GE Power and Water

New Generator Products

Generator User’s
Conference

Anthony Arrao
John Yagielski
General Electric Company
Schenectady, NY USA November 2015

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Generator Product Overview

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GE Generator Portfolio
H35 H55
Legacy
(7FH2B) (330)
Generator
H33 H53 H73 H75 Products
(7FH2) (324) (390H) (450h)

9F.03 9F.05 SS
9F.05 9F.03 SS
7F.0 7HA.01 7HA.02
4 7F.05 7HA.02 9HA.01 9HA.02 SS 9HA.02 9HA.02
SS SS60 Hz
W8X
Water-cooled 50 Hz
60 Hz
Modular H8X
Generator H2-cooled 50 Hz
Products 60 Hz
H6X
H2-cooled 50 Hz

0 100 200 300 400 500 600 700

Generator Output (MW)

3
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Modular Generator Philosophy (H6X and
H8X)

470 MW

510 MW

550 MW

590 MW

H6X H8X
• 6 leads up or 6 leads down • 3 leads up / 3 leads down
• GTE for Leads-up • Unit-mounted GNTE only
• 1 meter centerline height support with integral feet
• Direct fixator support
• 4 post vertical coolers in fan inlet bay
• No lower frame extension (LFE)
• Reach-in “Dog-house” style collector compartment
4

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Generator Overview

Benefits Key features

• Highly efficient
• Reduced site assembly
• Enhanced cooling capability
• Improved serviceability
• Increased reliability
Top line
lead exit
 One piece frame construction for simplified
installation
 Extended foot / fixator support for
maintenance/ serviceability
 Modular gas, seal oil and stator cooling
water systems
4 post  Stator water cooling system with integrated
vertical
coolers monitoring
 Packaged static excitation and static
starter
 Fieldbus technology – 50% less site wiring
 Sized for robotic air-gap MAGIC*
inspection to avoid generator moves

Extended Foot
(double end drive)

* Trademark of General Electric Company

5
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Double End Drive – Generator In The Middle

Rotor Removal
Extended Feet Frame Blocking Full generator lift Rollers, guide, axe and push jack

Stator relocation by heavy lift rigging integrated into plant design

Full lift capacity crane not required
6
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Heritage and Experience – Hydrogen and Water Cooled
Experience profile
Units Operating
shipped hours

GE water-cooled generators 589 153,160,000

- SS CC water-cooled 33 4,237,000

Phosphorus –free braze bars 132 6,430,000

GE hydrogen-cooled generators 3009 797,316,600

- H73/ H75 improved
end winding support system 76 5,052,600

Radial-cooled C-coil fields 1170 104,419,900

Proven technology for service reliability

7
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 Generator Features

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Stator Winding and Core
• 3 phase, 2 or 3 circuit configuration

• Class F 155(C) insulation

• Tetraloc* end-winding support

Encapsulated – monolithic structure for
minimum maintenance - 500+ units in
Connection rings
service
End windings

Silicon steel core

Iron clamping
flange with
ventilated flux
shield
Leak-free, corrosion-proof stator bar
Image is for water-cooled bars – support system
clip (H2O-only) same for conventionally cooled bars

Reliability & availability through service proven configurations

* Trademark of General Electric Company.
9
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Stator Slot Support System

• Slot support restraint accomplished by top and side ripple springs; tapered wedge
and slide
• H2O-cooled windings include molded conforming filler material

Provides radial and tangential restraint while allowing axial expansion

10
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Rotor and Field Winding
• Single layer C-coil winding
• Direct radial-flow cooling
• Axial flow fans
• Tilt-pad bearings
• Spring-loaded coil slot amortissuers for low-speed 2 pole rotor
static start capability

Outboard terminal stud

Robust architecture upgraded with outboard terminal stud from LSTG fleet
11
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Stator Core Isolation System
• Isolates stator core from frame structure
• Reduces forces transmitted to foundation
• Reduces stator frame vibration
– Reduce web plate stress
– Reduce acoustic noise

Bolts

Bolted springbar design for superior core vibration isolation

12
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H2 Generator Cooling Circuit

Once–through ventilation optimized for uniform cooling

without air gap baffling

13
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Packaging
Ribs integrated to the bearing cap

Increased axial clearance for removal

Field supported
by sling with
upper and lower
half end shield
in place

Double tilt-pad bearing with dual insulation

Endshield engineered for robust operation &

14
maintainability
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Collector and Brush Rigging
Common features:
 Cooling-air path is fully above floor, including inlet and exhaust silencing (no flow through
foundation and no customer ducting required)
 Junction boxes for heater and instrumentation are external (easy access)
 DC leads are external (connect with bus bar or cables)
 Rated IP54W
 New GE brush holder

Integral GT
turning gear

Double-end drive Single-end drive

Standardized collector design for Single & Double End

Drive 15
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New Proprietary Brush Holder Technology
Enhanced Features
 Lightweight aluminum construction with durable, hard,
anodized surface coating
 Double-wide holder for faster brush changing
 Integral, safe, insulated changing handle
 Rotated handle and large locking pin are clear indicators
of complete installation
 No tools required for replacement of brush or springs
 Taller box to avoid hang-ups, reduce selectivity, and
extend brush life
 Extensive validation testing at GE and H33(7FH2) site

New holder optimized for maintenance & longer life

16
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Seal Oil System

• Automated system control … eliminate need for human intervention

• Digital bus communications … added system diagnostics and controls
• Continuous real time monitoring

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Stator Cooling System
• GE High Dissolved Oxygen System
• Eliminates vacuum treating requirements
• Reduces operating cost with lower auxiliary loads

• Constant Flow/Ambient Following

• Fixed flow rate for minimal operator interface needs
• Ambient following temperature control – reduces auxiliary
cooling water demand, follows capability curve

• Reliability Enhancements
• Duplex strainers for on-line maintenance
• 100% redundant cooling pumps and heat exchangers
• Integral Stator Leak Monitoring System (SLMS HP*) for
online detection of stator bar leaks

• Fully integrated with Mark VIe control system

• Digital bus communications for total system diagnostics
and controls
• Alarm “pop ups” for recommended inspection/actions

Modernized with on-line maintenance & monitoring

Operability for combined-cycle operation
* Trademark of General Electric Company 18
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distributed in whole
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or in part, part, prior
without prior permission
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of the copyright the copyright
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 Validation and Test

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Validation
GE has invested $22.5MM into labs and test facility


2007- Non-metallic and materials labs
2009 • Insulation systems development


Generator armature development lab
Generator armature
• Bar force limits
development lab • Slot component testing


2010 Repair technology COE and MFG tooling
• Field rewind process automation … full-scale
validation
Automated Connection • New repair center
retaining ring ring insertion
assembly fixture • Retaining ring tooling and coil cleaning
• Connection ring insertion fixture … cycle and quality


2011 Generator validation and testing facility
• Full system thermal cyclic-duty and endurance testing
• Rigorous component level testing and materials
Generator endurance test
stand
validation

Multi-year investment in validation capability for new products

20
GE Title or job number
11/18/2015
Validation Progression

* Trademark of General Electric Company

Thermal cycling & endurance to simulate 1st year operation

21
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Factory Running Tests
• Open circuit up to 125% rated voltage
• Short circuit up to 120% rated current
• Heat runs with varying cold gas and H2-pressure
• Sudden short circuits up to 70% voltage
• Deceleration tests with:
• Varied mass and support stiffness
• Purposeful rotor unbalance
• Ventilation and Acoustic Surveys
• Negative and zero sequence reactance
• Thermal cycling and Endurance runs:
• 60+ stop / start cycles
• 350+ hours of “overload” operation

• Over 1500 additional validation sensors:

• Traditional and fiber-optic thermocouples
• Piezo and fiber-optic accelerometers
• Stator slot vibration
• Voltage / current probes and search coils
• Pressure and velocity probes

Comprehensive running test for

verification & characterization
22
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W86 and H84 Factory Test Result Summary
Mechanical performance
• Rotor and frame vibration levels well below operating limits
• End-winding and connection ring vibration levels well within fleet operating
experience
• No visual indications of change to the stator winding due to:
• 60+ thermal cycles
• 350+ hours of endurance runs
• Sudden short circuit tests up to70%

Electrical / Thermal performance

• Short circuit ratio exceeded expectation
• Rotor and stator winding temperatures below class B observable limits
• Core end iron temperatures significantly below fleet experience
• Back-of-core voltages well below operational limit
• Overall losses 4 to 5% lower than expected

Performance of first 2 units exceeded

expectations. H65 60Hz & H84 60Hz validation on-
going 23
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On-Line Monitoring

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Monitoring and Diagnostics – Available
modules

Advanced Monitoring
Systems

Stator Leak Monitoring

System – High Flow Circuit Analysis
Auto Shorted Turn
Performance (H2O only)
Analysis
(H20 only)

Enhanced Partial End winding

Discharge Analysis Vibration Monitor

Generator Health Monitor (GHM)

(knowledge based analysis of data) Collector Health
Monitor

25
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 Summary

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Summary
• GE’s new modular generators supersede
legacy products
• 50Hz and 60Hz applications
• Single-shaft and Multi-shaft

• Honed for combined cycle applications

- Cyclical operation
- Maintenance coordinated with prime mover

• Utilize proven technology for reliable

operation

• Increased online monitoring capability

• GE is committed to full life cycle

performance and quality

27

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GE Power and Water

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