Generator Sealing

Losses in percentage
60 MW Generator losses
Windage
10%
Rotor Loss
40%
26% Stator Cu. Loss
Stator Fe. Loss

12% 12% Stray losses
10/21/2019 mydocuments/npti/001b/GeneratorCo 1
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Losses in 60 MW Air Cooled Generator in Kw.
[Need for cooling]
Windage
132
Rotor
Loss
528
Stator
344 Cu. Loss
Stator
Fe. Loss
Stray
158 losses
158
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LossesHeatdissipationCooling
• All losses appear as HEAT which must be
removed to keep the temperature within
limits.
• OPTIONS-
• Air cooling.Air filters and fans.It may be like a
TEFC motor.
• Coolers may be inside the casing.
• Hydrogen cooling of Rotor & Stator & Core.
• Hydrogen cooling of Rotor & Water cooling of

Stator.
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Cooling of Air/Hydrogen in the Generator.
• The HOT air/Hydrogen is cooled by coolers
installed inside the Generator casing.
• These coolers may use C.W. water or
General Service water.
• D.M. water is also used.
• The D.M. water is then cooled in a DM/GS
cooler.
• Coolers may be conventional tubular or
Plate type.
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Superiority of Hydrogen as a coolant.
Hydrgen
Air Pressure in psi
0.5 30 45
Density 1 0.07 0.14 0.22
Thermal conductivity 1 6.7 6.7 6.7
Heat Transfer Co-efficient 1 1.55 2.7 3.6
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Where are the losses and heat ? ? ?
• Rotor slots - - - - - - Cu loss

• Stator slots - - - - - Cu loss
• Stator core - - - - - - Iron loss
• Special construction features to carry away the
heat.
• Ventilation ducts in stator core.
• Ducts in rotor slots.
• Fans on rotor for circulation of gases.
• Hollow conductors for stator water cooling.
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Hydrogen cooling equipments
• Hydrogen and Carbon-di-oxide cylinders.

• H2 and CO2 manifolds and piping, valves
for filling & purging out CO2.
• H2 gas drier.
• [silica gel crystals/Vacuum type]
• Purity meter for continuous monitoring of
gas purity.
• Shaft seal arrangement.
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Types of conductors
• Older and medium sized Generators were
built with solid conductors for Stator
and Rotor.
• Heat dissipation needed was not much.
• Heat is removed through the insulation.
• That means “Indirect Cooling”
• For higher capacities “Direct cooling” is
needed and so Hollow Conductors
were developed.
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Rotor Conductors -Types
SOLID HOLLOW
CONDUCTORS CONDUCTORS
Sub-Slot
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Stator conductors for water cooling.
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Hydrogen Cooling—Indirect & Direct
100 100
90 90
80 Conductor Temp. 80 Conductor Temp.

70 70
60 60
50 50
40 Hydrogen 40
30 Temp. 30
20 20
10 10
0 0
0 25 50 75 0 25 50
Hydrogen Pressure PSIG-------->>>>>> Hydrogen Pressure PSIG-------->>>>>>
INDIRECT HYDROGEN COOLING DIRECT HYDROGEN COOLING.
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Hydrogen-CO2 System
Diagram
Generator
Oil
Heater Pressure Regulators
Vent valve
Carbon-di-oxide
AIR
Hydrogen [150Kg/cm.sq].
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Pre-requisites for CO2- H2 filling.
• Gas tightness test of Generator casing.

• Tube leakage test of H2 coolers in casing.
• Tightness of Stator water cooling system.
• Readyness of Seal oil and Lube oil ckt.
• Both A.C. and D.C. seal oil pumps ready.
• Establish Lube oil and Seal oil circuits.
• Before switching in Seal oil, try to keep casing
pressure of at least 0.5Kg/sq.cm.
• Observe functioning of DPR.
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CO2 filling process
• Initially Generator casing will contain air.

• Start to admit CO2 through the heater and open the vent
valve to purge out air-CO2 mixture.
• Air will be slowly vented out.
• Keep watch on seal oil pressures.Oil may enter the
Generator.
• Monitor the CO2 content of vented gas till CO2 is above
98% in the vented gas.
• CO2 filling is completed.Keep casing pr.0.50kg/sq.cm
• Close CO2 filling valves.Stop heater also.
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Hydrogen filling process
• Start H2 filling and venting out the mixture
of CO2 and H2..
• Use H2 cylinders one by one.
• For each cylinder, test the H2 purity before
admitting to the casing.
• Continue filling H2 till purity of vented
gas shows more than 99% Hydrogen.
• Purity can be further raised to 99.7% in
operation.
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Removal [purging] of Hydrogen.
• Air can not be admitted directly.
• So, start filling CO2 and vent out H2.
• When CO2 in vented gas is above 98%,stop
purging.
• Now admit air in the similar way till CO2 is
purged out.
• Very cold CO2 should not be admitted to
the casing.
• It chills the Generator and moisture
condenses in it.
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Precautions while filling Hydrogen.
• CO2 should not be kept in Generator for long
periods.
• It is corrosive.
• During this process casing pressure may vary
between 0.5kg/sq.cm to 1.0kg/sq.cm.
• Seal oil pressure will be accordingly low.
• If DPR malfunctions,Gas will leak out or Oil may
enter the casing.
• Close watch is necessary.
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Ventilation
in VPI
Generator.
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Ventilation Scheme of Generator
TYPE OF COLING
• OPEN
•COOLING
WATER
MODULE
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Cross section of Generator.
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Four Flute cooling system for Rotor
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Stator Slot Insulation
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Cross section of Generator
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Sealing of Generator.
• When Hydrogen cooling is used,

• Sealing system becomes necessary.
• Oil sealing is employed successfully.
• Axial seals
• Radial seals.
• Seal oil circuit.
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Seal Oil System
Seal Oil System
From Lube
Oil
Generator
D.P.R.
#####
Strainer
VP
Hydrogen
Seperator
Tank
my documents TPS Overview 43
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Duplex Strainer
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Inner View-Duplex Strainer
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RING TYPE H2 SEAL
Bronz Ring
SPRING
AIR HYDROGEN
OIL VIPERS
SEAL OIL SUPPLY
SEAL OIL DRAIN
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AXIAL H2 SEAL
THRUST
BEARING HYDROGEN
AIR SIDE
SIDE
SEAL
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Seal oil circuit
• The seal oil tank top is connected to the
Generator casing.
• Seal oil pumps take suction from the bottom
of the tank.
• Oil passes through filters and coolers.
• Then through the DPR.
• Oil pressure is maintained above the
Hydrogen pressure at all times.
• Seal oil is then admitted to the seals.
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• From the seal, the oil has two paths.
• Hydrogen side oil flow. And,
• Air side oil flow.
• Air side oil flow mixes with lube oil flow in
the journal bearing.
• Hydrogen side oil flow goes to seal oil tank.
• From the tank the Seal oil pump again sends
the oil to the seals.
• {through coolers and filters}
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Seal oil system equipments
• Seal oil tank.
• AC & DC seal oil pumps.
• Duplex Strainers.
• Oil coolers.
• Seal oil tank float valve for level control.
• Differential Pressure Regulator-[DPR].
• Liquid level detectors.
• Pressure and Temperature gages.
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Case studies
• Koradi 120 MW unit 3.
• Axial seals. Problem of high seal face
temperature.
• Frequently,the Thrust pressure was made
zero
• During purging out H2, casing pressure was
made too low.
• Seal oil entered the casing.
• 21 barrels of oil drained from casing.
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Khaperkheda 210 MW unit#3
• Unit was at full load.
• Earlier there was a problem with strainer
isolating valves.
• These were 3-way valves & gate valves.
• Supplier representative was checking the
system.
• While operating the valves seal oil supply
was cut off.
• H2 escaped from in-board seal &caught
fire.
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Steps to avoid accidents.
• Study the system well.
• Note awkward location of valves and
equipments.
• Take possible corrective steps in advance.
• Ensure that all operators are fully familiar
with the system.
• The last is most important as ignorance may
result in serious accidents.
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3-Way valve operation
ROTATE UPPER VALVE QNTICLCKWISE
LOWER VALVE CLOCKWISE.
FOR UPPER VALVE ONLY
B IN SERVICE
BOTH CUT OFF

A B
A IN SERVICE
BOTH IN SERVICE
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Transposition of
Stator Bars
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Rotor without end-bells
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Rotor with retaining rings
[end – bells ]
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Bar Insulation
INSLATED. HIGH VOLTAGE

COPPER INSULATION
STRIPS
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Rotor Slots
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Assembled Core
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Retaining Rings {End-bells}
•NON-MAGNETIC, COLD WORKED MATERIAL

• WITHSTANDS CENTRIFUGAL FORCES DUE TO THE END
WINDINGS
• SHRUNK FIT HUB REINFORCES RETAINING RING AND
SECURES THE END WINDING IN THE AXIAL DIRECTION
• SNAP RING PROTECTS AGAINST AXIAL DISPLACEMENT OF
THE RETAINING RING.
• SHRINK SEAT AREA IS SILVER PLATED
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Stator Core Building
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Core Assembly
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Stator Coils Formation
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Lower Half Bearing
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Complete Bearing
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Salient Design Features of Bars.
 Roebel bars with 3600 transposition to

reduce eddy current losses
 Double glass lapped copper conductors.
 Multi turn design for low capacity high
voltage machines
 Resin rich mica / resin poor VPI insulation.
 Corona protection of straight part insulation.
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Generator Sealing

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Losses in percentage

Stator Fe. Loss

• Hydrogen cooling of Rotor & Stator & Core.

• Hydrogen cooling of Rotor & Water cooling of

• Rotor slots - - - - - - Cu loss

• Hydrogen and Carbon-di-oxide cylinders.

80 Conductor Temp. 80 Conductor Temp.

Hydrogen Pressure PSIG-------->>>>>> Hydrogen Pressure PSIG-------->>>>>>

INDIRECT HYDROGEN COOLING DIRECT HYDROGEN COOLING.

• Gas tightness test of Generator casing.

• Initially Generator casing will contain air.

• When Hydrogen cooling is used,

SEAL OIL SUPPLY

SEAL OIL DRAIN

BOTH CUT OFF

INSLATED. HIGH VOLTAGE

•NON-MAGNETIC, COLD WORKED MATERIAL

 Roebel bars with 3600 transposition to

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