FROM THE GENERATOR IT IS ESSENTIAL TO PROVIDE SHAFT SEALS AT BOTH ENDS WHERE THE SHAFT EXTENDS THROUGH THE CASING. THIS IS ACHIEVED BY PROVIDING RADIAL OIL FILMS IN THE SYSTEM, THIS OIL BEING KEPT AT A HIGHER PRESSURE THAN THAT OF THE HYDROGEN INSIDE THE GENERATOR. THE LOCATION WHERE THE ROTOR SHAFT PASSES THROUGH THE STATOR CASING ARE PROVIDED WITH RADIAL OR RING TYPE SEAL RINGS.THE SEAL EING IS FORMED BY JOINING TWO SEMICIRCULAR RINGS.
BABBIT METAL BABBIT METAL IS A COMPOSITION OF TIN, ANTIMONY AND COPPER .THE SEAL RING IS LINED WITH BABBIT METAL ON THE SHAFT JOURNAL SIDE.
BABBIT METAL HAS A LOW MELTING TEMPERATURE TO SAFEGUARD THE SHAFT IN CASE OF OIL STARVATION.
THE SEAL OIL IS SUPPLIED TO THE SEALING GAP FROM THE SEAL BODY VIA RADIAL HOLES AND ANNULAR GROOVE IN THE SEAL RING.
THE TWO HALF OF THE SEAL RING ARE GUIDED IN THE SEAL BODY, WHICH IS BOLTED ON THE END SHIELD SEALING PHENOMENON TO ENSURE EFFECTIVE SEALING THE SEAL OIL PRESSURE IN THE ANNULAR GAP IS MAINTAINED AT 1.5 KSC ABOVE THE GAS PRESSURE WITHIN THE GENERATOR CASING.
THE OIL DRAINED ON THE HYDROGEN SIDE AND AIR SIDE OF THE SEALRINGS IS THROUGH DRAINS IN THE SEAL BODY AND SEALING COVER RESPECTIVELY.
ON THE AIR SIDE RING RELIEF OIL IS SUPPLIED AT 0.5KSC ABOVE THE SEAL OIL PRESSURE LATERALLY TO THE SEAL RING VIA AN ANNULAR GROOVE. Seal oil system scheme
EQUIPMENTS IN SEAL OIL SYSTEM SEAL OIL PUMP ( 3 X 100%) DUTY VACUUM PUMP (1) SEAL OIL COOLER ( 2 X 100%) DUTY DIFFERENTIAL PRESSURE REGULATOR SEAL OIL FILTERS (DUPLEX & SIMPLEX) SEAL OIL PUMP SEAL OIL PUMP IS A THREE SCREW DESIGN POSITIVE DISPLACEMENT PUMP ONE DOUBLE THREADED DRIVING ROTOR AND TWO DRIVEN IDLER SCREWS ARE CLOSED MESHED AND RUN WITH A CLOSE CLEARANCE IN THE CASING INSERT. BY INTERMESHING, THE HELICAL PASSAGES IN THE ROTORS ARE DIVIDED INTO COMPLETELY SEALED COMPARTMENTS, WHILE ROTATING, TRAVEL UNIFORMLY AND WITH OUT UNDUE STRESSES FROM SUCTION TO DISCHARGE END. THIS ACTS LIKE A PISTON DUE TO LOW COMPRESSIBILITY OF OIL VERY HIGH PRESSURE MAY ARISE ON THE DELIVERY SIDE HENCE RELIEF VALVE IS PROVIDED ON THE PUMP CASING TO PROTECT THE SEAL OIL SYSTEM VACUUM PUMP THE VACUUM PUMP IS A SINGLE STAGE ROTARY VANE TYPE ROTARY SLIDING VANE PUMP CONSISTS OF A CYLINDRICAL CASING WHICH IS ECCENTRICALLY SUPPORTED THE ROTOR HAS VANES WHICH ARE FORCED APART BY SPRINGS THE VANES SLIDE ALONG THE CASING WALL. IT PUSHING FORWARD THE AIR DRAWN IN AT THE SUCTION CHANNEL AND FINALLY DISCHARGING IT AT THE PUMP THROUGH THE OIL IMMERSED DISCHARGE VALVE THE OIL ALSO SERVES AS THE PUMP LUBRICATION OIL LEVEL IN THE PUMP HAS TO ENSURED AS OIL VAPOUR GETS EXTRACTED WHEN EXPELLING THE GAS. SEAL OIL COOLER THIS COOLER IS DESIGNED FOR SERVICE WITH RAW WATER. COOLER CONSISTS OF I. UPPER WATER BOX II. SHELL III. TUBE SYSTEM IV. LOWER WATER BOX THE LOWER TUBE PLATE IS FIXED AND THE UPPER TUBE PLATE IS MADE FLOATING TO CATER FOR THE THERMAL DIFFERENTIAL EXPANSION BY USING A RUBBER RING. OIL INLET AND OUTLET ARE PROVIDED IN THE SHELL. THE CIRCULATING WATER SIDE OF THE TUBE PLATE AND THE INNER SURFACE OF THE WATER BOX ARE PAINTED WITH EPOXY COAL TAR SEAL OIL COOLER MAINTENANCE THE EFFICIENCY OF THE COOLER DEPENDS VERY MUCH ON THE CLEANLINESS OF THE COOLING SURFACE CLEANING OF THE INSIDE OF THE TUBES CAN BE CARRIED OUT BY MEANS OF SOFT BRASS WIRE BRUSH MECHANICALLY. IF THERE ARE HARD SCALES CHEMICAL TREATMENT HAS TO BE RESORTED LIKE WISE SHELL SIDE CAN BE CLEANED. SHELL CAN BE CLEANED IN A HOT BATH OF 10% CAUSTIC SODA SOLUTION IN CASE OF LEAKAGE OF COOLER TUBE IS SUSPECTED THE SHELL SIDE SHOULD BE SUBJECTED TO A PRESSURE OF 16 KSC USING LUBE OIL. KEEPING THE COOLER IN THE HORIZONTAL POSITION AND THE FAULTY TUBE SHOULD BE PLUGGED WITH TAPER PLUGS. 5 % OF THE TUBES CAN BE PLUGGED WITH OUT SACRIFICING THE DUTY. DIFFERENTIAL PRESSURE REGULATING VALVE DIFFERENTIAL PRESSURE REGULATING VALVE IS INTENDED TO REGULATE THE SEAL OIL PRESSURE BEING SUPPLIED TO SHAFT SEALS IN RELATION TO GAS PRESSURE IN THE GENERATOR CASING.
DIFFERENTIAL PRESSURE REGULATOR HAS 1. VALVE HEAD 2. MAIN BELLOWS 3. UPPER STUFFING BELLOWS 4. VALVE STEM 5. COMPRESSION SPRING 6. ADJUSTING NUT 7. CHECK NUT 8. YOKE 9. LOWER STUFFING BELLOWS 10. VALVE HOUSING 11. VALVE CONE
SEAL OIL TANK GAS IMPULSE OIL IMPULSE O I L S E A L S SEAL OIL PUMP DIFFERENTIAL PRESSURE REGULATOR A FUNCTION DIFFERENTIAL PRESSURE REGULATOR FUNCTION
THE DIFFERENCE BETWEEN OIL AND GAS IS SET BY COMPRESSION OF THE SPRING WITH HELP OF THE ADJUSTING NUT. COMPRESSION OF THE SPRING LEADS TO DOWN MOVEMENT OF THE VALVE STEM AND VALVE CONE. THIS MOVEMENT REDUCES THE PRESSURE THROUGH THE VALVE AS THE VALVE CLOSES AND INCREASES THE PRESSURE THROUGH THE LINE. INCREASE IN H 2 PRESSURE WILL LEAD TO COMPRESSION OF THE MAIN OPERATING BELLOW WHICH IN TURN WILL MOVE THE VALVE HEAD IN TURN VALVE AND VALVE CONE TO CLOSE THE VALVE CLOSING OF THE VALVE WILL REDUCE THE PRESSURE OF THE OIL AT THE OUT LET OF THE VALVE WHILE OIL PRESSURE GOING TO THE SEALS WILL INCREASE. DIFFERENTIAL PRESSURE REGULATOR B FUNCTION
GAS IMPULSE OIL IMPULSE OIL SEALS FROM GOVERNING OIL SEAL OIL FILTER THE DUPLEX AND SIMPLEX FILTERS ARE USED IN SINGLE FLOW RING TYPE SEAL OIL SYSTEM THE FILTER IS INSERTED INTO THE PIPE CIRCUIT BY MEANS OF FLANGES A CHECK IS KEPT ON THE STRAINER SCREEN BY MEANS OF THE RECOMMENDED DIFFERENTIAL PRESSURE INDICATOR . WHEN PRESSURE REACHES 0.6 KSC THE STRAINER SHOULD BE CLEANED. THE COMMON PROBLEM IS THE O RING FAILURE IN THE STOP COCK. SEAL OIL FILTER -I IF THERE IS LEAK FROM THE STOP COCK REMOVE THE PINS PULL OUT THE STOP COCK REMOVE THE O RING WASH OUT THE STOP COCK AND HOUSING INTRODUCE THE STOP COCK AFTER GOOD OILING BUT WITHOUT O RINGS INTO THE OPENING IN THE HOUSING PUSH THE STOP COCK UNTIL THE GROOVE FOR THE O RING IS FREE FIT THE O RING AND CAREFULLY PULL BACK THE STOP COCK UNTIL THE GROOVE AT THE OPPOSITE END IS FREE. CLEANING OF FILTER CHAMBER IS NECESSARY ONLY AFTER EVERY THIRD FILTER ELEMENT CLEANING
STATOR WATER SYSTEM ONE OF THE EFFICIENT WAYS OF TAKING AWAY THE LOSSES FROM THE WINDINGS OF ANY ELECTRICAL MACHINE IS BY DIRECT COOLING USING WATER.
EQUIPMENTS INVOLVED IN THE STATOR WATER SYSTEM EXPANSION TANK STATOR WATER PUMP STATOR WATER COOLERS STATOR WATER MECHANICAL FILTERS STATOR WATER MAGNETIC FILTERS POLISHING UNIT GAS TRAP STATOR WATER SYSTEM HEADERS INLET HEADER OUTLET HEADER STATOR WATER TO BUSHING LEADS
QUALITY OF THE DISTILLATE CONDUCTIVITY < 5 MICRO MHO, PREFERABLY < 1 MICRO MHO PH 6.5 TO 8.5 DISSOLVED OXYGEN MINIMUM, PREFERABLY LESS THAN 100 PPB DISSOLVED CO 2 NIL AMMONIA MINIMUM, PREFERABLY ZERO CHLORIDE MINIMUM, PREFERABLY ZERO DISSOLVED/UNDISSOLVED CU < 20 PPB DISSOLVED/UNDISSOLVED FU < 20 PPB DISSOLVED SOLIDS THE WATER SHOULD BE FREE OF ANY CHEMICALS FROM TREATMENT PROCESS,SUCH AS HYDRAZINE, MORPHOLINE,LEVOXINE,PHOSPHATES
THE EXPANSION TANK THE EXPANSION TANK IS A HERMETICALLY SEALED CONTAINER MADE OF STAINLESS STEEL. THE DM WATER FROM THE STATOR WINDING OUTLET HEADER DISCHARGES IN TO A SECTION OF THE TANK THROUGH PERFORATED PIPE. THE TANK IS UNDER A VACUUM OF 250-300MM OF MERCURY. THE TANK IS CLEANED DURING ANNUAL MAINTENANCE. THE FLOAT VALVE OPERATION IS CHECKED BY HAND FOR SMOOTH AND EASY OPERATION FROM ONE EXTREME LOWER POSITION TO EXTREME TOP POSITION. THE FLOAT IS CHECKED BY DIPPING IN WATER FOR 1 HOUR AT A TEMPERATURE OF 60 DEGREE CENTIGRADE THE HEALTHINESS OF THE TRANSDUCERS ARE CHECKED. ALL THE JOINTS ARE CHECKED FOR ANY LEAK.
EXPANSION TANK GAS OUT LET WATER INLET FROM WINDING TANK COVER TRANSDUCER RIB LEVEL GAUGE D R A I N WATER OUTLET TO PUMPS LINE REGULATOR STATOR WATER PUMP STATOR WATER PUMPS ARE SINGLE STAGE CENTRIFUGAL TYPE SPIRAL CASING AND OVERHANG IMPELLER .
THE PUMP SUCTION IS ARRANGED IN THE AXIAL DIRECTION WHILE THE DISCHARGE IS DIRECTLY RADIALLY UPWARD.
THE PUMP IMPELLER AND THE SPIRAL CASING IS OF STAINLESS STEEL CONSTRUCTION.
NORMALLY THE PUMP IS OVERHAULED ONCE IN 5000 HOURS. STATOR WATER COOLER
STATOR WATER COOLER UPPER WATER BOX TUBE PLATE SEALING CORD VENT PLUG PARTITION TUBE OUTER SHELL SEALING RUBBER DRAIN PLUG THERMOMETER STATOR WATER INLET STATOR WATER OUTLET VENT DRAIN PLUG LOWER WATER BOX RUBBER CORD STATOR WATER COOLER-I THE STATOR WATER COOLER IS SHELL AND TUBE TYPE HEAT EXCHANGER SUITABLE FOR VERTICAL MOUNTING THE SHELL IS MADE OF NONMAGNETIC STAINLESS STEEL AND THE DM WATER FLOWS THROUGH THE SHELL. TUBES ARE MADE OF STAINLESS STEEL AND THE COOLING WATER FLOWS THROUGH THE TUBES. TO HAVE EFFECTIVE HEAT TRANSFER BAFFLES ARE MADE OF BRASS ARE PROVIDED ACROSS THE TUBE NEST. THIS GUIDE THE WATER IN ZIG ZAG FASHION. THE TUBES ARE CLEANED BY NYLON BRUSH.
STATOR WATER COOLER -II WHEN PUSHING THE BRUSH THROUGH THE TUBES IT SHOULD ALSO BE TURNED AROUND SIMULTANEOUSLY IF THE DIRT DEPOSITS DO NOT COME WITH MECHANICAL TREATMENT CHEMICAL CLEANING IS NECESSARY. THE MOST CAUSE OF LEAKAGE IS TUBE PERFORATION OR LEAKAGE. THE ROLLED ENDS OF THE TUBE ARE LIKELY TO BECOME DEFECTIVE FIRST. REROLL THE AFFECTED TUBE WITH TUBE EXPANDER. IF NOT PLUG THE TUBE IF IT IS URGENT . UPTO 5% OF THE COOLING TUBE CAN BE PLUGGED WITH OUT AFFECTING THE DUTY
POLISHING UNIT-I POLISHING UNIT SERVES TO MAINTAIN LOW ELECTRICAL CONDUCTIVITY OF THE CONDUCTIVITY OF THE PRIMARY WATER. POLISHING UNIT IS CONNECTED IN PARALLEL TO THE MAIN CIRCUIT POLISHING UNIT CONTAINS 1. MIXED BED ION EXCHANGER 2. FILTER 3. FLOW METER 4. CONDUCTIVITY METER THE BASE SUBSTANCES OF THE EXCHANGER ARE POLYMERS. THE POLYMERS IN THE CATION EXCHANGER ARE HIGHLY ACIDIC GROUPS THE POLYMERS IN THE ANION EXCHANGER ARE HIGHLYBASIC GROUP. WHEN RESINS ARE EXHAUSTED THEY THEY MUST BE REPLACED.
POLISHING UNIT TECHNICAL DATA CAPACITY 2 M 3 DESIGN CONDUCTIVITY AT THE IN LET 1 MICRO MHO/CM CONDUCTIVITY OF THE WATER AT OUT LET 0.44 MICRO MHO/CM PH VALUE OF THE WATER AT THE INLET 6 TO 7 MICRO MHO/CM PH VALUE OF THE WATER AT THE OUTLET 70.2 OPERATING RESIN BED 6 MONTHS FINAL FILTER SIZE 5 MICRONS RESIN TULSION T 42 TULSION A-27 MP REAGENT HCL 30% 20.3KG NAOH 100% 11.5 KG
MAGNETIC FILTER-PRINCIPLE THE MAGNETIC FILTER IS OF PERMANENT MAGNET TYPE DESIGNED TO TRAP FERRO MAGNETIC PARTICLES
THE FILTER MAINLY CONSISTS OF AN UPPER AND A LOWER BODY HOUSING THE PERMANENT MAGNET SYSTEM, COMPRISING OF THE MAGNETS POLE SHOES AND POLE RINGS
THE DM WATER PASSES THROUGH TWO ANNULAR AIR GAPS IN WHICH THE FERRO MAGNETIC PARTICLES ARE FILTERED OUT. MAGNETIC FILTER MAINTENACE THE UPPER BODY IS REMOVED
WITH HELP OF THE REMOVABLE BOLTS THE POLE RING IS DISMANTLED .
THE POLE RING AND THE POLE SHOES ARE CLEANED AND THE ENTRAPPED FERRO MAGNETIC PARTICLES ARE THOROUGHLY WIPED
THE FILTER IS ASSEMBLED AND INSTALLED BACK IN POSITION AND O RING IS REPLACED , IF IT IS IN DAMAGED CONDITION
MAGNETIC FILTER
MAGNETIC FILTER TECHNICAL DATA MAGNET TYPE PERMANENT MAGNET THE CAPACITY OF THE MAGNETIC FILTER 36M 3 MAXIMUM INDUCTION DENSITY 4000GAUSS PRESSURE RATING NOT MORE THAN 10 KSC TYPE OF PARTICLES FILTERED HIGHLY AND MEDIUM MAGNETIC HYDRAULIC TEST PRESSURE 16KSC FOR 10 MINUTE PRESSURE DROP NEGLIGIBLE
STATOR WATER MECHANICAL FILTER THE FILTER BODY CONSISTS OF CYLINDRICAL BODY HAVING SEPARATE INLET AND OUT LET CHAMBERS. A PERFORATED CYLINDRICAL BODY HAVING HOLES ALL ALONG ITS LENGTH AND PERIPHERY IS SURROUNDED BY THE ASSEMBLY OF 30 TO 34 FILTER ELEMENTS. THE FILTER ELEMENTS ARE KEPT IN POSITION BY A HELICAL SPRING WHICH IS KEPT PRESSED BY A COVER. THE FILTER ELEMENTS CONSISTS OF CORRUGATED BRASS SHEET WITH A CENTRE HOLE AND TWO SIZES OF WIRE MESH APERTURES 0.224 MM AND 0.5 MM HELD IN ONE ASSEMBLY BY INNER AND OUTER BRASS RING. THE WATER AFTER PASSING THROUGH THE FILTERING ELEMENTS ENTERS THE PERFORATED CYLINDER FROM WHERE IT FLOWS TO THE OUTLET CHAMBER. IMPURITIES GET COLLECTED IN THE WIRE MESH. THE FILTER IS PROVIDED WITH DRAIN AND VENT PLUGS.
STATOR WATER MECHANICAL FILTER TECHNICAL DATA TYPE WIRE MESH TYPE RATED DISCHARGE 30 M 3
MAXIMUM PRESSURE RATING 12 KSC MINIMUM SIZE OF THE PARTICLES 0.224 THAT CAN BE FILTERED PRESSURE DROP 0.1 KSC TO 0.2 KSC PRESSURE DROP WHEN CLEANING IS RECOMMENDED 0.4 KSC MATERIAL OF THE BODY AND PERFORATED CYLINDER Stainless steel MATERIAL OF THE FILTER ELEMENT BRASS SIZE OF THE WIRE MESH 0.224 MM AND 0.5 MM HYDRAULIC TEST PRESSURE 38 KSC FOR 15 MINUTES GAS TRAP GAS TRAP IS USED FOR DETECTING THE PRESENCE OF HYDROGEN GAS IN THE STATOR WATER SYSTEM. PRESENCE OF THE GAS IN THE WATER SYSTEM IS POSSIBLE DUE TO LOOSE AND LEAK AS JOINTS AS THE WATER PRESSURE IS KEPT LOWER THAN THE HYDROGEN PRESSURE IN THE GENERATOR CASING. THE GAS ENTRAPPED IN THE WATER GOES TO THE UPPER CHAMBER FROM WHERE THE GAS IS SAMPLED FOR ANY MIXING. TOP POINTS OF THE SUPPLY AND DRAINAGE ARE CONNECTED TO ANY INLET POINTS OF THE DEVICE. THE THIRD POINT IS CONNECTED TO PIPE LINE AT THE OUTLET OF THE GENERATOR.
GAS TRAP -I DRAIN PIPE IS CONNECTED TO THE DRAINAGE SYSTEM. THREE POINTS OF THE INLET ARE CRACK OPENED AND THE WATER IS ALLOWED TO ENTER CONTINUOUSLY. THE WATER SO ENTERED WILL BE CONFINED TO LOWER CHAMBER OF THE DEVICE AND THE EXCESS WATER IS DRAINED TO THE DRAIN PIPE . IN CASE OF WATER CARRYING HYDROGEN,THE SAME IS LIBERATED AT THE TOP CHAMBER THE GAS ENTERS THE SPACE THROUGH THE CENTRE HOLE IN THE PLUG AND IS DIRECTED TO THE UPPER CHAMBER THROUGH THE SLOT IN THE PLUG. GAS SYSTEM-I GAS REQUIREMENT 56M 3 AMOUNT OF HYDROGEN REQUIRED TO FILL THE GENERATOR 300M 3 CASING TO RATED PRESSURE AT NTP-M/C STATIONARY AMOUNT OF HYDROGEN REQUIRED TO FILL THE GENERATOR CASING TO RATED PRESSURE AT NTP-M/C STATIONARY 340M 3 MAKE UP OF HYDROGEN REQUIRED /DAY 15M 3 AMOUNT OF CO 2 REQUIRED TO REMOVE HYDROGEN AT NTP 120M 3 WHEN MACHINE IS RUNNING 168M 3 AMOUNT OF CO 2 REQUIRED TO REMOVE AIR AT NTP 90M 3 WHEN MACHINE IS RUNNING 112M 3
EACH H 2 CYLINDER IS OF CAPACITY 46.7 LITRES AND CONTAINING APPROXIMATELY 7 M 3 AT 150 ATM NO. OF H 2 CYLINDERS REQUIRED TO FILL THE MACHINE WHEN STATIONARY 50 WHEN RUNNING 56 NO. OF CYLINDERS REQUIRED/DAY 2 TO 3
EACH CO 2 CYLINDER IS 30 KGS WEIGHT OF CO 2 WITH GAS EQUIVALENT TO 15M 3 OF GAS VOLUME. NO. OF CYLINDERS REQUIRED FOR PURGING HYDROGEN WHEN STATIONARY 11 RUNNING 14 NO. OF CO 2 REQUIRED FOR PURGING AIR WHEN STATIONARY 8 NO. OF CO 2 REQUIRED FOR PURGING AIR WHEN RUNNING 10 GAS SYSTEM-II GAS DRIER