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210 MW Turbo Generator's Hydrogen Gas Malaya Journal of Matematik, Vol.S, No.2, 3225-3231, 2020 https://doi.org/10.26637/MJM0S20/0830 210 MW turbo generator’s hydrogen gas cooling system online monitoring and controlling using node red flow based IOT S. Dhivya 1 Abstract This project is about design and implementation of remote monitoring and controlling of 210 MW TURBO GENERATOR’S HYDROGEN COOLING SYSTEM using NODE RED BASED IOT PROGRAM. The faster heat dissipation of generators in power plants calls for hydrogen cooling, and water is used as coolant to cool down the hot hydrogen which comes out from the hydrogen cooling system (HCS) at the generating end. Therefore, in large generating plants, the process of cooling and the coolant become integral parts of the heat exchangers. Hence, requirement of a reliable HCS is a must. The main aim of this project is to automatically refill the hydrogen gas in the hydrogen cooling system of turbo generators whenever the hydrogen level gets reduced than the desired hydrogen level. This system works well in both normal requirement conditions and also during critical requirement conditions, when there is an unexpected leakage in the system. The entire process control and monitoring, popularly known as human–machine interface of HCS, has been developed and simulated on NODE RED BASED IOT PROGRAM. Keywords Online Generator HCS Monitor, Auto and Remote HCS Monitor, Generator’s Hydrogen Pressure Level, Auto Refill of Hydrogen, Hydrogen Cylinder’s Pressure Level, ADS1115 ADC, Node-RED, Raspberry pi3B+, Blynk. 1Department of Electrical and Electronics Engineering, Bharath Institute of Higher Education and Research, Chennai, Tamil Nadu, India. Article History: Received 01 October 2020; Accepted 10 December 2020 c 2020 MJM. Contents forces as a result of Unlikely event of explosion of hydrogen and air mixture without any residual deformation. The Hy- 1 Introduction......................................3225 drogen gas coolers are housed longitudinally inside the stator 2 Design and Implementation Of Proposed System:3226 body. The stator core is made up of segmental varnished punching of Electro technical sheet steel with low loss factor. 3 Software:.........................................3227 The stator has a three phase, double layer, short pitched and 4 Simulation Design And Implementation: . 3227 bar type of windings having two parallel paths. Each slot 5 Simulation Results...............................3229 accommodates two bars. Each bar consists of solid as well as 6 Conclusion.......................................3230 hollow conductors with cooling water passing through. The stator bar insulation is done with epoxy mica thermosetting References.......................................3230 insulation. The stator bar top and bottom are connected by means of copper pipes at exciter end. The PTFE hoses are 1. Introduction connected between nipple on the stator bar and nipple on the A thermal power station is a power plant in which the main inlet and outlet water headers at turbine end. The stator wind- power is steam driven. Water is heated, turns into steam and ing temperature is measured by 60 nos. RTDS and 12 nos. spins a turbine which drives an electrical generator. of standby RTDS. The rotor shaft is made up of chromium nickel molybdenum and vanadium steel, the rotor winding is A.210MW TURBO GENERATOR: made up of silver bearing copper and rotor slot wedges are The stator body is totally enclosed gas tight fabricated struc- made up of Duraluminium. The rotor windings are cooled by ture, suitably ribbed internally to ensure high rigidity. It means of direct cooling method .of gap pick up method. In is designed mechanically to withstand internal pressure and this type of cooling the hydrogen in the gap is sucked through 210 MW turbo generator’s hydrogen gas cooling system online monitoring and controlling using node red flow based IOT — 3226/3231 the elliptical holes serving as scoop on the rotor wedges and The Hydrogen gas system performs the following func- it is directed to flow along lateral vent ducts on rotor copper tions:Provides means for safety filling of hydrogen gas into coil to bottom of the coil. The rotor cooling gas is circulated or purging out of, the machine.Maintains gas pressure inside by two single stage axial flow propeller type fans. The slip the machine at the desired value. Indicates the operator, at all rings are connected to the field winding through semi flexible times the condition of the gas in the machine, its pressure and copper leads and current carrying bolt placed radially in the purity. Removes moisture from the gas in the machine which shaft. may get into it from seal oil. In order to prevent the escape of hydrogen from generator casing along the rotor shaft, shaft seals provided with oil under TECHNICAL DATA: pressure are used. The shaft seal is provided with seal oil by a separate closed circuit system. To ensure free movement of Rated hydrogen pressure inside generator casing: 3.5 Kg/cm2 the sealing, the shaft seals are provided with pressure oil for Maximum hydrogen pressure at which signal is initiated: ring relief from governing oil system. The seal oil supplied to 3.7 Kg/cm2 the shaft seals, are drained from both air and hydrogen sides. Minimum hydrogen pressure at which signal is initiated: The air side seal is directly drained to the seal oil tank. The oil 3.3Kg/cm2 drained towards hydrogen side is passed through prechambers Rated cold gas temperature: 44◦C and intermediate oil tank before draining to the seal oil tank. Max. Permissible hot gas temperature: 75◦C Temperature is supervised continuously by monitoring seal Min. Purity of hydrogen permissible: 97% oil flow and seal oil temperature. For visual check on the flow Max. Permissible moisture content in hydrogen: 4500ppm of the oil towards hydrogen side, oil check pipes are provided Generator gas volume: 56 cu.m at either end of the generator. TECHNICAL DATA: 2. Design and Implementation Of Proposed System: Max.Continuous KVA Rating:247000KVA The prototype model of the proposed system is represented Max. Continuous KW Rating: 210000KW in simple in the block diagram representation as shown in the Rated Terminal Voltage: 15750 V figure 1. Rated Stator Current: 9050A Rated Power Factor: 0.85 lag Excitation Current at MCR condition: 2600A Excitation Voltage at MCR condition : 310V Rated Speed : 3000RPM Rated frequency:50 Hz Efficiency at MCR condition : 98.55% Negative sequence : 122 t=8 Direction of rotation when viewed from slip ring: clock- wise Phase connection: Double star No.of. Terminals brought out: 9(6 neutral and 3 Phase) Total gas volume of generator: 56 cum. Nominal Pressure of Hydrogen:3.5KG/Sq.cm Permissible variations: +0.2 Kg/Sq.cm Maximum temperature of cold gas: 44 deg C. Purity of Hydrogen (min): 97% B.Hydrogen Gas System: Fig.1. Block diagram representation of proposed 210MW Turbo Generator Online Monitoring and Controlling The Hydrogen gas is used as cooling medium in generator because of its higher heat transfer capacity and light weight. In the proposed system, the hydrogen gas level is automati- However it is having the property of formin and explosive cally monitored and controlled using smart monitoring and mixture when mixes with air. But the risk of explosion is controlling system.The hydrogen gas is automatically refilled almost eliminated, when the Hydrogen gas quantity is less during normal requirement conditions. During critical require- than 4% or more than 74%. So, in generator wherein hydrogen ment conditions, the hydrogen level is still maintained, even gas is employed in closed circuit, the purity has to be always when there is a leakage in the system. The leakage can be maintained beyond 90%,a hydrogen gas purity of about 99% traced and fixed without tripping off the entire unit. This is maintained inside the generator casing. ensures continuous and reliable functioning of the unit. 3226 210 MW turbo generator’s hydrogen gas cooling system online monitoring and controlling using node red flow based IOT — 3227/3231 A. Microcomputer Blynk Server is an Open-Source Nett based Java Server. It is responsible for forwarding messages from Blynk mobile ap- A series of small single board computers is used to construct plication to various micro controller boards and SBCs.Blynk Raspberry Pi. It was developed in the United Kingdom by is an Internet of Things platform. It aims to simplify building the Raspberry Pi Foundation to promote the teaching of basic mobile and web applications for the Internet of Things. computer science in schools and in developing countries. The Raspberry Pi hardware has evolved through many versions 4. Simulation Design And that has variations in memory capacity and peripheral device Implementation: support. The proposed method is implemented using RASPBERRY Node-RED is a flow-based development tool developed by PI 3 MODEL B. The Raspberry PI 3 Model B is the latest ver- IBM for wiring hardware devices together, APIs and online sion of the Raspberry PI. They are credit card sizecomputer. services as part of the Internet of Things. The browser UI is Add a keyboard, mouse, display, power supply, micro SD a graphical representation of flow where drag and drop node card with Linux distribution and NODE RED. You will have templates can be connected together. Here we use Simulink a full-fledged computer that can run application from word tools for developing this project with good efficiency in de- processor and spreadsheet.It has a Dual-Band wi-fi feature. veloping. This paper consists of two sections software and This Wi-Fi enabled microcomputer can be connected to per- hardware. In software section all tests are done in Node-RED sonal computers by using web HMI to monitor the parameters software and the simulation was done in Node-RED and the remotely. simulation result is as follows.
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