GE Power and Water

New Generator Products

Generator Users
Conference

Anthony Arrao
John Yagielski
General Electric Company
Schenectady, NY USA

November 2015

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distributed in whole or in part, without prior permission of the copyright owner.

Generator Product Overview

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GE Generator Portfolio
H35

H55

(7FH2B)

(330)

H33

H53

H73

H75

(7FH2)

(324)

(390H)

(450h)

Legacy
Generator
Products

9F.05 SS
9F.03
9F.05
9F.03 SS
7F.0
7HA.01
7HA.02
7F.05
4
7HA.02 9HA.01 9HA.02 SS

9HA.02
SS

W8X

50 Hz

Water-cooled

60 Hz

Modular H8X
Generator H2-cooled
Products
H6X

50 Hz

60 Hz
50 Hz

H2-cooled

100

9HA.02
SS60 Hz

200

300

400

500

600

700

Generator Output (MW)

3

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owner.

Modular Generator Philosophy

(H6X and

H8X)

470 MW

510 MW

550 MW

590 MW

H6X

H8X

6 leads up or 6 leads down

GTE for Leads-up

3 leads up / 3 leads down

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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only.

Generator Overview
Benefits

Key features

Highly efficient
Reduced site assembly
Enhanced cooling capability
Improved serviceability
Increased reliability

Top line
lead exit

4 post
vertical
coolers

One piece frame construction for simplified

installation
Extended foot / fixator support for
maintenance/ serviceability
Modular gas, seal oil and stator cooling
water systems
Stator water cooling system with integrated
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
shipped

Operating
hours

GE water-cooled generators
- SS CC water-cooled

589
33

153,160,000
4,237,000

Phosphorus free braze bars

132

6,430,000

GE hydrogen-cooled generators
- H73/ H75 improved
end winding support system

3009

797,316,600

76

5,052,600

Radial-cooled C-coil fields

1170

104,419,900

Proven technology for service reliability

7
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distributed in whole or in part, without prior permission of the copyright owner.

Generator Features

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in whole
or in part,
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Stator Winding and Core

Connection rings

End windings

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
service

Silicon steel core

Iron clamping
flange with
ventilated flux
shield
Leak-free, corrosion-proof stator bar
clip (H2O-only)

Image is for water-cooled bars support system

same for conventionally cooled bars

Reliability & availability through service proven configurations

* Trademark of General Electric Company.

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copied or distributed in whole or in part, without prior permission of the copyright
owner.

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
static start capability

2 pole rotor

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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owner.

H2 Generator Cooling Circuit

Oncethrough ventilation optimized for uniform cooling

without air gap baffling

13

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owner.

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 &

maintainability
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14

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
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15

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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Company. InformationClass
All Rights Reserved. This
material may not be copied or
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Export ControlledU.S. Government approval is required prior to export from the U.S.,
re-export from a third country, or release to a foreign national wherever located.

17

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
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copied ordistributed
distributed
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part, prior
without
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ofowner.
the copyright
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or in part,
permission
of the copyright
owner.

18

Validation and Test

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Validation
GE has invested $22.5MM into labs and test facility
20072009

Generator armature
development lab

2010

Automated
retaining ring
assembly

Non-metallic and materials labs

Repair technology COE and MFG tooling

Generator validation and testing facility

Connection
ring insertion
fixture

2011

Generator endurance test

stand

Insulation systems development

Generator armature development lab

Bar force limits
Slot component testing
Field rewind process automation full-scale
validation
New repair center
Retaining ring tooling and coil cleaning
Connection ring insertion fixture cycle and quality
Full system thermal cyclic-duty and endurance testing
Rigorous component level testing and materials
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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owner.

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 ongoing
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23

On-Line Monitoring

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Monitoring and Diagnostics Available

modules

Advanced Monitoring
Systems

Auto Shorted Turn

Analysis

Stator Leak Monitoring

System High
Performance
(H20 only)

Flow Circuit Analysis

(H2O only)
End winding
Vibration Monitor

Enhanced Partial
Discharge Analysis

Generator Health Monitor (GHM)

(knowledge based analysis of data)

Collector Health
Monitor

25

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owner.

Summary

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distributed in whole or in part, without prior permission of the copyright owner.

Summary
GEs 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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distributed in whole or in part, without prior permission of the copyright owner.

GE Power and Water

2015, General Electric Company.

GE Proprietary Information - The information contained in this document is
General Electric Company (GE) proprietary information. It is the property of GE
and shall not be used, disclosed to others or reproduced without the express
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All relative statements are with respect to GE technology unless otherwise noted.