GEK 95205B

August 2001

GE Power Systems
Generator

Description
7FH2 Generator
with Static Excitation

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be desired or
should particular problems arise which are not covered sufficiently for the purchaser’s purposes the matter should be
referred to the GE Company.
 2001 GENERAL ELECTRIC COMPANY
GEK 95205B Generator Description

TABLE OF CONTENTS

I. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

II. GENERATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Generator Frame and Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

III. STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A. Stator Frame and Spring Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. Stator Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C. Stator Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

IV. ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
B. Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
C. End Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
D. Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E. Field Winding and Retaining Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

V. GENERATOR COLLECTOR RINGS AND BRUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

A. Collector and Collector Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
B. Brush Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
C. Shaft Grounding Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

VI. GENERATOR VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

A. Ventilation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
B. Hydrogen Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

LIST OF FIGURES
Figure 1. 7FH2 Packaged Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2. Typical Stator Frame for Hydrogen-Cooled Turbine-Generator
with Spring-bar Core Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3. Typical Spring-bar Mounting of Stator Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 4. Stator Punching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 5. Stator End Winding Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 6. Armature Conductors Assembled in a Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 7. Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 8. Typical Collector Assembly 7FH2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 9. Typical Brushholder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Generator Description GEK 95205B

I. GENERAL

The generator package consists of the generator, hydrogen control equipment, CO2 control equipment, and
an end mounted auxiliary compartment. Access to the bearing sections of the generator is provided through
doors in the load coupling compartment and in the auxiliary compartment. Electrical details are shown on
the Generator Electrical Connection Outline. See the “Generator Design Data and Generator Capability
Curves” for specific generator rating information.

II. GENERATOR ASSEMBLY

A. General

The hydrogen-cooled turbine generator is enclosed for safe and reliable operation with hydrogen gas
as the cooling medium. The ventilation system is completely self-contained, including gas coolers and
shaft mounted fans, thus preventing the entrance of dirt and moisture. The separately excited rotating
field, driven by the turbine, is supported by bearings located in the end shields mounted on the generator
frame.

The generator is designed to operate continuously for long periods of time without shutdown and in-
cludes all of the necessary systems and controls for maintaining constant internal hydrogen pressure and
purity and for supplying cooling water and lubricating oil. Circulation of the hydrogen throughout the
generator frame is achieved by the shaft mounted fans located on each end of the rotor.

Figure 1. Hydrogen-Cooled Turbine-Generator

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GEK 95205B Generator Description

B. Generator Frame and Supports

The generator frame consists of an integral base for direct mounting on a slab foundation. The generator
is shipped with rotor in place. Each end of the rotor is supported by an elliptical journal bearing mounted
in the end shield. Five simplex horizontal hydrogen coolers are mounted horizontally in the base of the
unit. See Figure 1.

III. STATOR

A. Stator Frame and Spring Mounting

Construction of the stator frame and spring mounting is shown in Figures 2 and 3. The stator frame con-
sists of a gas-tight cylindrical casing of welded plate construction, reinforced internally in the radial
direction by stationary web plates, and in the axial direction by spring bars and braces.

A series of floating web plates are welded to key bars which support the stator core. The key bars are
fastened at their ends to the spring bars (see Figure 3) through floating web plates. The spring bars are
supported by the fixed web plates. This spring mounting of the core isolates both radial and tangential
magnetic vibration of the stator core from the outer frame and results in low frame vibration and quiet

Figure 2. Typical Stator Frame for Hydrogen-Cooled Turbine-Generator

with Spring-bar Core Suspension

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Generator Description GEK 95205B

FIXED WEB
PLATES

SPRING
BARS FLOATING WEB KEY BARS
PLATES
CORE

Figure 3. Typical Spring-bar Mounting of Stator Core

operation. The motion of the core is limited to safe magnitudes by means of stop collars on several of
the spring bars. The stator core punchings are held under pressure axially by flanges bolted to the ends
of the key bars.

B. Stator Core

The stator core is made up of segmented, annealed, insulated punchings (see Figure 4) of preferred grain-
oriented, high-quality silicon steel to give minimum electrical loss. These punchings are assembled in
an interleaved manner on keys machined integral with the key bars (ribs) and are separated into packets
by space blocks to provide ventilation ducts. The punchings are stamped from thin steel sheets and con-
tain open-end slots for the armature bars with dovetail slots for wedges to hold the armature bars in place.
Other dovetail slots at the back of the punching are for assembly and locking of the segments on the key
bars. Assembled punchings are clamped into a stiff cylindrical core by pressure applied through ductile
cast-iron end flanges by means of the stator key bars. Pressure is applied to the teeth by non-magnetic
steel fingers located under the end flanges (see Figure 5). In order to reduce end heating from end leakage
flux and its associated electrical losses, occurring at the ends of the stator core, the end packets of punch-
ings are stepped back to increase the gap between the punchings and the rotor. Teeth in the end packets
of punchings are split radially to restrict the flow of circulating currents. The punching insulation is a
thermo-setting varnish which maintains its insulating value at temperatures above the normal operating
temperature range.

C. Stator Winding

The stator winding (see Figure 5) is composed of insulated bars assembled in the stator slots, joined at
the ends to form coils and connected in the proper phase belts by bus rings. Each phase is split into groups
of coils 180 degrees apart. The stator bars are composed of insulated copper conductors (strands) trans-
posed by the “Roebel” method so that each strand occupies, for an equal length along the bar, every radial
position in the bar. This arrangement avoids circulating current loss which would otherwise be present
under load conditions due to the self-inductive distribution of magnetic flux in the coil slot. For details
of the transposed bar (see Figure 6).

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GEK 95205B Generator Description

Figure 4. Stator Punching

0
OUTSIDE
SPACE BLOCK
WEDGES (FINGER)
END GLASS TYING
COIL CORD

INSIDE SPACE
BLOCK (VENT
DUCT)

BINDING
BINDING BAND BAND
SUPPORT
STATOR
PUNCHINGS

CONNECTION
RINGS
STATOR KEYBAR STATOR
FLANGE

Figure 5. Stator End Winding Structure

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Generator Description GEK 95205B

FILLER
BETWEEN INSULATED TOUGH PITCH
CROSSOVERS COPPER WIRE
TRANSPOSED CONDUCTORS

LAYERS OF MICA TAPE

VERTICAL
SEPARATOR
RTD OR
FILLER

ARMOR TAPE

TRANSPOSITION OF INSULATED
CONDUCTORS IN ARMATURE BAR
DRIVING
WEDGE STRIP
(TEXTOLITE)

TYPICAL STATOR SLOT ASSEMBLY

Figure 6. Armature Conductors Assembled in a Bar

An electrical insulation system is applied to form the main “ground wall” of insulation over the stator
bar, which is composed of many individually insulated transposed strands. This insulation system con-
sists of several layers of mica tape bonded with a thermo-setting binder. The result is a high-density,
high-dielectric strength system which has high tensile strength throughout the operating temperature
range. The bars, with a composite build-up of layers of tape applied, are placed in a tank and subjected
to vacuum, pressure, and heating cycles, to remove the volatiles, compact the system to eliminate voids
and cure the binder.

An outer cover of armoring tape is applied to the core portion to protect the bar from abrasion in the slot.
To minimize the effect of corona, an electrical voltage grading system is applied to the bar in the slot
portion and extending several inches beyond the core.

Stator coil ends are covered with an outer layer of tape to bind and protect the mica insulation, after which
they are sprayed with epoxy paint. These end turns are securely restrained by the binding bands, which
are molded fiberglass rings supported from the stator core flanges. Conformable material is used to dis-
tribute the pressure at the surface of the end turns. The fiberglass ties, space blocks, and conformable
material are bonded with thermosetting resin. The armature bars are held in the coil slots by wedges driv-
en into the dovetail slots.

IV. ROTOR

A. General

Construction of the generator rotor is illustrated in the Generator Assembly and the Rotor Assembly
Drawings. The rotor is machined from a single alloy steel forging which has passed extensive tests to
assure that it has the required physical and metallurgical properties.

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GEK 95205B Generator Description

Slots machined radially in the forging body, contain the field coils. Subslots, machined under the coil
slots, supply cooling gas to radial holes in the field coils. The field coils are held in the slots against cen-
trifugal force by stainless steel wedges.

Rotor fans, providing ventilation for the generator, are assembled at each end of the rotor. The rotor is
cooled externally by gas flowing along the gap over the rotor surface, and internally by gas which passes
under the rotor end windings, through the rotor subslots, and radially outward to the gap through holes
in the field coils and slot wedges.

B. Bearings

The rotor is supported by and rotates in Eliptical Bearings mounted in the generator end shields.

The casing is split horizontally to facilitate assembly and disassembly. The bearing and the shaft seal
housing at the collector end of the generator are insulated from the generator frame to prevent the flow
of shaft currents.

C. End Shields

Generator rotor bearings, hydrogen shaft seals, and oil passages for supplying oil to the bearings are con-
tained in the outer end shields. The end shields are split on the horizontal centerline to facilitate their
removal to enable assembly and disassembly of the rotor. The joints between the shield halves and be-
tween the shield and stator frame are fitted and provided with grooves for the insertion of sealing com-
pound to seal the gas in the machine. Inner end shields are located between the ends of the armature wind-
ings and the outer end shields to separate the gas discharged from the fans from the gas entering the fans.
Seal rings are attached to the inner end shields to prevent gas leakage from the fan discharge back to the
fan inlet.

D. Shaft Seals

The escape of hydrogen from the generator along the shaft is prevented by a shaft seal attached to each
outer end shield, inboard of the bearing. This arrangement permits inspection of the generator bearings
without removing gas from the machine.

The shaft seal housing at the connection end of the machine is insulated from the generator frame to pre-
vent the flow of shaft currents.

E. Field Winding and Retaining Rings

The field winding consists of rectangular copper bars, fabricated into coils. Several turns in one pair of
slots around one pole form a coil. Several coils are assembled around each pole to form the winding.
The individual turns are insulated from each other. The coils are insulated from the slot wall in the body
portion by molded slot armors. To provide maximum ventilation and cooling, the end portions of the
field coils are left bare except for turn insulation. Molded ring insulation is provided between the coils
and the retaining rings, and glass blocking is provided in the end windings to separate and support the
coils and restrict their movements under stresses from temperature and rotational forces.

End turns are held in place against centrifugal force by retaining rings machined from high-strength,
heat-treated alloy steel forgings (18MN–18CR) which are shrunk and locked onto the centering rings.
The centering rings are not in contact with the shaft.

V. GENERATOR COLLECTOR RINGS AND BRUSHES

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Generator Description GEK 95205B

Site Flow Port

Figure 7. Typical Eliptical Bearing

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GEK 95205B Generator Description

A. Collector and Collector Connections

DC power is supplied to the field windings through the collector rings which are connected with the
winding through insulated copper bars assembled in the bored-out center of the rotor forging and con-
nected electrically to the field winding. At one end of the connection bars, terminal rods, or studs, as-
sembled in radial holes in the rotor shaft, connect the winding with the bars; at the other end, the bars
are connected to the collector.

The collector is an assembly consisting of a machined glass epoxy sleeve for insulation, and two
grooved, forged steel rings (see Figure 8).

The glass sleeve is assembled to the shaft with an interference fit and the collector rings are shrunk on
to the insulation sleeve and shaft assembly.

The glass sleeve insulates the collector ring from the steel shaft. For maintenance, the collector rings
can be removed, however, a new glass sleeve will be required when the collector rings are re-installed.

B. Brush Rigging

The brush rigging on the generator utilizes constant-pressure type brush holders (see Figure 9). By
means of a coiled spring, constant pressure is maintained on the top of the brush as it wears down. The
coiled spring is permanently attached to a back plate, forming a back plate and spring assembly. Also
attached to the back plate is a disconnect clip which engages the brush pigtail terminal and a connection
plate which is inserted in the contact clip of the brushholder support.

COLLECTOR
FAN

GLASS RETAINING COLLECTOR

SLEEVE SHAFT RING FAN HUB

H2 SEALS

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ BORE PLATE

COLLECTOR COLLECTOR BORE PLUG

RINGS TERMINAL
STUD

Figure 8. Typical Collector Assembly 7FH2

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Generator Description GEK 95205B

INSULATED HANDLE

RIVET

DISCONNECT CLIP CONNECTION PLATE

CONTACT CLIP

BACK PLATE & SPRING ASSY

ROLLER BRUSH HOLDER
CLIP SUPPORT
BRUSH

.12 BRUSH HOLDER

COLLECTOR RING SURFACE

Figure 9. Typical Brushholder Assembly

Assembled to the coiled spring is a roller and clip assembly. The coiled spring is positioned in the recess
at the top of the brush and the roller clip is fastened to the rivet hole of the brush.

An insulated handle is furnished for the assembly and removal of the brush back plate and spring assem-
bly. This handle serves all the brushes of the brush rigging. When not used, the handle should be removed
from the brush back plate and spring assembly, and stored in a safe and readily accessible place.

C. Shaft Grounding Brushes

Shaft grounding brushes are supplied on turbine-generator units to prevent damage to bearings by elec-
trical discharge through the bearing oil films. They also serve to complete the circuit for the generator
field- ground detector relay.

Shaft-to-ground voltages occur on units with static excitation systems. The output of the three-phase
full-wave bridge rectifiers is not pure dc, but it contains a 360 Hz ripple of appreciable magnitude. Under
certain conditions, this ripple can cause currents to flow through the capacitive circuit consisting of the
field insulation, the bearing oil film, and the distributed capacitance of the excitation system transform-
ers and rectifiers.

Shaft grounding brushes provide a low-impedance path to ground so that currents due to shaft voltage
flows harmlessly to ground, bypassing the bearings.

The grounding brush assembly consists of a yoke carrying two or more constant pressure brush holders
and is located at the turbine end of the generator shaft. Note that the collector-end bearing on the genera-
tor is insulated from ground to prevent the flow of current due to a loop-type voltage along shaft and

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GEK 95205B Generator Description

through bearings which may be produced by minor dissymmetry in the generator stator magnetic paths.
Therefore, the grounding brush must never be located on the collector end of the generator.

The brushes used in this grounding assembly are the same as those used on the collector rings for excita-
tion. The brush holder springs, for the grounding brushes, exert a higher pressure to assure a low brush
voltage drop for this low current application. The yoke should be electrically connected to the same sta-
tion ground as the generator frame.

VI. GENERATOR VENTILATION

A. Ventilation System

Rotor fans circulate hydrogen gas within the generator. They are the axial flow type with individual
blades fastened to fan hubs at each end of the rotor.

In the stator ventilation circuit, hydrogen is forced by the fans into the gas gap, and also around behind
the stator core. The stator is divided axially into sections by the web plates and outer wrapper so that
in some sections cold gas is forced from the outside of the core toward the gas gap through the radial
gas ducts, and in other sections it passes from the gas gap toward the outside of the core through the radial
ducts. Cooling gas is conducted through tubes or ducts to the proper section, and hot gas is directed
through the coolers. After the heat is removed, cold gas is returned to the rotor fans and recirculated.

The arrangement of alternate inward and outward gas flow in the stator core results in a substantially
uniform cooling of the core and windings, thus avoiding local heating and reducing stresses that could
result from temperature differentials.

B. Hydrogen Coolers

Five simplex coolers are mounted horizontally in the genrator base. Inlet and outlet water manifolds and
associated isolation valves are supplied for assembly with the water piping on the side of the base. The
ventilation arrangements is such that the flow of hydrogen is equally distributed through each cooler
within the gas tight casing and base.

The manifolds are designed for parallel coolant flow to each of the five coolers.

Each cooler has an extended tube sheet at the inlet end and a gland packed hydrogen seal at the opposite
end of the cooler.

Each hydrogen cooler section consists of a pair of water headers (water boxes), tube sheets, round tubes
with plate fins, all supported by a frame. The cooling water circulates in the tubes with two or more
passes as determined by the arrangement of partitions in the water boxes. The gas to be cooled flows
over the finned surface in a direction to obtain counterflow between the gas and the water, that is, the
hot gas enters on the water outlet pass and the cold gas leaves from the water inlet pass. The sections
should be piped in parallel for water flow.

1. Cooler Frame

The frame is of welded steel construction and consists of two-channel-shaped side plates forming
a box-like structure with end plates at each end. Strength is provided by diagonal pipe braces welded
to the corner bars and extending across the two open sides of the frame.

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Generator Description GEK 95205B

Rubber baffles are mounted on the sides of the cooler to prevent by-passing of gas, forcing the gas
to flow through the finned surface.

For proper cooler performance, it is essential that the amount of gas bypassing the cooler be kept
to a minimum.

2. Cooler Tubes

The tubes are of condenser tube quality as described by ASTM Specification B-111.

The extended surface on the outside of the tube consists of continuous plate fin with a shoulder
formed at the tube holes for stacking as required.

Both ends of each tube are roller-expanded into the tube sheets. Standard condenser tube expanders
for rerolling tube joints may be purchased from one of the various suppliers of this type of tool or
may be purchased through the General Electric Company. The expander should be sized to suit the
outside diameter of the tube and wall thickness. The length of the rolled joint should equal approxi-
mately 90 percent of the tube sheet thickness measured from the front face of the tube sheet. The
rolling should never extend beyond the back face of the tube sheet since this will produce a circum-
ferential ridge in the tube, resulting in a condition that may produce early tube failure.

3. Tube Sheets

In addition to the normal functions, the tube sheets of the simplex hydrogen cooler provide a hydro-
gen seal between the cooler and the generator frame. With the hydrogen seals at the tube sheets, there
is access to the tube ends, permitting repair and cleaning without removing the hydrogen cooler
from the generator. The gas seal at the floating end is provided by a compressed ring gasket which
bears on the edge of the floating end tube sheet. The edges of the floating end tube sheet are ma-
chined to provide good sealing surfaces. If these surfaces are scratched or gouged, they should be
repaired by filing or stoning until smooth. Deep gouges may be filled with soft solder before filing
smooth.

The fixed end sheet of the cooler has a pumping groove type seal. The sealing compound and method
of use is the same as for the generator end plate seal. The floating tube sheet uses a gland type seal.

Thermal expansion and contraction of the tubes may tend to be restricted by the piping to the water
connections therefore, it is important to avoid a rigid piping system at the point of attachment to the
cooler. A run of pipe, transverse to the tube axis, will provide sufficient spring in the piping to ac-
complish this.

4. Water Boxes

The water boxes or headers and covers are bolted to the tube sheets with bolts or studs which thread
into bottom-tapped holes in the tube sheets. Jack bolts in the covers facilitate removal of the covers.
The cooler frame has provisions for installing eyebolts for handling the cooler both in the horizontal
and the vertical position to assist installation. Reference should be made to outline drawing for size
and location of water-connection flanges.

5. Gaskets

Gaskets are provided in the joints between covers and water boxes, and between water boxes and
tube sheets. Before leaving the factory, the coolers are tested at 150 percent of the specified working

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GEK 95205B Generator Description

pressure and this test value is stamped on the nameplate, i. e., “T188P” stamped on the nameplate
indicates a test pressure of 188 psig.

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GE Power Systems

General Electric Company

One River Road, Schenectady, NY 12345
518 • 385 • 2211 TX: 145354