SEAL OIL SYSTEM

IN ORDER TO PREVENT ESCAPE OF

HYDROGEN 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
PLUGGED WITH OUT SACRIFICING THE DUTY.

% OF THE TUBES CAN BE

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.
6.
7.
8.
9.
10.
11.

COMPRESSION SPRING
ADJUSTING NUT
CHECK NUT
YOKE
LOWER STUFFING BELLOWS
VALVE HOUSING
VALVE CONE

DIFFERENTIAL PRESSURE REGULATOR A

FUNCTION

SEAL OIL TANK

GAS
IMPULSE

I
OIL
IMPULSE

SEAL OIL
PUMP

L
S
E
A
L
S

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 H2 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

OUTLET
HEADER

INLET
HEADER

STATOR WATER TO BUSHING LEADS

QUALITY OF THE DISTILLATE

CONDUCTIVITY

PH
DISSOLVED OXYGEN
DISSOLVED CO2
AMMONIA
CHLORIDE
DISSOLVED/UNDISSOLVED CU
DISSOLVED/UNDISSOLVED FU
DISSOLVED SOLIDS

< 5 MICRO MHO, PREFERABLY

< 1 MICRO MHO
6.5 TO 8.5
MINIMUM, PREFERABLY LESS THAN 100 PPB
NIL
MINIMUM, PREFERABLY ZERO
MINIMUM, PREFERABLY ZERO
< 20 PPB
< 20 PPB
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
LEVEL
GAUGE

RIB
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

TUBE
PLATE
SEALING
CORD
VENT PLUG
PARTITION

TUBE
OUTER SHELL
SEALING RUBBER

RUBBER
CORD

UPPER
WATER BOX

VENT

STATOR
WATER
OUTLET

DRAIN PLUG
THERMOMETER

STATOR WATER INLET

LOWER
WATER BOX

DRAIN
PLUG

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

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.

OF

POLISHING UNIT TECHNICAL DATA

CAPACITY

2 M3

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

36M3

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
RATED DISCHARGE

WIRE MESH TYPE

30 M3

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

56M3

AMOUNT OF HYDROGEN REQUIRED TO FILL THE GENERATOR

300M3

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

340M3

MAKE UP OF HYDROGEN REQUIRED /DAY

15M3

AMOUNT OF CO2 REQUIRED TO REMOVE HYDROGEN AT NTP

120M3

WHEN MACHINE IS RUNNING

168M3

AMOUNT OF CO2 REQUIRED TO REMOVE AIR AT NTP

90M3

WHEN MACHINE IS RUNNING

112M3

GAS SYSTEM-II

EACH H2 CYLINDER IS OF CAPACITY 46.7 LITRES AND CONTAINING

APPROXIMATELY 7 M3 AT 150 ATM
NO. OF H2 CYLINDERS REQUIRED TO FILL THE MACHINE
WHEN STATIONARY
WHEN RUNNING
NO. OF CYLINDERS REQUIRED/DAY

50
56
2 TO 3

EACH CO2 CYLINDER IS 30 KGS WEIGHT OF CO2 WITH GAS

EQUIVALENT TO 15M3 OF GAS VOLUME.
NO. OF CYLINDERS REQUIRED FOR PURGING HYDROGEN
WHEN STATIONARY
RUNNING
NO. OF CO2 REQUIRED FOR PURGING AIR WHEN STATIONARY
NO. OF CO2 REQUIRED FOR PURGING AIR WHEN RUNNING

11
14
8
10

GAS DRIER

THANK YOU