type: SGen5-3000W (125/67) SN = 941 MVA fN = 50 Hz

Project: BHEL 800 MW UN = 27,0 kV nN = 3000 rpm
No.: 12580 P.F. = 0,85 TCold Air (Geno) = 44 C
Exciter: ELR 70/90-30/6-20N
Air Gap Curve No Load Curve

Nominal Voltage Ceiling Voltage
Load Curve at RL = 0,0733 Ohms
1000
900
800
700
Excitation System Voltage [V]
600
500
400
300
200
100
0
0 50 100 150 200
Exciter Field Current [A]
BHEL,Haridwar
SIEMENS AG Rev. A H. Kaluza
Energy Sector
2-CCC-C01-00001 2009-11-27 E F PR GN ERF EN 3
Filename: BHEL_800MW - Excitation_System.xls

Version 1.0
Load characteristic of three-phase pilot exciter
ELP 50/42-30/16 f=400Hz; n=3000 rpm; Y connection

Exciter

Components Manual

2 Technical Data

2.4 Operating and Setting Values

BHEL,Haridwar
Siemens AG
(QHUJ\6HFWRU
Exciter Operational and Setting Values
Technical Data
The excitation machine goes into protection The control system receives a message that
mode (trips) when certain parameters reach their excitation has been lost, and initiates a fast
limit values. shutdown of turbine and generator. Further
Excitation can be lost because of a malfunction operation is then not possible.
in the excitation system or an open field winding. In Exciter The hydrogen pressure and flow of
such a case, no energy is produced, and the turbine cooling water are maintained.
starts to increase speed.
Setting Value
Operating
Parameter Tag Number Protec- Unit Remark
Control Alarm Value
tion
Cold air temperature +MKC61CT001A/B
- - 48 30 to 43
monitoring
+MKC65CT001A/B
Hot air temperature +MKC65CT002A/B - 83 78 50 to 63
monitoring, main exciter +MKC65CT002A/B C
Hot air temperature +MKC66CT001A/B
- - 78 50 to 63
monitoring, diode wheel

Bearing temperature +MKD21CT013 Acc. to
- 125 110 90
measurement +MKD21CT014 ISO
Bearing vibration +MKD21CY021 mm/sec

- 14.7 9.3
measurement, eff. +MKD21CY022 (RMS)
Shaft vibration +MKD21CY041
- 130 83 m
measurement +MKD21CY042
Insulation resistance, +MKC36CE001
rotor earth-fault - 5 80 k:
monitoring
BHEL,Haridwar
Energy Sector 1011e
0114E

Exciter

Components Manual

2 Technical Data

2.5 Measuring Instruments,

Connection points and Consumers

BHEL,Haridwar
Siemens AG
(QHUJ\6HFWRU

([FLWHU List of Measuring Instruments,

7HFKQLFDO'DWD Connection points and Consumers

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FRQWURO URRPDUHQRWQHFHVVDU\XQGHU QRUPDO H[FHHGWKHSHUPLVVLEOHYDOXHV
UXQQLQJ FRQGLWLRQV,QSULQFLSOHQRPDQXDO
LQWHUYHQWLRQV DUHUHTXLUHG :H QHYHUWKHOHVV
UHFRPPHQG REVHUYLQJWKH VWDWXV RIWKHH[FLWDWLRQ
PDFKLQHPRUHFORVHO\LIZDUQLQJVDUHLVVXHG
Measuring instruments:
Designation Function Type
0.&&( ,QGLUHFWPHDVXUHPHQWRIWKHRXWSXWFXUUHQW 0DJQHWLFWHVWFRLO

0.&&(
0.&&( *URXQG)DXOW'HWHFWLRQ (DUWKEUXVKHV
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SRLQWRIWKHH[FLWHUDIIHFWWKLVYDOXHWKHSURSRUWLRQDOLW\FDQWKHUHIRUHRQO\EHGHWHUPLQHGGXULQJDWHVWUXQLQWKH
WHVWED\LQWKHPDQXIDFWXUHU
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TXDGUDWXUHPHDVXULQJFRLOVFDQQRWEHUHFRUGHGDQGVRWKHUHFDQEHQRFDOLEUDWLRQ7KHUHIRUHWKHYROWDJH
VXSSOLHGE\WKHTXDGUDWXUHPHDVXULQJFRLOVLVIRULQIRUPDWLRQRQO\7KHVLJQDOVDUHQHLWKHUUHDGLQWRWKHPDLQ
FRQWUROV\VWHPQRUXVHGIRUWKHFRQWUROOHGV\VWHPRIWKHWXUERVHW+RZHYHUWKHVLJQDOVFDQEHXVHGE\WKH
PDQXIDFWXUHUWRILQGDQGUHFWLI\IDXOWVLQWKHH[FLWHUVHW

$OORFDWLRQXQGZLULQJE\FXVWRPHU

Warning:
Damages to the exciter. The cycle time of the measuring instruments must be selected so that the
exciter machine can be switched off safely when the permissible signal values are exceeded.

Siemens
(QHUJ\6HFWRU 0114E
H

([FLWHU List of Measuring Instruments,

7HFKQLFDO'DWD Connection points and Consumers

Connection points:
Designation Function Type
0.&*( 0DLQH[FLWHUZLQGLQJ &RQQHFWLQJWHUPLQDO

0.&*( 3LORWH[FLWHUZLQGLQJ &RQQHFWLQJWHUPLQDO
0.&$& &RROHU )ODQJH
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WUDQVGXFHU

List of Consumers:
Designation Function Connection
0.&&8 )XVHPRQLWRULQJVWURERVFRSH 9PD[9$

0.&$7 'U\HU 9N:+]
0.&*3 &RYHUOLJKWLQJ 9 :

Siemens AG
(QHUJ\6HFWRU 0114E
H

Exciter

Components Manual

3 Components
and Purchased Parts

Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU

Exciter

Components Manual

3 Components
and Purchased Parts

3.1 General

Siemens
BHEL,Haridwar AG
(QHUJ\6HFWRU
Exciter General Technical Description
Components and Purchased Parts
The basic task of the excitation machine is to x Measuring Devices and Supervisory Equipment
provide sufficient electric power for the voltage con-
troller (AVR) and generator rotor winding.
It is a 6-pole excitation machine with a perma- 1
nent-magnet auxiliary exciter (PMG), which is driven
at a speed of 50 rps.
2
1 System
3
The excitation machine is a synchronous AC 10
machine with the field winding in the stator and ro- 4
tating armature coils. The generator rotor coils re-
quire direct current (DC). The induced alternating
current is rectified by rotating rectifiers for this pur-
pose.
The excitation machine has one bearing and two 5
air-water coolers. An auxiliary exciter with perma-
nent magnets is integrated into the system. It sup-
plies the electric power for the main exciter via the
voltage controller.
6
2 Main Components
eserved
The exciter consists of the following main com-

ponents:
x Base frame mounting all exciter components
and connecting the foundation anchors to the 7
foundation 8
x Exciter rotor with coupling, DC connection to the
generator rotor winding, diode wheel rectifier,
core-and-coil assembly of the main exciter, pilot
9
exciter rotor, fan and slip rings for the rotor
ground fault detection
x Bearings supporting the rotor shaft 1 Three-phase pilot exciter
x Brush and brush holders of the rotor ground 2 Slip rings and brushes mounted for ground-fault test
3 Inductive exciter current measurement (magnetic test coil)
fault detection 4 Three-phase exciter
x Air guide cover of the diode wheel 5 Diode rectifier set
x Stator main exciter generating the magnetic field 6 Three-phase AC line
7 MULTI-CONTACT connection
x Pilot exciter stator 8 Rotor winding (generator)
x Air-water cooler unit to remove the thermal los- 9 Stator winding (generator)
ses of the exciter 10 Automatic voltage regulator (not in scope of delivery)
x Fan Fig. 1 Basic Arrangement of Brushless Excitation
x Cover System with Rotating Diodes
x Measuring devices (cold air temperature, main
exciter hot air temperature, diode wheel hot air
temperature, bearing temperature, absolute and
relative bearing vibrations)
3 Construction
The exciter with rotating diodes substantially
consists of the following main components:
x Rotating rectifier wheels (RR wheels)
x Three-phase exciter
x Three-phase pilot exciter
x Cooler
Siemens AG
Energy Sector 1011e
0114E
4 Rotating rectifier wheels

Figure 1 shows the basic arrangement of the ex- The main component of the rotating rectifier is
citer. The three-phase pilot exciter has a revolving the rectifier wheel which has 120 diodes and 60
field with permanent magnetic poles. The three- fuses. The securing devices can be monitored dur-
phase AC is fed to the field of the revolving- ing operation by a stroboscope (not an automatic
armature main exciter via a stationary regulator and function). The rectifier bridge is designed redun-
rectifier unit. The three-phase AC induced in the dantly so that full load operation, including overexci-
rotor of the main exciter is rectified by the rotating tation (ceiling operation), is possible, even if a circuit
rectifier bridge and fed via a DC lead in the rotor breaker has tripped in a bridge branch.
shaft to the field winding of the generator rotor. The main components of the rectifier wheels are
the silicon diodes which are arranged in the rectifier
1 2 3 4
wheels in a three-phase bridge circuit. The internal
arrangement of a diode is shown in Figure 3. The
pressure required on the contact surfaces of the
diode is generated by mechanical distortion created
by disk springs, and the main pressure is generated
by the centrifugal force of rotation. The diodes are
designed for the high electrical and mechanical
loads which occur, and have a very high fault toler-
ance.
1 Coupling
2 Rectifier wheel
3 Rotor of main exciter
4 Fan
Fig. 2 Exciter Rotor
The exciter set is designed analogously to this

basic circuit, which can also be seen in figure 2.
The rectifier wheels and the rotor of the exciting
machine are arranged one behind the other on one
shaft. The shaft is coupled rigidly to the generator
rotor, and bearing-mounted at the end. The genera-
tor and exciter rotors are thus mounted on three
bearings. 1 Heat sink 5 Pressure piece with cooling
The two sections of the shaft are coupled me- 2 Insulation 6 MULTI-CONTACT lamellas
3 Disk-type diode 7 Disk spring
chanically, the DC leads are also coupled in the
4 Insulated bolted connection 8 Contact bridge
centre bore of the shaft to the contact pins and so-
ckets of the MULTI-CONTACT electrical contact Fig. 3 Diode Design
system. This contact system can also slide to com-
pensate for thermally related changes in the lengths Figure 4 shows additional components accom-
of the conductor parts. modated in the rectifier wheels. Two diodes each
are mounted in each aluminum alloy hest sink and
thus connected in parallel. Associated with each
heat sink is a fuse which serves to switch off the two
diodes if one diode fails (loss of reserve blocking
capability).
BHEL,Haridwar
Siemens AG ELR-3.1-0001-0209 / 2
Energy Sector 0114E
1011e
5 Three-phase main excitor

For suppression of the momentary voltage peaks
arising from commutation, each wheel is provided The three-phase main exciter is a 6-pole revolv-
with six RC networks consisting of one capacitor ing-armature generator. The poles together with the
and one damping resistor each, which are combined exciter and damper winding are housed in the cas-
in a single-resin-encapsulated unit. ing. The exciter winding is arranged on the lami-
nated magnet poles. There are bars in the pole
The insulated and shrunken rectifier wheels ser- shoe area, the end faces of which are wired to a
ve as dc buses for negative and positive side of the damper winding. A magnetic test coil is fitted be-
rectifier bridge. This arrangement ensures good tween two poles to measure the exciter current in-
accessibility to all components and minimum of cir- ductively.
cuit connections. The two wheels are identical in
their mechanical design and differ only in the for- 1 2 3
ward directions of the diodes.
The direct current from the rectifier wheels is fed
to the DC leads arranged in the center bore of the
shaft via radial bolts.
The three-phase alternating current is obtained
via copper conductors arranged on the shaft circum-
ference between the rectifier wheels and the three-
phase main exciter. The conductors are attached by
means of banding clips and equipped with screw-on
lugs for the internal diode connections. One three-

phase conductor each is provided for the four di-
odes of a heat sink set. The leads come from a bus-
ring system on the exciter rotor. Viewed in the
circumferential direction, the phases of the three-
phase conductors change cyclically.
1 2 3
1 Magnet pole
2 Stator
3 Magnetic test coil
Fig. 7 Main Exciter
The rotor consists of laminated sheets that are

pressed together by pressure rings held by through
tension bolts. The three-phase winding is located in
1 Rectifier wheel grooves in the laminated rotor. The winding bars are
2 Diode located in the laminated core area in the form of
3 Fuse
Roebel bars. The end windings of the rotor winding
Fig. 4 Rectifier wheel are held by glass-fibre bands. The side facing the
rectifier wheels is the connection end of the rotor
winding. The ends of the winding are led to a bus-
ring system, to which the three-phase leads to the
rectifier wheels are also connected.
BHEL,Haridwar
Siemens AG ELR-3.1-0001-0209 / 3
Energy Sector 1011e
0114E
After impregnation by total immersion in syn- 7 Cooling of the exciter set

thetic resin, and hardening, the complete rotor is
The exciter set is air-cooled. The cooling air is
shrunk onto the shaft. The bearing is located behind
circulated in the closed circuit, and recooled in 2
the fan. The plain bearing with circulating oil lubrica-
coolers arranged on the sides of the exciter set.
tion is connected to the turbine oil supply.
1 2 3
6 Three-phase pilot exciter
The three-phase pilot exciter is a 16-pole sta-
tionary-armature generator. The casing contains the
laminated core with the three-phase winding. The
rotor consists of the hub with poles mounted. Each
pole is composed of individual permanent magnets,
which are metallically sheathed all the way round by
non-magnetic material to hold them securely, and
braced by screw bolts to the external pole shoe. The
rotor hub is shrunk onto the free end of the shaft.
1 2 3
1 Rotating rectifier cover

2 Three-phase main exciter
3 Fan
Fig. 9 Exciter (without cover)
The entire exciter set is enclosed by a cover that

closes so tightly that it also serves to guide the cool-
ing air. The space under the cover is the cold-air
compartment. The fan and the rectifier wheels suck
the cold air out of this compartment and, after it has
fulfilled its cooling task, feed it as hot air into the
compartment below the base plate. From there, the
air passes through the cooler back into the cold-air
compartment again to complete the circuit.
The rectifier wheels are enclosed by a casing,
and designed for self-ventilation in combination with
the air guidance.
A fan is mounted on the shaft for the main ex-
citer. Cold air is fed to both sides of the main exciter
through an appropriately designed casing. The rotor
cooling air is fed to the outside through ducts below
the body of the rotor.
The pilot exciter lies in the cold air flow from the
fan. It has a low cooling air requirement, and there-
1 Permanent magnet wheel
2 Stator winding
fore it does not have its own connection to the hot-
3 Stator air compartment.
Fig. 8 Permanent magnet pilot exciter
Siemens
Energy Sector 1011e
0114E

Exciter

Components Manual

3 Components
and Purchased Parts

3.2 Cooler

Siemens
BHEL,Haridwar AG
(QHUJ\6HFWRU
Exciter Cooler
Components and Purchased Parts Technical Description
The cooler is intended for cooling air with the

help of water flowing through the tubes. The cooler
is designed to operate at operating pressures of up
to 12 bar. The maximum operating temperature is
+90 C. The permissible operating pressures and
temperatures are to be found on the name plate.
The main design groups of the heat exchanger
are core tubes with large-area fins pushed on, wel-
ded to the tube sheets and detachable chambers.
The cooler contains stainless-steel tubes with
large-area, aluminum fins. The chambers are made
of stainless steel. The tubes are welded to stainless-
steel tube plates.
Note:
You will find more detailed informa-
tion in the manufacturers documenta-
tion and in the drawing.
Fig.1-Exciter Cooler
Siemens
Energy Sector 1011e
0114E

Exciter

Components Manual

3 Components
and Purchased Parts

3. Dryer

Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU
Exciter Dryer
1 General After regeneration, the dryer wheel material is

again capable of absorbing moisture.
A dryer (dehumidifier) is provided to avoid the
formation of moisture condensate inside the exciter The adsorption of moisture and regeneration of
with the turbine-generator at standstill or on turning the dryer wheel material take place simultaneously,
gear. using separate air streams, which ensures a con-
tinuous drying of the air.
1 2 3 4 5 6 7 A shutoff valve is located in the pipe of the dry air
outlet. This stop valve prevents air being sucked in
via the dryer wheel if the regeneration is not running
(dryer switched off!) while the exciter set is operat-
ing under load.
2.1 Operating Principle

The dehumidification takes place in a slowly ro-
tating dryer wheel (approximately 7 revolutions per
hour). The honeycomb dryer wheel consists of a
magnesium silica alloy containing crystalline lithium
chloride. The inlet side of the dryer wheel is subdi-
vided so that 1/4 is available for regeneration
and3/4 for the adsorption section. This clear separa-
tion is maintained in the entire adsorption dryer.
2.1.1 Adsorption Section

The air to be dehumidified passes through the
adsorption section of the dryer wheel, with part of
the moisture contained in the air being removed by
1 Dry air outlet 5 Housing the adsorbent material, i.e. lithium chloride. The
2 Shutoff valve 6 Dry air inlet moisture is removed as a result of the partial pres-
3 Regeneration air inlet 7 Regeneration air outlet sure drop existing between the air and the adsorb-
4 Thermostat
ent material.
Fig. 1 Exciter Dryer
2 Mode of Operation
The dryer dehumidifies the air within the exciter
enclosure. The dryer wheel is made of a non-
flammable material. On its inlet side, the wheel is
provided with a system of tubular ducts, the sur-
faces of which are impregnated with a highly hygro-
1 Regeneration air outlet 4 Fan
scopic material.
2 Dryer wheel 5 Filter
The tubular ducts are dimensioned so that a la- 3 Heater 6 Dry air outlet
minar flow with low pressure loss is obtained even Fig. 2 Schematic Diagram
at high air velocity; thus there are low friction losses.
The moisture absorbed by the dryer wheel is re- 2.1.2 Regeneration Section
moved in a regeneration section by a stream of hot In the regeneration section of the dryer wheel,
air directed through the wheel in the opposite direc- the accumulated moisture is removed from the dryer
tion of the inlet air and then discharged to the at- wheel by the heated regeneration air.
mosphere.
Uniform rotation of the dryer wheel ensures con-
tinuous dehumidification of the air within the exciter.
BHEL,Haridwar
Siemens AG ELR-3.4-0001-0209 / 1
Energy Sector 1011e
0114E
Exciter Dryer
2.2 Control Logic Switch on conditions (Auto switch ON):

To activate the exciter dryer, set Auto switch to Dryer MKC75 AT001
ON position. The equipment is started as soon as Speed Turning speed
the turning speed is reached.
Taking in or out of operation depends on turbine Switch off conditions (Auto switch ON):
speed. Dryer MKC75 AT001
A running dryer can be switched off manually by Speed > Turning speed
taking the electrical system out of service. However,
it cannot be switched on manually.
BHEL,Haridwar
Siemens AG ELR-3.4-0001-0209 / 2
Energy Sector 0114E
1011e

Exciter

Components Manual

3 Components
and Purchased Parts

3. Measuring Devices
and Supervisory Equipment
Siemens
BHEL,Haridwar AG
(QHUJ\6HFWRU
Exciter Measuring Devices and Supervisory
Components and Purchased Parts Equipment
Bearing Vibration
The absolute vibration of the bearing pedestal

housing is measured by sensors.
The sensors are provided, mounted and wired by
the customer. The mounting point is specified in
agreement with the customer.
Note:
For more detailed information about
the sensor positioning see drawing
2-7200-441853 in section 3.3.
BHEL,Haridwar
Energy Sector 1011e
0114E
Shaft Vibration
Special sensors are fitted to detect the relative

shaft vibrations. Boreholes are provided in the bear-
ing cover for these sensors. The measurement of
the shaft vibration provides information about the
running characteristics of the shaft (bearing play,
imbalance etc.).
The sensors are provided, mounted and wired by
the customer. The installation point is specified in
agreement with the customer.
Note:
You will find more detailed informa-
tion about the boreholes in the draw-
ing on the following page.
Siemens
BHEL,Haridwar AG ELR-3.5 -0002-0209
Energy Sector 0114E
1011e
Exciter Protection and Monitoring
Description of Components and Auxiliary Ground Fault Detection
1 Ground Fault Detection

Rotor ground fault detection can be monitored For this reason, rotor ground-faults are monitored
via slip rings. They are connected to the DC output continuously by a two-stage design.
voltage inside the rotor. This system is located on
Values: See Operational and Setting Values (Sec-
the non-drive end of the exciter shaft before the
tion 2.4)
exciter bearing. Both slip rings are fitted with two
parallel acting double layer (carbon-silver) brushes, The carbon brushes can be permanently fitted.
which can be replaced during operation. The carbon dust produced is transported outside
The rotor ground-fault monitoring records high through the brush holder assembly casing. The air
and low-resistance ground faults in the exciter cir- flow required to do this is taken from the exciter fan.
cuit. This is important for the safe operation of a Furthermore, the DC output voltage of the exciter
generator, because a double fault causes magnetic can be measured by means of the slip rings. The
unbalances and very high currents flow through the downstream evaluation equipment must be de-
fault points, and destroys the component affected signed for this.
extremely quickly. Therefore, it is extremely impor-
tant that single ground faults are reported, and pro-
tective measures initiated, if at all possible, while
they are still developing.
Connection to the
pressure area of
main exciter fan
(air inlet)
Carbon brushes
Measuring slip ring
Housing outlet
for air including
coal dust
Fig. 1 Air flow in the brush holder assembly Fig. 2 Carbon brushes in the brush
holder assembly
BHEL,Haridwar
Energy Sector 1011e
0114E
Stroboscope
Fuses on the rectifier wheels may be checked The continuous sequence of flashes can be in-
during operation with the stroboscope. A separate terrupted at any time by switching off the flow or
flash tube is provided for each wheel (A and B). The return with the push button. This then gives a sta-
tubes, which are controlled through a common con- tionary image which allows the exact observation of
trol unit, are permanently installed in the rectifier a single circuit breaker.
wheel enclosure. This permits easy monitoring with- The device switches off automatically after about
out any adjustment outside the exciter enclosure 2 minutes. If this time is insufficient for observation,
being required. the device can be immediately switched on for an-
Figure 1 shows the basic arrangement of a fully other 2 minutes by pressing the ON button. This can
transistorized stroboscope. The electronics required be repeated any number of times.
for control of the light signals are contained in the The stroboscope contains 4 plug-in printed cir-
control unit and in the tubular lamps. The tubular cuit boards that can be readily replaced to correct
lamps are connected to the control unit by cables. any malfunctions.
The stroboscope is located adjacent to the recti- The capacitor and high-voltage transformer re-
fier wheel in the exciter enclosure so that the fuses quired to produce the firing pulses for the flash
may be observed from outside the exciter enclosure tubes are located on a printed circuit board accom-
while controlling the stroboscope. modated in the flash lamp socket assembly.
To synchronize the sequence of flashes with the Operating controls are located on the front panel
generator shaft rotation, the system frequency is of the control unit for ease of operation. Selection of
utilized to activate the flashes. A PLL system, con- each button is indicated by an illuminated dot on the
trolled through two pushbuttons causes the flashes surface of the pushbutton.
to be timed so that a slow-motion observation of the

fuses is possible. The observation period for 1 full The power connector, the two connectors for the
revolution of the rectifier wheel (360) is approxi- flash lamps and the fuse are located on the rear of
mately 25 seconds. the control unit.
All connectors have a mechanical lock and are
protected against dust and water. The cables are
run in flexible metal conduit for protection against
mechanical damage.
1 Flash tube 1 (A wheel) 5 Feed pushbutton 8 ON pushbutton

2 Control unit 6 Pilot lamp for control voltage 9 OFF pushbutton
3 Pushbutton for flash tube 1 7 RETURN pushbutton 10 Flash tube 2 (B wheel)
4 Pushbutton for flash tube 2
Fig. Stroboscope Components and Operating Elements
BHEL,Haridwar
Energy Sector 1011e
0114E
Resistance Temperature Detectors (RDTs)
Resistance temperature detectors are used for Four-Wire Connection

temperature measurements on the exciter to meas-
ure the cold gas and the hot gas temperatures. Both If the two element leads are not alike or if the
RTDs with four wire connection and double-element three-wire method of compensation would be too
RTDs with four-wire connection each are used. costly, a four wire circuit should be used. Figure 2
When making measurements with RTDs the re- shows the circuit diagram of the four-wire method.
sistance element is exposed to the temperature to
be measured. The RTD works on the change in
electrical resistance of a conductor as a function of
temperature. The approximate value may be calcu-
lated by the following formula:
R = R0 x (1 + x T)
Where:
R0 = reference resistance at 0 C
= temperature coefficient and
T = temperature in C
The standard reference resistance of the plati-

num resistance element is 100 ohms. The tempera-

ture coefficient is = 3,85 x 10-3 C-1, this being the
mean value for the range 0 - 100 C.
Fig. 2 Four-Wire Connection
Leads RL1 and RL2 from the pair of lead wires

to the RTD Pt 100, while the other set of lead wires
RL3 and RL4 from the RTD are connected to ampli-
fier. Being a normal differential amplifier, it amplifies
only the voltage drop across the RTD to the re-
quired output voltage level.
Due to the mostly very high input resistance of
amplifier, the resistance of lead wires RL3 and RL4
from the RTD to the amplifier is negligible even it
would be substantially increased by the provision of
a safety barrier (explosion protection). To obtain
optimum results, the four-wire connection is gener-
Fig. 1 Resistance Characteristic for Platinum RTD's
(100 at 0 C)
ally used.
BHEL,Haridwar
Energy Sector 1011e
0114E
Thermocouple
Thermocouples are used for temperature meas- 2 Compensating Leads

urements on the exciter to measure bearing tem-
peratures. Thermocouples are mainly employed Compensating leads serve to extend the ther-
where small time constants require fast temperature mocouple up to the cold junction. When exposed to
indication. a temperature up to 200 C they produce the same
thermoelectric emf as the associated thermocouple.
See DIN IEC 60584 for calibration data and limits of
1 Operating Principle error of compensating leads.
Temperature measurement with thermocouples The sheath enclosing and protecting the com-
is carried out as described in the next paragraph. pensating lead wires has also been colour-marked
for the various thermocouples:
Two conductors of dissimilar materials, i.e. the
positive and the negative conductor (thermoelectric Ni CrNi = green
elements), are joined at one end (hot junction) to
produce an electromotive force (emf), i.e., a ther-
moelectric emf (in mV). The magnitude of the emf is 3 Cold junction
dependent upon the temperature difference be- For measuring temperature via a thermocouple,
tween the temperature to be measured and that of the cold junction temperature must be known. A
the other two ends of the conductors. To use the cold junction at a temperature of 0 C can be easily
thermoelectric emf for temperature measurement, produced by melting ice. The use of thermostats
the free ends of the conductors are exposed to a with reference junction temperatures of 20 C and
constant temperature (cold junction temperature) 50 C is also possible. Note that these cases certain
and connected to a milli voltmeter calibrated in C. corrections must be added to the calibration figures
of the particular thermo-couple which are referred to
0 C. To do this, add the thermoelectric emf due to
the cold junction temperature to the measured
thermoelectric emf and read measuring pint tem-
perature to obtain the total thermoelectric emf.
1 Hot junction 5 Connecting cable

2 Thermocouple 6 Milli voltmeter
3 Compensating lead 7 Compensating resistor
4 Cold junction
Fig. 1 Thermocouple
Fig. 2 Voltages as Function of Temperature for

Standardized Thermocouples according to
DIN IEC 60584
The cold junction can, however, also be imple-

mented by using a Pt 100 RTD for determination of
the actual temperature. The temperature is referred
to the calibration figure for 0 C by electronic
means. The electronic cold junction also avoids the
temperature error due to the junction between the
compensating leads and the copper leads.
Siemens
Energy Sector 1011e
0114E
Thermocouple
Thermocouple NiCr Ni
Identification
(acc. to DIN IEC 60584) K
Measuring range (in C) -270 to +1370
Colour identification of insulating sheath

Positive pole green
Negative pole white
BHEL,Haridwar
Siemens AG ELR-3.5-0006-0209 / 2
Energy Sector 1011e
0114E

Exciter

Components Manual

4 Operation
and Supervision

Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU
Exciter Turning and Running up
Operation and Supervision
Perform the following steps to run up the exciter:
1 Start-up of the exciter Actual condition
Bearing oil supply system in operation
Cooling system in operation
Bearing oil inlet temperature/pressure See turbine manual
Measuring Devices and Supervisory Equipment activated
Automatic voltage regulator ready for operation

2 Command: Run up exciter
n > Speed: Dryer OFF

Speed n approx. 90 %
Bearing vibrations Normal
Bearing metal temperatures Normal
COLD AIR TEMPERATURE Normal
Rotor earth-fault monitoring normal (No)
Field circuit breaker closed
Desired value of the rated voltage set
Speed n = rated speed
Siemens
Energy Sector 1011e
0114E
Exciter Operation under Load
There are no special requirements for the opera-

tion under load of the excitation machine.
Siemens AG
Energy Sector 1011e
0114E
Exciter Shutdown
Perform the following steps to shutdown the exciter:
1 Command: Shutdown of the exciter Actual condition
Generator power output S < 0,05 SN
Shutdown of the turbine Manual shutdown
Generator circuit breaker Automatically opened by reserve power protec-

tion
Speed Approx. 90 %
Excitation Switch of the exciter circuit open

Turning-gear operation See turbine manual
Cooling system out of operation
Speed n = 0 s-1 (at room temperature)

n speed: Dryer ON
Shutdown procedures completed
BHEL,Haridwar
Energy Sector 1011e
0114E
Exciter Standstill
Operation and Supervision General instructions
The operating conditions may make it necessary

to stop the excitation machine and generator for a
short time.
During a standstill, the bearing-oil circulation can
be taken out of operation.
The interior of the exciter is dry during operation
under average European climatic conditions.
To prevent condensation during an outage, the
in-built Munters dryer switches on automatically
when the machine falls below the turning speed.
BHEL,Haridwar
Energy Sector 1011e
0114E

Exciter

Components Manual

5 Troubleshooting


Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU
Exciter General
Troubleshooting
The details given herein on faults, their possible Unless corrective measures can be taken in ac-
causes and the corrective measures cannot be con- cordance with the following instructions the genera-
sidered complete in every respect, since all possible tor should be shut down.
troubles cannot be covered in advance. If required, the services of the manufacturer
In most cases, the operator will have to decide should be requested. In most cases, however, suffi-
on the measures to be taken. The individual meas- cient details will be found in this manual.
ures required depend on the mode of operation.
BHEL,Haridwar
Energy Sector 1011e
0114E
Exciter Ground Fault Detection
Troubleshooting
Faults and Possible Causes Remedy
Ground fault detection system disturbed:
Carbon brushes have poor or no contact with

measuring slip rings.
Install carbon brushes and plug-in brush holders
strictly in accordance with maintenance instruction
(see section 6.6-0001).
Exciter voltage response takes longer than 5 s. Fault alarm is automatically extinguished after
removal of cause.
High-resistance ground fault in exciter circuit

(RE <80 k:)
After a ground fault is reported, the cause of the

ground-fault message must be investigated immedi-
ately.
If it is possible to disconnect the generator from
the power system and to de-excite it, the insulation
resistance of the excitation circuit can be measured
If the measured insulation resistance is insuffi-
cient, in order to avoid major consequential dam-

age, the machine should only continue to be oper-
ated after consultation with the supplier.
Low-resistance ground fault in exciter circuit

(RE <5 k:)
The electrical generator protection initiates a trip

at RE <5 k:, and the generator is disconnected from
the power system and de-excited.
If the measurement of the insulation resistance
(see section 6.13-0001) confirms the ground fault,
further operation of the generator is forbidden. The
supplier must be informed and engaged to rectify
the fault.
If the measurement of the insulation resistance
does not detect a ground fault, the absence of a
ground fault must be tested once again at rated
speed before the generator may be excited again.
Siemens AG
Energy Sector 1011e
0114E
Exciter Exciter Temperatures
Troubleshooting
High hot air temperature at main exciter:

and/or
High hot air temperature at rectifier wheels:
Change in the cooling water conditions With a rise in cold water temperature, higher
cooling water flow is required for removal of the loss
heat. Increase cooling water flow.
High cold air temperature:

If the cooler malfunctions, the turboset must be
Insufficient cooling water flow or cooler is fouled
on water side.
unloaded, and shut down at the first possible oppor-
tunity.
If there are no leaks, the cooler must be cleaned
(original cooler documentation). When this is done,
the main exciter, rectifier wheels and pilot exciter
must, if necessary, be covered with a tarpaulin.
All the necessary maintenance work on the coo-
ler is described in the original cooler documentation.
Siemens
Energy Sector 1011e
0114E
Exciter Cooler
Troubleshooting
Liquid in exciter: Unload and shut down turbine-generator First i-

dentify the defective cooler section. Close cooling
The cause is a leak or a tube rupture at the coo-
ler tube bundle.
water inlet and outlet of this cooler section.
Drain the water from the cooler. If the defective
cooler tube cannot be identified by a simple visual
examination, disassemble the cooler section. Re-
move water inlet/outlet and return water chambers-
All cooler tubes must be separately subjected to a
leakage test.
Leakage Test of Individual Tubes:

To perform the leakage test, use rubber plugs at
one end and a hollow plug with a small tube fitting
for connection to a water or air line at the opposite
end (see Fig. 1).
1 Compressed air hose 5 Tube

2 Hose 6 Plug
3 Hollow plug 7 Tube sheet
4 Cooler section
Fig. 1 Identifying a Defective Cooler Tube
Plug the tube to be tested at both ends and apply

a low test pressure via the air or water line.
For checking purposes, a pressure gauge can be
installed in the line, which will indicate a pressure
drops even for minor leaks after a short time.
If the leakage test in performed without pressure
gauge, a visual examination on the air side must be
possible.
Leakage Test With Air in Water:

Dry the individual tubes by blowing air through
the tubes. Plug all tubes of the cooler section at one
end and place cooler section in a water basin.
Each tube can now be leak tested with air at 0.5
bar, max. During the leakage test, air bubbles will
escape from the tubes.
BHEL,Haridwar
Siemens AG ELR-5.4-0001-0209 / 1
Energy Sector 1011e
0114E
Exciter Cooler
Troubleshooting
Note that isolated air bubbles may rise from ac-

cumulations of trapped air in the cooler section
which have nothing to do with the leak to be identi-
fied.
1 Plug
2 Tube sheet
3 Cooler tube
4 Tube sheet
Fig. 2 Plugging a Detective Cooler Tube
Note:
If several defective tubes are identified, it
must be decided right away whether the
heat removal capacity remaining after
plugging of the defective tubes is suffi-
cient for emergency operation.
Plug the detective tube at both ends (see Fig. 2).

Remove all plugs from the remaining tubes. Then
bolt on water inlet/outlet and return water chambers
and perform a leakage test of the cooler section at
the specified test pressure.
If no leak is detected, the cooler section should
be installed, filled with water and vented. The cooler
section may remain in operation until the next in-
spection. During the next inspection or outage the
cooler section should be replaced.
BHEL,Haridwar
Siemens AG ELR-5.4-0001-0209 / 2
Energy Sector 1011e
0114E
Exciter Fuses in the Exciter
Troubleshooting
Fuse indicator tripped: Note:

Failure of corresponding diode or diodes. After operation of one or several fu-
ses, it may be necessary to observe
the respective operating limitations
If the number of blown fuses per bridge branch

and rectifier wheel has reached the maximum ad-
missible value, it is no longer permissible to con-
tinue on-load operation of the generator. The num-
ber of blown fuses indicates a severe fault in the
excitation system, the cause of which must be iden-
tified and removed. To do this, the turbine-generator
must be shut down immediately.
The work on the exciter set must be done with
the rotor ground fault sensor system switched off
and the measuring brushes raised. The exciter co-
ver and one half of the air guide cover of the rotating
rectifier wheels must be dismounted. The defective

fuse must be brought into an accessible position by
turning the entire shaft train of the turboset. All fuses
in the A and B wheels must be visually examined
during the turning. First release the defective fuse
from the contact strap of the heat sink by unscrew-
ing the self-locking nut. Then release and unscrew
the screw which holds the fuse on the wheel. A sim-
ple continuity test establishes whether the fuse is
electrically switched off or the fuse indicator re-
sponded as a result of a mechanical defect. How-
ever, mechanical triggering is quite unlikely. The
defective fuse must be replaced.
If the fuse switched off electrically, the cause of
the fault (defective diode) must be measured. To do
this, the connecting stranded wires between the
heat sink and the three-phase component must be
released. The heat sink must then be dismounted.
To do this, the laminated cloth countersunk
screws!!!! on the external surface of the rectifier
wheel must be released destructively. They must
always be replaced by new screws (see section
8.19-0001, BGR 6531, part 129781). The new
screws are tightened with a torque of 5 Nm, and the
head is secured with Loctite 454. The diodes must
then be removed.
BHEL,Haridwar
Siemens AG ELR-5.5-0001-0209 / 1
Energy Sector 1011e
0114E
Troubleshooting
A variable source of direct current of at least

1000 V with a constant output voltage is required for
the measurements. The direct voltage is applied to
the diode against the conducting direction. Further-
more, a microammeter is looped into the conductor
between the voltage source and the diode connec-
tion to measure the reverse current.
The reverse blocking characteristic of a diode is
determined by raising the voltage applied in stages
up to a maximum of 1000, and determining the re-
verse current in each case. At least three measured
values should be obtained so that a characteristic
curve can be drawn. Voltage steps of 500, 750 and
1000 V should be aimed at. The maximum permis-
sible reverse current at 1000 V is 500 A. The cor-
responding diode must be replaced if this limit value
is exceeded.
The following checks must be made before fitting
new diodes and fuses:
After cleaning the heat sink and its insulation, the
insulation resistance between the disconnected heat
sink and the wheel must be tested with at least 500

and not more than 1000 V. The insulation resistance
should be more than 10 megohms.
As both the fuses and the diodes are tested on
the manufacturer's premises, there is no need to
recheck the key data before they are fitted. It simply
has to be ensured that the replacement diode is the
same type as the defective diode (ensure that the
conducting direction is correct) and that it is in the
same conducting-state voltage class. Classes 22,
32 and 42 are used. The information is to be found
in the diode designation after T2 (e.g. class 32:
D690S26TT2 32). The height of the diodes on each
heat sink must also be checked. The difference
must not exceed 100 Pm. The 2 screws on the heat
sink must be screwed in with a torque of 23 Nm.
A contact lubricant (silicone paste) must be ap-
plied to the contact surface of the diode/heat sink.
The connecting stranded wires must be attached
to the three-phase current supply line by self-locking
nuts.
BHEL,Haridwar
Siemens AG ELR-5.5-0001-0209 / 2
Energy Sector 1011e
0114E
Troubleshooting
When a fuse is fitted, it must be ensured that the

contact surface (end face) of the fuse is lying solidly
on the contact surface of the wheel. After the fuse
has been properly screwed to the wheel and to the
strap of the heat sink, the surface contact must be
checked with a feeler gauge. If a gap greater than
0.1 mm is found between fuse and wheel in the area
of the contact surfaces, the fuse must be remounted
in the locking strap after any necessary reworking,
e.g. refilling the borehole. Finally, the fixing screw in
the end face must be secured. If a number of fuses
and diodes must be replaced, then the necessary
work must be performed in the same way. A fuse
must not be replaced without checking or replacing
the diodes.
The running behaviour of the exciter set is not af-
fected when diodes and fuses are replaced, be-
cause the differences in the weights of the spare
parts are insignificant.
The insulation resistance of the exciter set, in-
cluding the rotor winding, must be checked before
the exciter and air duct covers are remounted. The

insulation resistance must not be less than
1 megohm when measured with a megger with a
500 V measuring voltage.
After the covers have been mounted and the ro-
tor ground fault sensor system has been restarted,
the generator can be brought into operation again.
BHEL,Haridwar
Siemens AG ELR-5.5-0001-0209 / 3
Energy Sector 1011e
0114E
Exciter Stroboscope
Troubleshooting
Faulty stroboscope:
At a mains voltage of 230 V, pin 2 is connected

to 9 on plug-connector strip.
Mains voltage must be applied to pins 1 and 9 on
the plug-connector strip 2. If no voltage is available,
check the cable and the fuses.
Note:
The voltage values indicated below
may have a tolerance of 15 %.
Defect on circuit board 1:

Check whether voltage is applied to the following
A mains voltage of 230 V is applied to pins 3 and
8.
measuring points:
Ground/pin 12 Approx. 325 V DC
Plug-connector strip 1 (circuit board viewed from Ground/pin 6 Approx. 23 V DC
below) Ground/pin 7 Approx. 5 V AC
1 2 3 4 5 6 7 Ground/pin 11 Approx. 24 V AC
o o o o o o o
Press the ON button (hold the button if the relay
o o o o o o does not pick up): The circuit board needs to be
replaced if voltage is available at pins 2/3 and 8/9,
8 9 10 11 12 13 while no voltage is available at pins 6, 7, 11 and 12.
A major deviation in the voltages available at the
pins may indicate a short-circuit on another circuit
board. Remove circuit boards 2 to 4. Now, voltage
must either meet or exceed the indicated value at
these pins. Switch off the device, then insert one
circuit board after the other until voltage breaks
down at the measured point again. Replace the
defective circuit board.
Relay d1 must operate when pressing the ON

button. If the relay drops out again when the button
is released, press and hold the button again. Meas-
ure the voltage between pins 11 and 5 (15 V DC).
A mains voltage of 230 V is applied to pins 1 and
9.
Replace circuit board 3 if no voltage is available. If
voltage is available, circuit board 2 needs to be re-
placed.
Plug-connector strip 2 (circuit board viewed from
below)
1 2 3 4 5 6 7
o o o o o o o
o o o o o o
8 9 10 11 12 13
Siemens
Energy Sector 1011e
0114E
Exciter Stroboscope
Troubleshooting

Plug-connector strip 3 (circuit board viewed from Ground/pin 13 Approx. 23 V DC
below) Ground/pin 7 Approx. 15 V AC
1 2 3 4 5 6 7 Ground/pin 11 Approx. 5 V AC
o o o o o o o Ground/pin 9 Approx. 6 to 9 V DC
o o o o o o If voltage is missing on pin 7, or if voltage on pin

9 is either zero or 15 V, the circuit board needs to
8 9 10 11 12 13
be replaced if voltage is available at pins 11 + 13.
Defect on plug-connector strip 4:

Check whether voltage is applied to the following
Plug-connector strip 4 (circuit board viewed from measuring points:
below)
Ground/pin 12 Approx. 325 V DC
1 2 3 4 5 6 7 Ground/pin 11 Approx. 325 V AC Minimum
o o o o o o o Voltage must not exceed 280 V between ground
and pin 9, butvoltage must not be 0 V either. The
o o o o o o circuit board needs to be replaced if these voltage
data are not true.

8 9 10 11 12 13
If only one lamp is working, the fault is not on the

Flash lamp does not work device but on the lamp. Replace the lamp.
Functional check: Interchange the lamp connectors.
Siemens
Energy Sector 1011e
0114E
Exciter Exciter Dryer
Troubleshooting
Exciter dryer disturbed:
Limit switch failed to operate, i.e. motor-actuated

flap is hot in OPEN position.
Set lever for manual operation at flap shaft to
OPEN position and lock lever with locking device.
Check flap including actuator for proper me-
chanical condition.
After fault removal and loosening of the lever
lock, the lever should remain in the OPEN position.
Open door in exciter enclosure behind which the

dryer is located from the operating floor. Following a
Overheat protection has switched off the exciter
dryer. In most cases, the cause is no or an insuf- short cool down period, the overheat protection
ficient air flow. automatically returns the dryer to service.
Check whether air is drawn in via the intake
parts on both side of the air dryer.
If yes, the air flow passage is obstructed. Inspect
pre-filter in door for contamination.
If air is drawn only, via one intake part, the free
flow of dry air or regeneration air is obstructed. Re-

store free flow conditions.
If no air is drawn in via both intake parts, the ven-
tilator motor in the dryer has failed. The exciter dryer
should be de-energized, disassembled and returned
to the manufacturer's works for repair. A 2 kW hea-
ter-blower should be used inside the exciter enclo-
sure for dehumidification as long as the dryer is not
available due to repair
Siemens AG
Energy Sector 1011e
0114E

Exciter

Components Manual

6 Maintenance


BHEL,Haridwar
Siemens AG
(QHUJ\6HFWRU

Exciter

Components Manual

6 Maintenance

*HQHUDO

Siemens
BHEL,Haridwar AG
(QHUJ\6HFWRU
Exciter General
Maintenance
Reliable operation of the exciter will be ensured The assignment and number of Siemens AG
only if maintenance, inspections and overhauls are product service personnel required for an inspection
carried out at regular intervals so that any faults can should be planned well in advance to enable Sie-
be detected and corrected before they result in mens to make the necessary arrangements. In
costly failures. Following each maintenance and addition, the period available for execution of the
inspection, the next one is scheduled. inspection should be indicated.
Provided that commercial tools can be used and The spare parts stored for maintenance, repairs
that no special skills are required for the dismantling and overhauls should be checked at regular inter-
and erection work, the inspections can be per- vals. Components packed in plastic sheeting mostly
formed usually by skilled power station personnel. In contain a desiccant which must be replaced or reac-
all other cases, however, such as for the inspection tivated from time to time.
of the shaft seals and their auxiliaries, the services
of experienced Siemens AG product service per-
Danger:
sonnel will be required.
Machine parts start-up. These may
The shutdown of a exciter for inspection should cause injury to persons. Switch off the
be made in exactly the reverse order of start-up. electric power to the generator and its
Following an inspection, the exciter should be re- auxiliary systems during any work
started in the same way as during initial start-up. performed on them, and take adequate
measures to prevent accidental re-
starting.
Do not remove the cover from the ex-

citation machine until the generator
and the turbine have come to a com-
plete standstill, and only then start
work on the rotor or bearings.
Siemens
Energy Sector 1011e
0114E
Exciter Standstill during maintenance,
Maintenance Long-term storage
1 Prevention of condensation 3 Long-term storage

In order to prevent corrosion, the exciter must be Each period of storage longer than 12 months is
protected against the formation of a condensation- termed long-term storage.
related film of moisture. The function or quality of the goods must not by
The external dryer therefore has to remain in op- impaired by the storage.
eration throughout the entire outage, even during When outdoor storage is unavoidable, the stored
turning gear operation. goods must be protected, either by hardwearing
exterior packaging or an equally good type of sur-
2 Exciter dryer face protection.
2.1 Operation without a hydrogen-filled The outdoor storage area must provide adequate
generator protection of the stored goods against rain, in situ
water, ground moisture, dirt, vermin and unauthor-
In the event of lengthy outages without hydrogen
ized access.
in the generator, the exciter set dryer must be run in
closed circuit. In this operating mode, the air under The stored goods must be covered by water-
the exciter cover is sucked in through the dry air proof tarpaulins or located under a protective roof.
inlet. This is also dehumidified in the exciter set Stored components, especially in the case of
dryer, and led under the exciter cover again. The long-term storage, must be inspected at monthly
continuous circulation makes the air under the cover intervals for surface protection, nitrogen pressure
extremely dry. and the indicator colour of the moisture indicators.
Any damage to the surface protection (outer
2.2 Operation with hydrogen-filled generator layer of the packaging), fall in the nitrogen pressure
If the generator is filled with hydrogen, then the or change in the colour of the moisture indicators in
exciter set dryer must be run in open circuit. In open the air-tight packaging found during an inspection
circuit, air is sucked out of the machine house via an must be recorded by the responsible personnel.
air filter, dehumidified in the dryer, and fed under the
exciter cover.
BHEL,Haridwar
Energy Sector 1011e
0114E

Exciter

Components Manual

6 Maintenance

0DLQWHQDQFHGXULQJ2SHUDWLRQ

Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU
Exciter Maintenance Intervals
Maintenance
Refer to Section
Every 3 months
Every 6 months
Annually
Monthly
Weekly
Daily
Work Required
1 Check the ventilation and the drain pipes of the cooler X

6.2-
0002
2 Check leakage water indicator X
6.2-
3 Check exciter bearing insulation X
0003
Check make-up air filter in exciter enclosure and re- 6.2-

4 X
place filters in exciter dryer 0004
6.2-
5 Check carbon brushes for wear and damage X
0005
6.2-
6 Check fuses of the rectifier wheels X
0006
BHEL,Haridwar
Energy Sector 1011e
0114E
Exciter Cooler and Leakage Water Indication
Maintenance
Every 6 months
Every 3 months
Work Required
Annually
Monthly
Weekly
Daily
1 Check the ventilation and the drain pipes of the cooler X
2 Check leakage water indicator X
1 General 2 Cooler
Special measures should be taken to prevent During normal operation, the cooling water flows
corrosion damage to the cooler. Cooler sections through all cooler sections. Since the coolers are
having no cooling water flows for some time may be designed for full capacity at maximum cooling water
subject to standstill corrosion. In addition to many temperature, the condition may arise that the cool-
other corrosive influences, such as the different ers are supplied with smaller cooling water flows for
elements of the cooling water, locally differing de- long periods. Depending on the type of the cooling
posits, raw materials, etc., there exists the danger water, this may result in deposits due to the lower
that micro-organisms on the tube walls may die and water velocity in the cooler. To prevent cooler dam-
decay due to a loss of fresh water supply (lack of age, it is therefore recommended to rinse the cool-
oxygen). Ammonia is formed from such decay which ers with the full water flow during short outages. In
may lead to stress corrosion cracking. Corrosion addition, the coolers should be frequently cleaned
damage can only be properly prevented if the cooler with brushes. For heavy cooler contamination and if
is drained on the water side, cleaned, completely operational restrictions and shutdowns are undesir-
dried and maintained in a dry condition. With the able, it is recommended to install a continuous
generator in commercial operation, such measures cooler water purification system. You will find further
are often unfeasible, particularly in cases of short information about the maintenance work required on
outages. In such cases, the measures outlined be- the cooler in the original cooler documentation. All
low should be taken. the instructions it contains must be observed and
complied with.
Fig. 1 Exciter cooler Fig. 2 Cleaning brush
BHEL,Haridwar
Siemens AG ELR-6.2-0002-0209 / 1
Energy Sector 1011e
0114E
Exciter Cooler and Leakage Water Indication
Maintenance
3 Leakage Water Indication

3.1 Installation and Principle of Operation
The inlet to a leakage water indicator is located
under the centre of the exciter set. During operation,
the sight glass of the system must be filled with
water up to a specified maximum level. This liquid
seal prevents the inflow of contaminated ambient air
into the exciter as well as the outflow of cooling air
from the exciter.
3.2 Refilling Water in Leakage Indication

The water in the loop seal evaporates. Therefore
it must be refilled when the level has dropped to a
specified minimum. Only distilled water with a colour
indicator (methyl red sodium salt, 3 g per 1 dm3
water) should be used for this purpose.
Particular care should be taken to ensure that
the maximum level depending on the operating
condition is not exceed, i.e. during operation the
level must not exceed the marked maximum level.
3.3 Leakage Water

The leakage water indicator should be checked 1 Drain
during each walk down inspection, but at least once 2 Sight glass
3 Liquid level (exciter shut down)
per shift. Following factors indicate a leaking exciter 4 Liquid level (exciter in operation)
cooler: 5 Floor drain
6 Refill nozzle
the amount of leakage water
7 Inlet under exciter cooler
the level above the marker 8 Maximum level indicator
the level rises to the upper end of the sight glass
Fig. 3 Leakage Water Indication
the water is discharged from the loop seal into
the floor drain.
To protect the exciter set and its sensitive com-
ponents the exciter must be shut down immediately.
The generator must be unloaded, de-excited and
shutdown.
BHEL,Haridwar
Siemens AG ELR-6.2-0002-0209 / 2
Energy Sector 0114E
1011e
Exciter Bearing
Maintenance
Every 3 months
Every 6 months
Annually
Monthly
Weekly
Daily
Work Required
1 Check exciter bearing insulation X
1 General 2 Checking the bearing insulation

Maintenance of the bearings is not necessary Checking the bearing insulation during operation
during normal operation. However, bearing vibra- may be done by the way of the shaft voltage prevail-
tions, bearing temperature, oil temperature and oil ing with the generator running in an excited condi-
pressure must be monitored. The points in section tion. For this purpose, the potential of the insulated
5.1-0001 must be observed during start-up. The oil bearing is accessible external to the exciter. With
pressure of the shaft lift is set so that the shaft never the generator running, the components coming into
reaches more than 50 % of the diametral bearing contact with the shaft are separated from the shaft
clearance. by an oil film, which has insulating properties. Con-
sequently, a non-defined resistance value is set up
the potential measuring point of the bearing sleeve
which is dictated by the magnitude of the resis-
tances of the oil film and insulating parts
BHEL,Haridwar
Energy Sector 1011e
0114E
Exciter Air Filters and Exciter Dryer
Maintenance
Every 3 months
Every 6 months
Annually
Monthly
Weekly
Daily
Work Required
1 Check make-up air filter in exciter enclosure X
Perform functional check of exciter drying system and

2 X
clean filters, if necessary
Inspect and, if necessary, replace pre-filter in exciter
3 X
dryer (only relevant for effective operating period)
Inspect and, if necessary, replace dust filter in exciter
4 X
dryer
1 Make up Air Filters in Exciter Enclosure 2.1 Pre-Filter

Make-up air filters in the exciter enclosure can The pre-filter is installed in the door behind which
be contaminated by the continuous addition of the the exciter dryer is located. This door is an integral
air in the exciter cooling circuit. They should be part of the exciter enclosure.
checked at regular intervals and replaced, if re- The pre-filter consists of a coarse (Acelan) filter
quired. and a fine (Microsorlit-F) filter. The coarse filter is
located upstream of the fine filter.
2 Exciter Dryer
Check the filter pads for contamination from time Replacing the Pre-Filter:
to time, clean them in good time or replace. Slightly To inspect or replace the pre-filter, open the
contaminated filter pads should be blown out with door accommodating the pre-filter.
clean compressed air from the clean air side or Loosen wing nuts and then remove filter frame
washed in a water bath at a water temperature of and the two filter pads.
approximately 30 C, adding a neutral detergent. In case of slight contamination the fine filter can
Depending on the operating conditions, the ball be reused if in proper condition.
bearings of the ventilator and the gear motor should In case of more severe contamination, the filter
be filled with new grease every two to three years. pads should be replaced.
For reassembly of the filter, follow the same
Note: procedure in reverse order.
The dryer is not in operation under
load. Consider only the effective oper-
ating periods of the exciter unit dryer
for maintenance.
BHEL,Haridwar
Siemens AG ELR-6.2-0004-0209 / 1
Energy Sector 1011e
0114E
Exciter Operating and Supervision
Maintenance Air Filters and Exciter Dryer
2.2 Dust Filters

One dust filter each is provided behind the intake
branches on both sides of the exciter dryer. With
proper and regular maintenance of the pre-filter,
dust filters will be required only once per year.
Replacing the Dust Filters:

Notice:
The exciter dryer must never be
brought into operation without an
additional air filter.
Open the door accommodating the pre-filter.

Disconnect electrical and mechanical connec-
tions, if necessary, and remove dryer.
Loosen screws at connection branch by about
three turns.
Turn connection branch counter clockwise for
1 Connection branch 5 Inspection port

removal. 2 Screw 6 Filter frame
Remove filter frame with dust filter. 3 Protective gratings 7 Filter pad
Blow out dust filter with compressed air from the 4 Overheat protection 8 Filter frame joint
air-leaving side or wash dust filter. If necessary, Fig. Exciter Dryer
replace dust filter.
Reinsert filter frame with clean dust filter into the
dryer. To do so, ensure that the filter frame joint
is in the bottom centre position
Refit connection branch and turn it clockwise
before tightening the screws.
After replacement of both dust filters, properly
restore all connections.
Close door and energize exciter dryer.
The exciter dryer is ready for further operation.
BHEL,Haridwar
Siemens AG ELR-6.2-0004-0209 / 2
Energy Sector 1011e
0114E
Maintenance
Every 3 months
Every 6 months
Annually
Monthly
Weekly
Daily
Work Required
1 Check carbon brushes for wear and damage X
1 Maintenance and Supervision of Carbon 2 Replacing the Carbon Brushes

Brushes
To replace the carbon brushes, complete the fol-
lowing procedures:
Carbon brushes should be checked for wear at
regular intervals. During operation, the useful length Release and withdraw brush holder from bayo-
of each carbon brush can be determined by a visual net lock at brush carrier segment by pressing
inspection of the delivered gage stick. To do this, and turning it counterclockwise.

insert the gage stick into the hollow bore of the Break electrical connection at cable lug.
brush holder When the handle of the gage stick
contacts the brush holder, the carbon brush has Pull brush box with carbon brush off the brush
reached its minimum size of 15 mm (0.6 in.) and holder.
must be replaced immediately. Withdraw carbon brush from brush box at the
Carbon brush wear depends on several factors rear end.
and may thus be different in each individual case. Insert new carbon brush into brush box from rear
For this reason, checking at shorter intervals is rec- end.
ommended during the initial phase of operation.
Push brush box with carbon brush over the
The normal service life of a set of carbon brus- brush holder.
hes can only be determined after a prolonged ser-
vice period. Restore electrical connection at cable lug.
After checking for wear, the plug-in brush holder Check and, if necessary, adjust brush contact
should be released from the bayonet lock at the pressure to approximately 6 N.
brush carrier segment. Remove only one brush Insert brush holder into brush carrier segment
holder at a time. Check carbon brush for damage and engage bayonet lock.
(e.g., cracks between carbon and silver layers) by a
visual examination. If damage is detected, the car-
bon brush must be replaced.
Siemens
Energy Sector 0114E
1011e
Maintenance
Note:
1 Carbon brushes should be replaced
with new ones having contact faces
which match the slip ring contour.
Grinding of new brushes to the re-
quired contour should be done using
a model of the ring contour or by
grinding to size at the slip ring when
2 the unit is at rest.
The carbon brushes should be re-
placed in sets of two only. When in-
serting new brushes, make sure that
the carbon layer comes before silver
layer in direction of rotation.
Note:
One brush per slip ring is sufficient to
monitor for ground faults. Two un-
used brushes can be used when
changing the brushes.
1 Air flushing connection

2 Bore for gage stick
3 Plug-in brush holder
4 Connecting terminals
Fig. Brush Holder for Ground Fault Detection
Siemens AG
Energy Sector 1011e
0114E
Exciter Fuses on Rectifier Wheel
Maintenance
Every 3 months
Every 6 months
Annually
Monthly
Weekly
Daily
Work Required
1 Check fuses of the rectifier wheels X
Fuse Monitoring
With the aid of the stroboscope, whose light fre- The position of the fuse indicator shows whether
quency is automatically controlled, it is possible to a fuse is intact or has blown due to diode failure. If
observe each separate fuse on both wheels. the colour-coded fuse indicator has taken a radial
To activate the stroboscope, press the ON push- position, the fuse has blown. To determine the con-
button. After pressing the pushbutton LAMP 1 or dition of the entire rectifier wheel, it is necessary to
know in which arm of the bridge each blown fuse
LAMP 2 the fuse can be observed in the respective

belongs. The bridge arm can be determined from
rectifier wheel. By pressing the FEED or RETURN
the colour marking above the fuse on the edge of
pushbutton, flashes can be timed so a continuous
the rectifier wheel.
slow-motion observation of each fuse is possible.
Operating limitations must be observed if several
fuses have blown (see section 2.3-0001).
In normal operation, fuses should be monitored
at least once per day. A check is required at once
following abnormal operating conditions, e.g., short-
circuit on the system close to the power plant, asyn-
chronous running, etc. If the exciter is operating with
defective fuses, monitoring should be done on hour-
ly basis. If no additional fuses have blown after two
further shifts, normal running routine may be contin-
ued.
1 LAMP 1 pushbutton 5 RETURN pushbutton

2 LAMP 2 pushbutton 6 ON pushbutton
3 FEED pushbutton 7 OFF pushbutton
4 Pilot lamp for control voltage
Fig. Stroboscope for Fuse Monitoring
BHEL,Haridwar
Siemens AG ELR-6.2-0006-0209 / 1
Energy Sector 1011e
0114E
Exciter Fuses on Rectifier Wheel
Maintenance
2
1 Rectifier wheel 4 Fuse

2 Colour marking on rectifier wheel 5 Stroboscope lamp
3 Fuse indicator
Fig. 2 Arrangement of Fuse Indicators
BHEL,Haridwar
Siemens AG ELR-6.2-0006-0209 / 2
Energy Sector 0114E
1011e

Exciter

Components Manual

6 Maintenance

0DLQWHQDQFHDW6WDQGVWLOO,QVSHFWLRQ

Siemens AG
BHEL,Haridwar
(QHUJ\6HFWRU
Exciter General information
Inspection
The scope of work to be performed during a re

Checking the Lamination Tapes
vision depends mainly on the equipment on which
defects have been detected since the last revision. A check should be made to ensure that the pro-
It will therefore be necessary to extract from the jecting contacts of the lamination tapes are spirally
operating log all deficiencies to be corrected during distributed on the entire circumference of the con-
the inspection. For this reason, before starting the tact sleeve.
inspection it is necessary to make a statistical sum-
mary of all unusual incidents that have been re-
corded in the operating logs.
Dismantle and clean exciter set

The exciter rotor must be removed. The coupling
flange of the rotor must be checked at the centering
seat and the fitting holes. The coupling bolts must
be checked and measured for mechanical deforma-
tion.
Dirt collected in the cooling air ducts of the rotor,
and on the diodes, fuses and heat sinks must be
removed. Cleaning must be done very carefully to
avoid damaging the many insulation points. It is
therefore recommended to remove this dirt with a
brush, (non-linting) cleaning cloth and vacuum clea-

ner. Special care must be taken to clean the porce-
lain body of the diodes.
Drying Out Windings

1 Insulation
If the exciter dryer is not in operation due to spe- 2 Contact sleeve
cial circumstances during a prolonged outage of the 3 Plug-in contact strip
exciter, the resulting formation of a moisture film on Fig. 1 Section Through Contact Sleeve
the surface of the winding may lead to a reduced
insulation resistance. If the dryer cannot be placed
in operation, hot air should be admitted into the
exciter by means of a fan-forced heater with a rating
of approximately 2 kW.
Siemens AG
Energy Sector 1011e
0114E
Exciter Inspection Intervals
Inspection
Inspection
Major inspection
Intermediate in-
spection
Work Required
1 Dismantle exciter X
2 Check insulation resistance of windings X X
3 Replace fuses X
4 Check condition and performance of rectifier wheels, check stator and rotor windings X X
5 Check coupling flange X
6 Renew the lamination tapes X
7 Check alignment X
8 Check bearing and pipe insulation X X
9 Replace bearing and pipe insulation X
10 Check condition and performance of bearing pivoted segments X X
11 Check bearing surface and Babbitt bonding X
12 Check bearing clearances X
13 Check the hemispherical seat of the bearing shell in the bearing pedestal X
14 Check labyrinth rings and, if required, replace seal strips X
15 Check air filter and, if required, replace air filter X X
16 Check condition and performance of measuring devices X X
17 Check condition and performance of ground fault detection system X X
18 Check performance of stroboscope X X
19 Clean exciter coolers on water side X X
Dismantle exciter cooler, check on water and gas sides; clean, if required; replace gas-
20 X
kets and perform pressure tests
Note:
The operating times between the inspections correspond to these of the generator. If there are deviations
of the scope of inspection from the present generator manual, the requirements stated therein must be
observed.
Siemens AG
Energy Sector 1011e
0114E
Exciter Cooler
Inspection
You will find all necessary information about the In the case of a brief outage, it will mostly be suf-
maintenance work required on the cooler during the ficient to supply the coolers with a small water flow
standstill in the original cooler documentation. The and to flush them with the full water flow twice
instructions it contains must be observed and com- weekly.
plied with. In the case of a prolonged outage, the coolers
Suitable measures must be taken on all coolers should, however, be drained on their cooling water
taken out of service to prevent standstill corrosion in sides and dried.
the cooler tubes.
BHEL,Haridwar
Energy Sector 1011e
0114E
Exciter Bearing
Inspection
1 General
The manufacturer must be consulted if scoring is
The bearing-oil circulation must be started up found. It must be ascertained whether the bearing
once per week, and the entire circuit flushed with can continue to be used.
water-free oil. If the oil circulation is activated, the
rotor must driven by the turning gear. If a low insulation resistance has been meas-
ured, the particular bearing must be thoroughly ex-
amined for possible damage caused by cathodic
2 Inspection effects.
The insulation resistance of the insulated bearing The insulation of the bearing cradle must be
must be measured before each inspection. The cleaned, as otherwise the insulating properties
bearings must then be dismounted and cleaned could be impaired.
thoroughly. The bearing shells and shaft bearing
points must be checked to ensure that they are in
good working order.
Siemens
Energy Sector 1011e
0114E
Inspection
1 Maintenance Measures The mounting parts and the state of the hoses
The brushes of the ground fault detection system between fan and brush holder assembly have to be
should be removed to prevent the formation of rust checked. As required, replace these parts.
on the slip rings in cases where the generator or the The measuring slip-rings and insulating parts
exciter is shut down for more than 2 days. must then be cleaned with a lint-free cloth soaked in

In the case of a prolonged outage, a protective cleaning fluid (Rivolta or similar).
coating should be applied to the measuring slip It is recommended to change the carbon brushes
rings. in the plug-in brush holders of the rotor ground-fault
monitor after each inspection.
2 Inspection The carbon brushes used must match the con-
tour of the slip-ring. After the exciter set has been
Dust and dirt collected on the measuring slip-
assembled, the entire monitoring system must be
rings and the associated insulating parts, and in the
subjected to a functional test.
air duct of the brush holder assembly as far as the
air outlet, must cleaned out with a vacuum cleaner.
BHEL,Haridwar
Energy Sector 1011e
0114E
Exciter Make-up air duct filter
Inspection
The filters must be checked regularly for soiling, Place the filter mats in the water bath with the
and cleaned or replaced when necessary. dirty side down (the side that faces into the ma-
Lightly soiled filters should be carefully knocked chine). Then rinse the mats with clean water.
out or blown out with compressed air. Filters must
be blown out from the air intake side.
If this is not adequate, the filter mats must be
washed out. They are washed out in a water bath at
about 30 C, with neutral washing-up liquid added to
reduce the surface tension.
BHEL,Haridwar
Energy Sector 1011e
0114E
Exciter Checking the Insulation Resistance of
Inspection RR Wheels
Regular inspection work should include checking Detail X

the insulating sections between the diode heat sinks
and rectifier wheels. Leakage paths may be formed
at these points as a result of dirt deposits, rendering
the fuses connected after the diodes ineffective in
the event of a failure. In the event of a diode losing
its blocking capability, an interruption of the respec-
tive bridge arm by the fuse would then no longer be
ensured, resulting in a phase-to-phase fault in the
main exciter circuit.
After removal of the fuses, the insulation resis-
tance between point a and b or a1 and b1 respec-
tively, can be measured by means of a crank induc-
tor. The measuring voltage is from 500 to 1000 V.
The insulation resistance between the heat sink and
rectifier wheel should not be less than 10 M. Fig. 2 Detail X
a, b and a1, b1 Measuring points to check insulation resis-

tances after removal of fuses
1 Fuse 5 Tension bolt 9 Three-phase AC line

2 Diode 6 Hot air outlet 10 Direct-current line
3 Heat sink 7 Rectifier wheel (+ polarity) 11 Bolt of non-conducting material
4 Rectifier wheel (- polarity) 8 Insulation
Fig. 1 Checking the insulation at rectifier wheels
Siemens AG
Energy Sector 1011e
0114E
Exciter Measurement of the Insulation Resis-
Inspection tance on the Rotor, Stator and Exciter
Set Windings
During manufacture and transport, the insulating Danger:

of the rotor winding and the exciter winding may Fire and explosion hazard due to
have been exposed to moisture which could reduce escaping H2 gas.
the winding insulation resistance. The insulation Do not use fire, an open flame and
resistance should therefore be measured prior to spark-generating activities in the
initial start-up, after prolonged outage periods and vicinity of the generator filled with
after work on the windings. If required, the exciter hydrogen (H2). Do not perform any
should be dried until a sufficient insulation resis- activities which causing sparks in
tance is obtained. the generator filled with H2 due to a
static charging and potential spark-
Required Insulation Resistance of Winding ing during the insulation resistance
The insulation resistance should be amount to measurement, the rotor shaft must
1MOhm at 40 C. be properly grounded at turbine and
exciter ends.
At winding temperatures other than 40 C,
a correction can be made using the curve shown in
Fig. 1.
Measurement of Insulation Resistance

Prior to each measurement, the generator must
be de-excited and any static charges removed by
grounding the windings.
Stator:
The cables must be unscrewed from the terminal
board of the exciter stator.
Rotor:
The measuring brushes in the ground-fault mea-
suring device must be removed from the slip-rings.
The insulation resistances of the individual windings
must be measured against ground by a megger.
Stator and Rotor:

The insulation resistance is measured by an in-
sulation meter with a 500 V measuring voltage at
the measuring slip-rings of the ground fault monitor
arranged in the area of the exciter. This voltage
does not pose any danger to any of the devices
lying in the exciter circuit. The duration of the test Slot temperature in C
should be about 2 minutes. The winding capaci-
tance must be discharged for at least 2 minutes Fig. 1 Correction curve for insulation resistance
after each measurement. measured (Rmeas.) to a temperature of 40 C
BHEL,Haridwar
Energy Sector 1011e
0114E
Exciter Insulation Test Report
Inspection
Checking the Insulation Resistances of Rotor 3. If the exciter rotor is not coupled, the ground fault
Windings in Sealed Packing monitor brushes are raised. The rotor winding is
The insulation resistance of the rotor winding connected by the measuring slip-rings which ha-
should be checked after shipment has been com- ve previously been temporarily bridged. The
pleted and at intervals of one month during any bridge must be removed after the measurement
subsequent storage period. The results should be has finished. If the rectifier wheels are accessi-
recorded in the table below. ble, the measurement can also be made there,
as the wheels have +/- potential. Here again a
Notes: bridge must be made.
1. The insulation resistance should be measured 4. All the necessary information about the proce-
with an insulation measuring device, applying a dure for coupled exciters can be found in the
voltage of 100 V, but not more than 250 V. present original generator manual.
2. Prior to each measurement, any static charges 5. After each measurement, any static charges
should be removed by grounding the windings as should be removed by short circuiting the wind-
a precautionary measure (10 minutes). ing through the rotor body (at least 20 minutes).
Job name: Order no.: Type: Component:

Shipping or Storage Prior to
Phase shipment
Date
Name
Company
Storage Area
Temperature in Storage
Area (C)
Relative Humidity of
Ambient Air in Storage
Area (%)
Rotor Temperature (C)
Moisture 50
Indicator in DE 40
Packing
30
blue or
pink? 50
NDE 40
30
Pressure of Nitrogen
Blanket (bar) (if required)
Measuring voltage (V)
15 sec
30 sec
Insulation Resistance (MOhm)
45 sec
1 min
2 min
3 min
4 min
5 min
6 min
7 min
8 min
9 min
10 min
BHEL,Haridwar
Energy Sector 1011e
0114E
Exciter Checking the Insulation for Protection
Inspection from Shaft Currents
General Finally measure the insulation resistance to the

During operation of a generator, voltages are set base frame of the bearing pedestal with the con-
up along the rotor shaft due to magnetic unbal- nected pipework. If this value is higher than
ances. These shaft voltages would cause a destruc- 3 MOhm proceed with mounting of the exciter rotor.
tive current to flow through the bearings and other
components if the rotor shaft were not insulated Final Check
from ground at least at the exciter end. For reasons After the exciter rotor has been coupled to the
of interchangeability, all stator components coming generator rotor and insulated from the bearing ped-
into contact with the generator rotor are insulated. estal, a final insulation check should be performed.
At the exciter, all bearings or the complete exciter The total insulation resistance must not be less than
are insulated. 1 M:. Due to contact with the shaft, the measuring
circuit covers in parallel:
Pedestal Bearing of Exciter
TE/EE bearing
The insulation resistance between the bearing
pedestal and base frame should be measured im- TE/EE shaft seal
mediately after mounting of the pedestal. Exciter bearing pedestal with pipework
With satisfactory insulation, a value in excess of
10 MOhm is to be expected. Following this, the as-
sociated oil pipe has to be bolted to the bearing
pedestal being careful to insulate it. It is also rec-
ommended to repeat the insulation resistance

measurement after fitting of each individual pipe. If a
sufficiently high resistance value is measured
(5 MOhm) proceed with fitting of the next pipe.
Siemens
Energy Sector 1011e
0114E
Exciter
Components Manual
Special
Assembly Instructions
Siemens AG
BHEL,Haridwar
Energy Sector
Exciter Special Assembly Instructions
Assembly
1 Steady bearing
Until assembly, the exciter shaft is stabilized at
the drive end by a steady bearing. The steady bear-
ing must be dismounted before the RR air ventila-
tion housing can be mounted.
Steady bearing drawing 1-7701-434454b
Note:
The steady bearing cannot be dis-
mounted until the exciter has been
coupled to the generator.
2 Transport Securing Device

The shaft must be secured by retaining bolts on
the steady bearing in order to prevent it horizontal
slipping during transport. The retaining bolts must
be removed before the exciter is commissioned.
Fig. 1: Retaining bolt
A transport securing device must be fitted be-

tween the shaft and the bearing shell to prevent the
shaft moving vertically. The transport securing de-
vice must be removed before the exciter is assem-
bled in the power plant, and commissioned.
3 Vibration Pickup
The customer should mount vibration pickups to
measure the vibration of the bearing housing and to
record the relative shaft vibrations.
The mounting points of the vibration sensors are
to be agreed with the customer. For more detailed
information about the sensor positioning see draw-
ing 2-7200-441853 in section 3.3 and drawing
4-447277 in section 3.5.
BHEL,Haridwar
Energy Sector 1011e
0114E

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Technical Customer Documentation

Operating and Maintenance Manual

Product Technical Documentation

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0--0010--12580/1--6 0212E

General Safety Information for Hydrogen-Cooled Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0--0100--0003/1-2 0810E

Rating Plate Data for Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1--1605--12580 0811E

MKY - Protection and Monitoring Devices Tab 4.11

MKA70 --- Cooler .

Maintenance and Supervision --- Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 ---4250---0004 0114E

2.2 Mechanical Data

Dimensional Drawing ........................................................................................ 0-7902-509914b (

2.3 Electrical Data

2.4 Operating and Setting Values

2.5 Measuring Instruments, Connection points and Consumers

3 Components and Purchased Parts

4 Operation and Supervision

6.2 Maintenance during Operation

6.3 Maintenance at Standstill / Inspection

Ground Fault Detection..................................................................................... ELR-6.3-0005-0209 (

This manual contains information on the operation and

4.11 Protection and Monitoring Devices

10 Trouble-Shooting review and revision process, and you should receive

1 Generator Documentation For carload shipments:

method of shipment, please contact Siemens AG in

2 Product Service J Name of consignor

J Reason for return of parts.

1 Introduction D: (Function Key 3)

Category 1 identifies the function

rators and their auxiliary systems.

Supply and vent lines for

Air Control valve, piston-operated

Non-combustible gas Pressure relief valve, spring-loaded

Waste gas Pressure relief valve,

Process flow line, signal line Level control valve

Lines, crossing Ceck valve

Lines, joining Restricting orifice

Tee branch Sight glass

U-Loop Mixing section

Flexible line Orifice plate

Drain funnel Heat Exchangers and Tanks

Reduction of the line Shell-and-tube heat exchanger

Control valve Machines

Multi-way valve M Electric motor

Check valve Centrifugal pump

Check valve, lockable Diaphragm pump

Pressure reducing valve,

Gate valve Exhauster and vacuum pump

Three-way cock Coupling, general

Separator, general E Electrical

Filter, general F Flow rate

Air or gas filter, general L Level

Liquid filter, general M Moisture

Tubular element filter P Pressure

Ion exchange filter T Temperature

.... Gas dryer Y Vibration

Measurement and Control Framing for valve and fitting identification

Flow measurement Framing for measuring point identification

Controller, general Terminal Points in Supply Circuits

Flow guide for volumetric flow meter System limit

1 General 3 Safety Notices and Warnings

WARNING is used for medium-risk hazards which, if not

2 Normal Generator Operation

A generator has the following functions,

800MW TG O&M Manual Yeramarus

800MW TG O&M Manual Yeramarus

Dimensional Drawing ........................................................................................ 0-7902-509914b (

Ground Fault Detection..................................................................................... ELR-6.3-0005-0209 (