Hydrogen seal oil system

110 MW, BHEL Generator at GNDTP Bathinda is hydrogen cooled i.e

hydrogen is used to dissipate the heat produced on account of various losses
taking place in generator. Hydrogen is used as cooling medium primarily
because of its superior cooling properties and its low density. Thermal
conductivity of hydrogen is roughly seven time that of air. It has also been a
higher heat transfer coefficient. Its ability to transfer heat through forced
convection is about 50% higher than air. Density of hydrogen is 1/14 times
than that of air at a given temperature and pressure. This reduces the windage
losses and makes quieter operation of machine. But hydrogen is explosive
with air in the range of4-76%. Therefore proper sealing of hydrogen in
generator is must. Sealing is provided with the help of seal oil rings capable
of maintaining a thin film of oil 0.2-0.3 mm thick at a pressure higher than
hydrogen pressure inside the generator. Hydrogen seal oil system is fool proof
with double seal arrangement at both end of generator. Double seal
arrangement includes
1 Outer seal or air side seal
2 Inner side seal or hydrogen side seal
Outer seal is provided with help of SOP when the machine is at stand still or
on barring gear and with the help of MOP when the machine is running above
2930 rpm. SOP or MOP takes suction from MOT and after sealing it goes
back to MOT through stilling tank. The inner seal is provided with the help of
main seal oil pump (AC) or through an emergency MSOP (DC) irrespective
of the fact whether the machine is at stand still or running at full load. MSOP
(AC) normally takes suction from vacuum tank and in case of emergency
from equalizing tank. MSOP (DC) takes suction from equalizing tank and oil
after sealing the inner seal goes back to stilling tank. Equalizing tank level is
made up with the help of stilling tank through an interconnecting pipe. Oil in
vacuum tank is taken from equalizing tank and the air in vacuum tank is
removed with vacuum pump.
Hydrogen parameters
1 Hydrogen pressure
2 Inner seal oil pressure
3 Outer seal oil pressure
4 Hydrogen purity

0.05 kg/cm2 up to 82.5 MVA

2.00 kg/cm2 above 82.5 MVA
0.7 kg/cm2 more than hydrogen pressure
0.5 kg/cm2 more than hydrogen pressure
Around 98%

Depending on the load on the machine, the hydrogen pressure is

maintained. In case the pressure drops the same can be made up by filling the
fresh hydrogen. For maintaining the purity of hydrogen gas some fresh
hydrogen is filled and simultaneously some hydrogen is drained from
generator till the desired purity is achieved
Filling the machine with hydrogen gas when the machine is at rest
Hydrogen filling is carried out in following steps
Scavenging the air content by carbon dioxide and
Scavenging the carbon dioxide with hydrogen
Carbon dioxide is used for initial scavenging to avoid any possibility of
formation of explosion mixture of air and hydrogen inside the machine.
Before starting to fill the hydrogen gas to pressure of 2 ata to the machine that
is at rest, it is necessary to store
At least 18 cylinder of CO2 of 22 kg each
48 Cylinder (288 m3) of H2 gas
Preparation of filling
Shaft sealing system should be brought to normal operation. Its proper
functioning includes emergency operation, signalizations, alarm etc.
should be checked
On the control panel in U.C.B. put changeover selector switch in lower
range i.e. 500 mm water column.
Scavenging the air content by carbon dioxide
Open valve no 41, 42, 43 & 44 to H2 gas dryers
By remote operation from gas panel keep the gas analyzer ready for
measuring the mixture
Open exhaust valve no 51 and 52
Connect CO2 cylinder with CO2 distributor, open valve no 65 or 67 (by
turn ) and start filling CO2 gas in the machine and a pressure of 150-200
mm of water column is maintained in the machine by partial closing of
valve 51 or 62 if necessary
When purity of 85-90% CO2, in air in the machine is achieved, close
valve 51, increase the pressure in machine to 150-200 mm of water
column and stop filling CO2 from cylinders by closing valve 65 and 67
NOTE-If the subsequent filling of H2 in the machine is not commenced
within half an hour from the completion of CO2 filling operation, it
is necessary to maintain a pressure of CO2 of 200-450 mm of water
column to avoid any penetration of air

Scavenging the carbon dioxide with hydrogen

Connect H2 cylinder to H2 distributor and open corresponding valve 54
and 56
Open exhaust valve 61 and 62 to reduce the CO2 gas pressure to 200300 mm of water column
Open valve 53 and start filling H2 gas through top header in the
machine
Regulate exhaust valve 61 and 62 in such a way that a pressure of 200300 mm of water column is maintained through the filling operation
As soon as the purity of H2 gas in the machine reaches 97%, close the
exhaust valve 61 and 62 and raise the H2 gas pressure to desired valve
and stop filling the gas
Scavenging machine with CO2 to exhaust H2 gas

Disconnect all the H2 gas cylinder connected with distributor

Close valve 54 and 55
Open valve 51 and 62 to decrease pressure to 200 mm of water
column. Change the changeover switch in U.C.B to low pressure range
Open valve 65 and 67 and start filling CO2
Maintain the pressure in machine around 200 mm of WC throughout
the operation of scavenging by suitably regulating the valve 51 and 62
Switch on the gas analyzer to read % of CO 2 in hydrogen. Filling of
CO2 is continued till the purity of 85-90% is achieved and stops filling
the gas. About 160 kg of CO2 is required for the purpose
Close the valve 65, 67 and 51
Connect dry compressed air to valve 52 and start filling the air
Open valve 61 and 62 for scavenging the CO2
Maintain the machine pressure around 200 mm of water column
Continuing filling the air till the purity of CO 2 gas in the air drops to
5%
Keep the seal oil system running through out the operation of
scavenging

Interlock of seal oil system

1. Tripping of MSOP(AC) will trip vacuum pump and MSOP(DC) will start
of auto

2. Vacuum pump will not start unless MSOP(AC) is running

3. After starting MSOP(AC), MSOP(DC) has to be tripped manually
Emergencies of seal oil system.
Following are the emergencies commonly faced at seal system
Sn Defect
Identification Immediate action to be taken
1 Purity of
Signal and
1. Start filling fresh H2 from cylinders in
H2 gas
alarm `low
generator and simultaneously drain
below
purity of
already filled H2 from machine till desired
92%
hydrogen`
purity is achieved
2. If site and UCB indicator gives different
purity than carryout chemical analysis
2 Low
Signal alarm Check the pressure of sealing oil entering the
pressure
minimum oil airside of sealing ring. This should be 0.55
of sealing pressure on
kg/cm2 more than the H2 pr.in the machine
oil on air air side of
1. If the pressure is normal than the fault is
side of
sealing ring
with signaling equipment
sealing
2. If the pressure is less than the fault is may
ring
with the regulating valve that can be
during
rectified by regulating spring in the valve.
sealing by
If this adjustment fail than isolate the
both the
regulating valve for repair or replacement
rings
after ensuring H2 side seal with main
pump and emergency pump is also ready
3 Low
Signal alarm Check the pressure of sealing oil entering the
pressure
minimum oil H2 of sealing ring. This should be 0.7 kg/cm2
of sealing pressure on
more than the H2 pressure in the machine
oil on H2 H2 side of
3. If the pressure is normal than the fault is
side of
sealing ring
with signaling equipment
sealing
4. If the pressure is less than the fault is may
ring
with the regulating valve that can be
during
rectified by regulating spring in the valve.
sealing by
If this adjustment fail than isolate the
both the
regulating valve for repair or replacement
rings
after ensuring H2 side seal with main
pump and emergency pump is also ready
4 Lowering Signal alarm 1. Open valve on line between stilling tank
of oil in
minimum
and equalizing tank if it has been closed
balancing level in
by mistake
tank
balancing
2. If the level falls continuously than the

tank
5

Increase
of level in
vacuum
tank

Signal and
alarm
`maximum
level in
vacuum tank

1.

2.
3.
4.

lowering
of level in
vacuum
tank

Abnormal
loss of H2
that has
not been
caused by
decreasing
load or
decrease
of temp of
machine

Signal and
alarm loss of
pressure in
main pump
and
emergency
pump starts
on auto

1.
2.
3.

fault is probably with float valve in

hydrogen defoamer tank
If the vacuum tank is full of foam than
decrease the vacuum by valve 9. If the
temp in vacuum tank is too high than cool
the oil by opening the valve 10 partially
If the oil is not with foam than check the
valve 5 weather it is properly closed
If the level of oil increases continuously
than close the valve 4 till the level drops
to normal
If the level still rises than the fault is with
float valve and than the same may be
isolated for repair and vacuum may be
bypassed
Check if the valve 4 is fully porn
Allow oil to flow to vacuum tank through
valve 5
If there is no fault with valve 4 than float
valve in vacuum tank is probably faulty.
and than the same may be isolated for
repair and vacuum may be bypassed

1. Check that exhaust valve 51, 61, 62 and

63 are close
2. Check for the proper position of valve 52,
53, 65 and 69
3. Ascertain for leakage in machine
4. Check for the tightness of joints at gas
panel by progressive disconnection of
individual pressure gauges, gas analyzer,
and pressure switches etc.
5. Carry out chemical analysis of gas
6. If the loss of hydrogen gas exceed 24 m 3
per day switch over to lower range of 500
mm of water column and reduce the
output of machine. If the loss still
continue to exceed the limit than expel the
hydrogen with carbon dioxide and stop
the machine or operate the machine with

air cooling at reduced load