15.

4 Prerequisites
Undertake a thorough inspection of systems under purview before carrying out generator drying out
and the air-tightness test to ascertain the following (Table 15.1):

15.4.1 Typical List of Apparatus/Instruments

Apparatus/instruments that are typically required for drying out and the air-tightness test of large
generators are listed below. Specification and/or quantity of each of these items would vary from
project to project and shall have to be assessed by concerned personnel associated with the test.

i. resistance temperature
detectors ( RTDs )
ii. 100 V megger
iii. 250 V megger
iv. 5 kV megger
v. forced air heater of 2 kW rating vi. continuity
tester
vii. winding temperature recorder
viii. U-tube manometer
ix. precision pressure gauge
x. soap solution

Table 15.1 Areas/items to be checked and satisfied

Ok
Sl. No. Areas/Items (√)
 1 Verify availability of protocols jointly signed by the customer, the engineer, the generator
manufacturer, and the supplier (contractor) certifying erection completion of the following
equipment and system:
i. Generator checks include the following:
a. generator placed on foundation
b. bearings fitted
c. rotor threaded in
d. end-shield assembled
e. alignment complete and foundation bolts tightened
f. generator field connection complete
ii. Exciter is erected and aligned, and coupling bolts are tightened
iii. Excitation system including AVR erection is complete
iv. Generator lube oil system erection is complete and flushed (Chapter 6) and is in
operation
v. Generator seal system erection is complete, seal oil system is flushed, and initial
circulation is complete and in operation
vi. Generator stator cooling water system erection is complete, flushed, and
drained completely. The water circuit is completely dried with circulation of hot
dry air
vii. Hydrogen and carbon dioxide gas systems, including piping, valves, and valve
rack erection, are complete
viii. Hydrogen coolers, seal oil coolers, and stator water coolers erection are
complete. Piping and valve connections in the cooling water side are complete
2 A trial run of the following equipment are successful, and respective protocols jointly
signed by the customer, the engineer, the generator manufacturer, and the supplier (
contractor ) are available:
i. seal oil pumps
ii. stator cooling water
pumps iii. exhausters
3 All thermometers, pressure gauges, H2 gas analyzer, and so on, are calibrated and installed.
Calibration certificates are verified
4 Check that both “line” and “neutral” side connections of the generator to the bus duct are
open
5 Ensure that the generator body earthing is done as recommended
6 Ensure that access to the generator and its auxiliaries are free from any obstacle
Continued
Table 15.1 Areas/items to be checked and satisfied—cont’d
Ok (√)
Sl. No. Areas/Items
7 Verify that the required statutory clearances have been obtained
8 The generator bearing pedestal insulation value is measured and found to be >1 MΩ
 9 Instrument air of the following quality is available:
i. Air must be free of corrosive contaminants and hazardous
(flammable or toxic) gases ii. Maximum total oil or hydrocarbon content,
exclusive of noncondensable, must be 1 mg kg1
iii. Air must be practically free of dust. Maximum particle size in air stream must not
exceed 5 μm
iv. Oxygen content of the expended air shall be between 20% and 21% V V1
v. The dew point at line pressure is at least 15 K below the minimum possible generator
casing temperature. In no case should the dew point at line pressure exceed 283 K

Note
If the generator casing temperature exceeds 313 K, the dew point at line
pressure may be raised up to 293 K

vi. Air pressure must be between 0.6 and 0.9 MPa gauge

10 Temporary platforms are provided wherever required

11 Apparatus/instruments generally required for drying out and air-tightness testing (Section
15.4.1) are arranged
12 Safety gadgets (Section 15.4.2) are arranged

15.4.2 Typical List of Safety Gadgets

Equipment generally used for safety of operating personnel during generator drying out and the air-
tightness test are given below:

1. safety shoes (provided with insulation material at the bottom) of assorted sizes;
2. hand gloves;
3. hardhats of assorted sizes;
4. side-covered safety goggles with plain glass;
5. first aid box;
6. sufficient lighting arrangements; 7. safety sign boards;
8. safety tags.
15.5 Preparatory Arrangements
Preparatory work for generator drying out and the air-tightness test are described below separately.

15.5.1 Generator Drying Out

15.5.1.1 Checking of RTDs

1. Check continuity of each RTD with a continuity tester;

2. Measure resistance of each RTD with a Wheatstone Bridge (Fig. 15.6) and the corresponding ambient
temperature;
3. Measure IR value with 100 V megger;
 A
i1 i1

R1 R4
M N
G
R2 R3

i i2 i2

E Switch
Fig. 15.6 Wheatstone Bridge.

Record the values of steps 1, 2, and 3 in Table 15.2.

Table 15.2 RTD checking

Ambient
Temperature Resistance
RTD No. Location (K) Continuity (Ω) IR Value (MΩ)
⋮
15.5.1.2 Checking of bearing and seal insulation

Enclose IR values of the following areas from erection log sheets as “attachments”:

1. generator bearings before rotor threading; this value should be above 10 MΩ;
2. generator bearings immediately after rotor threading; this value is expected to be less than
10 MΩ;
3. inner and outer labyrinth rings;
4. pedestal bearing of exciter before fixing of exciter rotor; this value should be above 10 MΩ;
5. after fixing of each oil pipes;
6. final value between rotor shaft and earth.

Measure IR value between generator rotor and earth with a 100 V megger, and record the value (Table
15.3). This value should be above 1 MΩ. In the event a lower value is obtained, dry out all bearings,
seals, oil pipes, and so on, until the IR value exceeds 1 MΩ.

Table 15.3 Bearing insulation

Measured Between Ambient Temperature (K) IR Value (MΩ)
Generator stator and earth
15.5.1.3 Measurement of IR of stator winding

While meggering one phase of stator winding, the other two phases not under testing must be shorted
and earthed. Using a 5 kV power megger, measure the IR of each phase of stator winding. Record 1-min
(IR1) and 10-min (IR10) megger readings in Table 15.4, and calculate the PI (PI¼IR10/IR1). On completion
of meggering, discharge the tested winding for at least 15 min by connecting it to earth.
The measured IR value must be above 1 MΩ kV1 of generator-rated voltage at 313 K and calculated PI
should be greater than 2.0. If the results fail to meet these requirements, it is recommended to dry out
the generator.

Table 15.4 Insulation resistance of stator winding

Ambient
IR10 PI
Measured Temperature Voltage Applied
¼ IR1
Between (K) (kV) IR, 1 min (MΩ) IR, 10 min (MΩ)
R–E
Y–E
B–E
Note: R—red phase, Y—yellow phase, B—blue phase, E—earth.

15.5.1.4 Measurement of IR of rotor circuit

There are two sliprings on the generator shaft, one slipring connected to the rotor winding and the
other in contact with the shaft. Measure the IR between these two sliprings with a 250 V megger, and
record the value in Table 15.5. The measured IR value must be above 1 MΩ at 313 K.
Table 15.5 Measurement of insulation resistance of rotor circuit

Ambient Temperature Voltage Applied IR Value (MΩ)

Measured Between (K) (V)
Two sliprings

15.5.2 Generator Air-Tightness Test

1. Verify that turbine and generator lube oil pump/s are running and the bearing lubrication system is
in service;
2. Start the seal oil pumps and put the seal oil system in operation;
3. Fill the stator winding with stator cooling water and stator cooling water tank up to the normal level;
4. Close the following valves:
a. valve connecting the waste gas pipe with the generator;
b. vent valve in the waste gas pipe;
c. stator cooling water supply line valves;
d. all valves on the H2 gas supply to the generator;
5. Connect a U-tube manometer on the waste gas pipe of the stator cooling water tank;
6. Verify that the H2 supply line inlet valve to the generator is closed. Connect compressed air upstream
of this valve;
7. Connect a U-tube manometer or a precision pressure gauge in the H2 supply line inlet to the
generator.
15.6 Operating Procedure
The procedure for drying out the generator is completely different from the generator airtightness test
procedure; hence; they are dealt with separately in following paragraphs.

15.6.1 Generator Drying Out

Present-day generators are usually provided with epoxy resin insulation on the stator windings. The
advantage of epoxy resin is that it seldom absorbs any moisture; hence, under normal circumstances it
may not be required to resorting to assisted drying out of insulation. Notwithstanding this attractive
characteristic, moisture does form a film on the surface of the insulation of the stator windings during
transportation, storage, and erection. This film of moisture can be removed easily by heating the
generator enclosure at a temperature just above the ambient temperature.

Remove manhole covers on both sides of generator end shields. Insert one forced air heater of

2 kW rating through each manhole, and keep the air heaters running. Note down the temperature
inside the generator enclosure. On reaching a steady temperature state, measure and record IR value of
all three phases connected together. Continue with this process and record IR values in Table 15.6 until
the measured IR value exceeds 1 MΩ kV1 of generatorrated voltage at 313 K and PI value becomes
greater than 2.0.

Do not switch off the forced air heaters.

Put the stator cooling water system into operation, but do not put the cooler of this system (Fig. 15.4)
into service. Allow the system to run for about 6 h.

Switch off the forced air heaters and take them out. Put back the manhole covers.

Table 15.6 Generator drying out

Generator
Ambient Enclosure IR10
Temperature Temperature IR, 1 min IR, 10 min PI¼
Reading No. Date/Time (K) (K) (MΩ) (MΩ) IR1
1
2
⋮
15.6.1.1 Resistance measurement of stator winding

Measure resistance of each phase of the stator winding with a Kelvin Double Bridge (Fig. 15.7) , and
record the results in Table 15.7.
 d

P G
Q

c
p q

a R m r n S b
I I

RR E

Fig. 15.7
Kelvin Double Bridge.
Table 15.7 Measurement of resistance of stator winding

Ambient Temperature Resistance (Ω)

Measured Between (K) Remarks
R1–R2
Y1–Y2
B1–B2
15.6.1.2 Capacitance and tanδ measurement

Measure capacitance and tanδ of the stator winding with a Schering Bridge (Fig. 15.8), and record the
results in Table 15.8.

R1
R2

C1
A B

C3
C2
R3

Fig. 15.8
Schering Bridge.

Table 15.8 Capacitance and tanδ measurement

Measured Capacitance ( Farad )
Temperature Between Measured
Sl. No. (K) Terminals Test Voltage Standard Measured tanδ
1
2
⋮.
15.6.2 Generator Air-Tightness Test

1. Open the H2 supply line inlet valve to the generator (Step 6, Section 15.5.2). Allow the instrument air
to enter the generator casing until the casing air pressure rises to about
0.4 MPa. Close the valve;

2. Verify that the seal oil pressure is higher than the generator casing air pressure;
3. Keep the generator casing pressurized for 48 h;
4. Take hourly readings of pressure and temperature (Table 15.9) ;
5. During the pressurizing period, keep vigilance on the U-tube manometer on the waste gas pipe of the
stator cooling water tank (Step 5, Section 15.5.2). Even a small increase in pressure recorded in this
manometer indicates a leak in the stator cooling water system; 6. Identify the leaked area/s with soap
solution and rectify the defect;

Note
Suspected areas of leakages are flange joints, welding joints, welds, bushings, valve glands, relief valves,
manifold connections, drain connections, instrument connections, gas dryer, and so on.

7. Loss of air from the generator casing may be calculated using the following formula:

K 24 P1 +PB1 P2 +PB2
VLA ¼ VG
Z T1 T2

where VLA: loss of air per 24-h period (m3) ( s.t.p.),

K: a constant (to be supplied by the generator manufacturer),

Z: duration of leakage test ( h),

VG: generator volume (m3) ,

P1: pressure inside the generator casing at the start of the leakage test (Pa g),

P2: pressure inside the generator casing at the end of the leakage test (Pa g),

PB1: barometric pressure at the start of the leakage test ( Pa),

PB2: barometric pressure at the end of the leakage test ( Pa),

T1: temperature of air inside the generator casing at the start of the leakage test (K), and T2:
temperature of air inside the generator casing at the end of the leakage test ( K ). If VLA is found to be
less than VLP, which is the permissible amount of leakage allowed by the generator manufacturer,
then the H2 gas system is considered sufficiently tight. If, however, VLA is higher than VLP, identify the
leakage with soap solution, rectify the defect, and repeat the leakage test and subsequent
calculation until acceptable results are achieved.

8. Record all readings per Table 15.9.

 Table 15.9 Readings of generator air-tightness test

Casing Air Pressure Barometric Casing Air

(Pa g) Pressure (Pa g) Temperature ( K )
Stator Cooling
Reading Water Start Stop Start Stop Start Stop
No. Time Tank Pressure (Pa) (P1) (P2) (PB1) (PB2) (T1) (T2)
1
2
⋮
47
48
15.7 Conclusion
On successful completion of generator drying out and the air-tightness test, a protocol (Table 15.10)
may be signed jointly by the customer, the engineer, the generator manufacturer, and the supplier (
contractor ).

Table 15.10 Protocol for generator drying out and the air-tightness test
Type of Test Findings Remarks
Generator drying out IR value of insulation of stator windings is greater Generator is cleared for
than H2 filling (Chapter 16)
1 MΩ kV1 of generator-rated voltage at 313 K, and PI
value is greater than 2.0
Generator air-tightness VLA<VLP
test
Signed by the customer Signed by the engineer Signed by the generator Signed by the supplier (
manufacturer contractor )
References
[1] D.K. Sarkar, Thermal Power Plant—Design and Operation, Elsevier, Amsterdam, Netherlands, 2015.
[2] IEEE Standard No. 43-2000: Recommended Practice for Testing Insulation Resistance of Rotating Machines. [3] D.L.
McKinnon, PdMA Corporation Tampa, FL, United States. IRP of a Healthy Insulation System.
[4] IEEE Standard No. 43–2013: Recommended Practice for Testing Insulation Resistance of Rotating Machines.