Generator

STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET 1 OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
1. PLANT DETAILS :
The 500 MW generator is coupled to the 500 MW KWU turbine.
The rated parameters of the generator are listed in plant
details (Section-1 of Testing schedule for generator
protection and generator ba!. The design and constructional
features are outlined briefl! belo". #enerator manual
supplied b! the manufacturer ma! be referred for details of
abo$e.
ST%T&' (&)* +
The stator bod! is a totall! enclosed gas tight fabricated
structure suitabl! ribbed internall! to ensure high
rigidit!. ,!drogen coolers are housed longitudinall!
inside the stator bod!. 'igid end shields close the casing
and support the fan shields.
ST%T&' -&'. +
The stator core is made up of segmental $arnish insulated
punchings of cold rolled grain oriented silicon gel and is
assembled in an interlea$ed manner on core bars. Steel
spacers for $entilating ducts are pro$ided for radial
cooling of core b! h!drogen. The core is held pressed b!
means of hea$! non-magnetic steel press rings "hich are
bolted to the ends of the core bars. %dditional support is
pro$ided to the teeth portion. /n order to isolate the
stator bod! and thus the foundations from magnetic
$ibrations0 the core bars are designed to pro$ide elastic
suspension of the core in the stator frame.
ST%T&' W/1)/1# %1) /1SU2%T/&1+
The stator has a three phase0 double la!er short corded bar
t!pe "indings ha$ing t"o parallel paths. .ach coil side
consists of glass insulated solid and hollo" conductors "ith
cooling "ater passing through the latter. The elementar!
conductors are 'osbel transposed in the slot portion to
minimi3e edd! current losses. The coil sides are firml! held
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET 2 OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
in position b! fibrous slot "edges. The o$erhang portion of
the coil is securel! lashed "ith glass chord to bondage
rings and special brac4ets of non-magnetic steel0 "hich are
in turn fi5ed to the core press rings.
)/ST/22%T. ,.%).'S+
'ing t!pe "ater headers0 made of copper are pro$ided
separatel! for distillate inlet and outlet in the stator on
turbine side. The headers are supported on insulators and
isolated from stator bod!. The "inding ends are solidl!
soldered into the coil legs "hich are then ultrasonicall!
tested. /ndi$idual bars are pro$ided "ith "ater inlet6outlet
connections made of 7.T.8.. ,oses0 The bar heads are
insulated b! fiber molded co$ers.
T.'M/1%2 (US,/1#S+

Water cooled terminal bushings are housed in the lo"er part
of the stator on the slip ring side0 7orcelain insulators
are pro$ided to insulate the terminal bars from the stator
bod!. .ffecti$e sealing is pro$ided bet"een the terminal
bushings and the stator bod! to a$oid an! possible lea4age
of h!drogen. Terminal bushings are housed inside a chamber
made of non-magnetic steel plates. Three phase terminals and
three neutral terminals are brought out. The terminal plate
of the end terminals0 "here bus bar connections are made is
sil$er plated.
'&T&'
The rotor is of c!lindrical t!pe9 the shaft and bod! being
forged in one piece from chromium nic4el mol!bdenum and
$anadium steel. The rotor "ith all the details assembled is
d!namicall! balanced to a high degree of accurac! sub:ected
to ;0< o$er speed for ; minutes.
8/.2) W/1)/1#+
The field "inding is made from hard dra"n sil$er bearing
copper. The "inding is held in position and b! non-magnetic
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET 3 OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
rotating ring in the o$erhang portion. #ap pic4up method is
used for direct h!drogen cooling of rotor.
The main slot insulation is of glass cloth impregnated "ith
.po5! resin. The inter turn insulation consists of la!ers of
prepped glass cloth glued to the bottom of each conductor.
The end "indings are pac4ed "ith bloc4s of glass laminates
to separate and support the coils and to restrict their
mo$ement under stress. The end "indings are insulated from
the retaining rings "ith the help of glass epo5! molded
segments.
S,%8T M&U1T.) 8%1S
8or circulating the cooling gas inside the generator t"o
propeller t!pe fans are shaft mounted on either end of the
rotor bod!. 8an hubs are made of allo! steel forging and are
a shrun4 fit on the rotor shaft. The allo! steel cast fan
blades are machined in the tail portion to suit the fan hub
and held in position "ith the help of conical pins. The
blades can be easil! remo$ed from or assembled in the fan
hub. 8an shields fi5ed to the end shields guide the gas
flo".
'.T%/1/1# '/1#S+
The end "indings are held in position b! retaining rings of
floating t!pe shrun4 fit on the rotor bod!. The rings are
scre"ed to pre$ent a5ial mo$ement b! loc4ing nuts.
S2/7 '/1#S+
The slip rings consists of helicall! groo$ed allo! steel
rings shrun4 on the rotor shaft and insulated from it. The!
are mounted on a single0 common steel bush0 "hich has an
insulating :ac4et pre-molded on it. The complete bush "ith
sliprings are pro$ided "ith inclined holes for self
$entilation. The helical groo$es cut on the outer surface
help impro$e the brush performance.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
8/.2) 2.%)+
The slip rings are connected to the field "inding through
semi-fle5ible copper leads and current carr!ing bolts0
placed radiall! in the shaft. T"o semicircular hard copper
bars insulated from each other and from the rotor shaft are
placed in the central bore or the rotor :oining the t"o sets
of current carr!ing bolts "ith special profiled precision
conical threads.
#%S -&&2.'S
8our longitudinall! mounted gas coolers are mounted in the
stator bod!. The! are made out of admiralt! brass "ith
coiled copper "ire "ound on them staggered form so as to
e5pose ma5imum surface area to h!drogen.
(.%'/1#S+
#enerator bearings are of pedestal t!pe "ith spherical
seating to allo" self alignment and are supported on a
separate pedestal on slip ring side and in the 2.7 casing on
the turbine side0 (earing bush is of cast steel lined "ith
"hite metal. &il catchers and deflectors are pro$ided to
pre$ent a5ial lea4age of oil. To pre$ent shaft currents slip
ring side bearing and connecting pipes are insulated from
earth.
S,%8T S.%2S+
/n order to pre$ent lea4age of h!drogen from the generator
casing radial thrust t!pe shaft seals are pro$ided on either
side "here the shaft e5tends out from the generator. The
seal consists of seal liner "ith babbit pressing against the
shaft caller of the rotor. Seals are defined in testing
schedule of seal oil s!stem.

STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET 5 OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
NAME PLATE DETAILS
'%T.) )%T% = &67 TU'(& #.1. M%/1 .>-/T.' 7/2&T .>-/T.'
%77%'.1T 7&W.' 5?? M@% ------ A5 K@%
%-T/@. 7&W.' 500 MW BC?0 KW ------
-U''.1T 1A1AA % AB00 % 1D5 %
@&2T%#. ;1 E 1.05 K@ A00 @ ;;0 E ;; @
8'.FU.1-* 50 ,G ------ H00 ,G
78 0.?5(2%# ------ ------
ST%T&' W)# -&11 ** ------ ----
,*)'&#.1 7'.SS B.5 (%' ----- -----
-&1T 7.'M U1(%2
2&%)
? < ------ ------
'%T.) 8/.2)
@&2T%#.
-U''.1T
BH0 @
H0H0 %
------ -------
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET 6 OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
2. TESTING OBJECTIVE :
T& T.ST T,. #.1.'%T&' .FU/7M.1T %1) M%K. /T '.%)* 8&'
.>-/T%T/&1 %1) S*1-,'&1/G%T/&1.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET ! OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
3.0 PROPOSAL
B.1 Tests as detailed in item-? shall be carried out on
generator0 confirming the manufacturers test reports.
B.; /nsulation resistance tests on generator rotor0 stator
and bearing pedestals shall be carried out.
B.B Winding resistances for both stator and rotor "ill be
measured and recorded.
B.H /mpedance of rotor "indings shall be measured and
recorded.
B.5 -hec4s6Tests shall be carried out all the embedded
resistance temperature detectors.
B.A The brush gear assembl! shall be chec4ed tested as per
its standard chec4list and test procedure.

STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET 8 OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
4. SERVICES REQUIRED
H.1 2aborator! eIuipments6test sets for measurement of
electrical parameters reIuired in specific tests (5K@
motori3ed megger0 Kel$ins bridge or micro ohm meter.
H.; /llumination at reIuired locations.
H.B ;H0 @ %.- po"er suppl! for testing.
H.H -ommunication facilit! at test area.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET " OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
5.0 S A F E T Y PRECAUTIONS+
5.1 The test area shall be clearl! defined and
cordoned off.
5.; The test team leader is full! a"are of the
nature0 location0 and probable duration of the
tests.
5.B The other agencies "or4ing in the test area are
informed about the test in progress.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET 10 OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
A. EMERGENCY PROCEDURE +
A.1 Shoc4 treatment chart and first aid bo5 shall be
a$ailable.
A.; .mergenc! telephone numbers of fire and hospital shall
be prominentl! displa!ed near b!.
A.B The test in progress shall immediatel! be stopped and
all line apparatus disconnected and eIuipment suitabl!
earthed in case of a accident or abnormalit!. Such
instruction "ill be recei$ed from the team leader.
A.H The test team is full! a"are of measures to be ta4en in
the e$ent of in:uries to an! personnel 6 damage to an!
machiner!.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET 11 OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
C. STATE OF PLANT +
C.1 #enerator .rection complete and satisfactor!. %ll
erection test results6log sheets a$ailable for the
follo"ing +
- Mounting of embedded parts and foundation plates.
- .rection of stator.
- #as tightness and ,!draulic tests.
- Measurement of insulation resistances of $arious
parts of generator0 ).-. resistances and
impedances.
- -ontinuit!0 ).-. resistance and /' chec4s of 'T)s.
- 7urge tests of rotor $entilation canals.
- 'otor insertion tests.
- (earing ad:ustment tests.
- %lignment or generator rotor.
- /nclination or shaft :ournal test results.
- -oupling alignment results of generator and 27
rotor.
- Magnetic %5is ad:ustment results.
- 8an and shield clearance results.
- )T/ chec4s on generator rotor.
- Shaft seal ad:ustment results.
- Temperature monitoring s!stem.
- -entering and offset-setting of brush gear.
- 8i5ing of brush holder and brushes.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET 12 OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
C.; 8ollo"ing Testing6-ommissioning schedules completed
satisfactoril! and results6records a$ailable +
- #enerator #as Tightness Test.
- ,!draulic test and oil flushing of seal oil
s!stem.
- Seal &il S!stem J -irculation
- ,!draulic test and flushing of primar! "ater
s!stem.
C.B %ll the s!stems mentioned in C.; are in totall!
normalised condition and a$ailable for generator testing.
C.H 8ire protection s!stem (-&
;
s!stem is made a$ailable.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET 13 OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
?. T E S T METHOD +
?.1 /1SU2%T/&1 '.S/ST%1-. &8 #.1.'%T&' W/1)/1#S +
?.1.1 Measure and record insulation resistance of
stator "indings.
Megger used + KKKKKKKKKK K@ Motori3ed
Serial 1&. + KKKKKKKKKK 'ange + KKKKKKK
%mbient Temp. KKKKKKKKKKKKKKKKKK
'elati$e ,umidit! + KKKKKKKKKKKKKKK
(if practical
(.TW..1 @&2T%#.
%772/.)
/.'.
1 M/1.
/'
10
M/1.
/'10
7./.L--------
/'1
-1 J .
-; J .
-B J .
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET 1 OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
?.1.; Measure = record rotor "inding insulation
resistance.
Megger used +KKKKKKKKKKKKK K@
Motori3ed6,ard +KKKKKKKKKKKKK
Serial 1&. +KKKKKKKKKKKKK
%mbient Temp. +KKKKKKKKKKKKK
(.TW..1 @&2T%#. %772/.)
/1SU2%T/&1
'.S/ST%1-.
'otor Terminal=
earth
?.;. '.S/ST%1-. M.%SU'.M.1T &8 #.1.'%T&' W/1)/1#S +
Using a Kel$ins bridge6suitable test set measure and
record generator "inding resistances.
Test set used and details of test set.
Measured
bet"een
Temperature 'esistance
-orrected
'esistance
at
o
-
Test
-ertificate
$alue.
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET 15 OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
-H J -1
-5 J -;
-A J -B
'&T&'
W
/
1
)
/
1
#
S
1&T. + 'otor Winding resistance measurement to be ta4en from
main e5citer "inding terminals
'.M%'KS +
?.; Test on #enerator embedded resistance temperature
detectors.
Measure continuit! resistance and /nsulation
resistance of #enerator 'T)S. 'ecord obser$ation
belo" +
Megger used KKKKKKKKKKKKKK
&hm meter used KKKKKKKKKKKK
Sl.
1&.
'T)
1o.
2&-%T/&1 -&1T/
1U/T*
'.S/ST%1-. /' '.M%'KS
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET 16 OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
Sl.
1&.
'T)
1o.
2&-%T/&1 -&1T/
1U/T*
'.S/ST%1-. /' '.M%'KS
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET 1! OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
9. COMPLETION CRITERIA +
"#1 THE RECORD $ALUES OF TESTING CARRIED OUT ON GENERATOR
ARE COMPLETED AND %EPT ALONG WITH THIS TESTING
SCHEDULE#
"#2 GENERATOR AU& SYSTEM FOR RUNNING GENERATOR ARE LISTED
AND %EPT ALONG WITH THIS SCHEDULE#
"#3 GENERATOR IS READY FOR COMMISSIONING#
STATION: NTPC SIMHADRI BHEL REF NO : PS-DC-186-500-
NTPC REF NO: SIM/1/TS/ /
SHEET 18 OF 18
PLANT AREA : ELECTRICAL SYSTEM
TESTING SCHEDULE : 500 MW STEAM TURBINE GENERATOR
10. APPENDICES
)'%W/1#S+ /. S-,.M%T/- )'%W/1#S &8 +
1. #enerator 'T)s
;. 7rimar! "ater s!stem.
B. ,!drogen #as filling.
//. 8%-T&'* T.ST '.7&'T &8 #.1.'%T&' +
2&# S,..TS +
/ /' @%2U.S0 W' @%2U.S &8 #.1.'%T&'
// 2/ST &8 7'&T.-T/&1S /1-2U).)
/// '.%)/1.SS &8 %U>. S*ST.MS