Hydrogen Cooled Generators: Common Leak Points and How to Find Them Fast

When a hydrogen-cooled generator starts consuming more makeup gas than usual, the question is always the same: where is it going? Knowing the most common leak points ahead of time makes it possible to narrow the search quickly instead of surveying the entire machine from scratch.

The Usual Suspects

• Shaft seals, particularly seal oil systems showing signs of wear or pressure imbalance

• Bushing and terminal connections at the casing penetration points

• Casing seams, manhole covers, and inspection hatch gaskets

• Gas piping connections, valves, and pressure instrumentation

Start With the Data You Already Have

Before any physical inspection, review recent gas consumption trends and purity readings. A sudden change often points toward a specific system (seal oil, for example), while a slow, steady decline is more consistent with general gasket or seam degradation across the machine.

Fast, Targeted Detection Methods

Portable hydrogen sniffers let a technician move quickly across the most likely points without shutting the unit down. Soap-bubble testing remains a reliable, low-tech confirmation method for accessible joints once a sniffer narrows down the general area.

When to Bring in a Specialist

If consumption trends keep climbing despite a visual and sniffer-based check of the usual points, or if the leak appears to be internal to the seal oil system, it's time for a more thorough inspection. Catching this early avoids the far more disruptive scenario of a forced outage to address a leak that was manageable months earlier.

Ready to get ahead of leaks before they cost you? Contact StrongForce, Inc. at 833-735-3257 or info@StrongForceInc.com to schedule a survey or speak with one of our field engineers.