Doc043 53 30241

Application Note: ORBISPHERE and Hydrogen Measurement for Stator Coolant
Hydrogen Measurement in Hydrogen-Cooled

Turbo Generators
Introduction
Why use hydrogen for stator coolant purposes? The gas which fills any generator is also present in
the generator's air gap, and due to high turbulence it develops a certain amount of friction loss; the
so-called windage loss. This effect heats up the gas. The cooling gas is circulated in a closed loop to
remove heat from the active parts, and is then cooled by gas‐to‐water heat exchangers on the
stator frame. The working pressure is up to 6 bar. The best gas for this task should have:
 Low friction loss to avoid heating itself

 A high heat capacity to pick up heat with minimum temperature rise.
With its low viscosity and high specific heat, hydrogen is the best gas available and is therefore used in
large generators where the cooling requirements are severe. Even then the low density of hydrogen is a
disadvantage so it is always used at elevated pressure.
Stator Design and Cooling Systems

In general, three cooling approaches are used:
 For generators up to 300 MW, air cooling can be used

 Between 250-450 MW, hydrogen cooling is employed
 For the highest power generators, up to 1800 MW, hydrogen and water cooling is used. The
stator winding are made of hollow copper tubes cooled with water circulating through
them. The rotor is hydrogen-cooled.
Benefits of gaseous hydrogen cooling include:
 High specific heat, and highest thermal conductivity at 0.168 W/(m-K) of all gases.
 Hydrogen has a very low viscosity, a favorable property for reducing drag loss
 It is 7-10 times better as a coolant than air
 Hydrogen is easily detected with hydrogen sensors
 A hydrogen cooled generator can be significantly smaller, and therefore less expensive than
air-cooled generators
 Easy to manage – not readily miscible with CO2 purge gas
 Helium with thermal conductivity of 0.142 W/(m-K) was considered a coolant as well,
however its high cost hinders its adoption despite its non-flammability.
Hydrogen Impurities Impact on Plant Efficiency

Hydrogen has very low viscosity, a favorable property for reducing drag loss in the rotor. These losses
can be significant as the rotors have a large diameter and high rotational speed. Every reduction in the
purity of the hydrogen coolant increases windage loss in the turbine. As air is 14 times denser than
hydrogen, each 1% of air corresponds to about a 14% increase in density of the coolant and the
associated increase of viscosity and drag. A purity drop from 97% to 95% in a large generator can
increase windage loss by 32%, which is equal to 685 kW for a 907 MW generator. The windage losses
also increase heat losses of the generator and associated cooling problems.
The absence of oxygen in the atmosphere significantly reduces the potential damage of the windings
insulation by eventual corona discharges. These can be problematic as the generators typically operate
at a high voltage, often 20 kV.
Air Contamination in the Gas Circuit

The bearings have to be leak‐tight. A hermetic seal, usually a liquid, is employed; turbine oil at pressure
higher than the hydrogen inside is typically used. A metal ring (e.g. brass), is pressed by springs onto the
generator shaft and the oil is forced under pressure between the ring and the shaft. Part of the oil flows
into the hydrogen side of the generator, another part to the air side. The oil entrains a small amount of
air. As the oil is recirculated, some of the air is carried over into the generator. This causes a gradual air
contamination buildup and requires maintaining and controlling hydrogen purity.
Scavenging systems are used for this purpose. Gas (a mixture of entrained air and hydrogen released
from the oil) is collected in the holding tank for the sealing oil, and released into the atmosphere. The
hydrogen losses have to be replenished, either from gas cylinders or from on‐site hydrogen generators.
Degradation of bearings leads to higher oil leaks, which increase the amount of air transferred into the
generator. Increased oil consumption can be detected by a flow meter associated with each bearing.
Stator Maintenance and Purge Sequences

Requirements regarding gas cooling between normal operation and maintenance are different. During
and after shutdown the generator enclosure is purged before opening it for maintenance, to avoid a
highly explosive mixture of air and hydrogen. It requires the hydrogen loop to be purged using the
following sequence:
1. Hydrogen is purged by an inert gas. Carbon dioxide (or nitrogen) is used for this purpose as it
does not form high explosive mixtures with hydrogen and is inexpensive.
2. The inert gas is replaced by air. Gas purity sensors are used to indicate the end of the purge
cycle, which shortens the startup and shutdown timers and reduces consumption of the purge
gas. At the end, fresh air replaces all other gases allowing operators to work inside the
generator. Carbon dioxide is favored as it is easily displaced by hydrogen due to a very high
density difference.
3. After maintenance operations, air is replaced by the inert gas
4. The inert gas is replaced by hydrogen and the generator is ready for operation.
In the following table the measurement goal is described as well as the best suited ORBISPHERE system.
As a global solution, H2 and CO2 measurements will fulfill the main analysis requirements.
Main Operation Location System Goal of Measurement

Power generation H2 stator loop 510 H2 H2 purity up to 99%, generator
efficiency
H2 stator loop 510 O2 H2 purity up to 99.99% (option)
H2O lop 510 H2 H2 leak control in the water loop
Maintenance
CO2 purge 510 CO2 End purge indicator
Service in air H2 stator loop 510 CO2 Operator safety
CO2 purge 510 CO2 End purge indicator
H2 refill 510 H2 Efficiency, H2 purity
Security
The flammability limits (4 ‐ 75% of hydrogen in air at normal temperature but greater at higher
temperatures), its autoignition temperature at 571°C, its very low minimum ignition energy, and its
tendency to form explosive mixtures with air require provisions to be made for maintaining the
hydrogen content within the generator above the upper or below the flammability limit at all times and
other hydrogen safety measures.
When filled with hydrogen, overpressure has to be maintained as the inlet of air into the generator
could cause a dangerous explosion in a confined space.
Benefits
In summary, measuring hydrogen for stator coolant brings several benefits, including:
 Allows stability of high hydrogen purity to keep the generator at its highest efficiency
 Reduces risks of hydrogen leaks and unplanned outages
 Minimizes downtime during generator maintenance
 Improves operator and plant safety
 Reliable hydrogen sensing technology reducing risks of false alarms.
FOR TECHNICAL ASSISTANCE, PRICE INFORMATION AND ORDERING:

Tel: 800-227-4224 | E-Mail: techhelp@hach.com
To locate the HACH office or distributor serving you, visit: www.hach.com
DOC003.53.30241.Apr15© Hach Company, 2015. All rights reserved.

In the interest of improving and updating its equipment, Hach Company reserves the right to alter specifications to equipment at any time.

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Application Note: ORBISPHERE and Hydrogen Measurement for Stator Coolant

Hydrogen Measurement in Hydrogen-Cooled

 Low friction loss to avoid heating itself

Stator Design and Cooling Systems

 For generators up to 300 MW, air cooling can be used

Benefits of gaseous hydrogen cooling include:

Hydrogen Impurities Impact on Plant Efficiency

Air Contamination in the Gas Circuit

Stator Maintenance and Purge Sequences

Main Operation Location System Goal of Measurement

FOR TECHNICAL ASSISTANCE, PRICE INFORMATION AND ORDERING:

DOC003.53.30241.Apr15© Hach Company, 2015. All rights reserved.

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