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1
Production begins in the bar shop, where employees
unspool rolls of copper wiring, brading the wires together,
AND CREATE LONG FLAT BARS.
The stator of one large Weighing in at
BAR SHOP Hydrogen Generator contains
64.3 MILES of copper wire
33,264 lbs. Thats
about SIX Chevy
Suburbans
2
HEATED AND SHAPED
Flat bars are
INTO PRECISE CURVATURES needed
for the model of Generator.
3
Each bar is wrapped in an average of
16 LAYERS of insulated tape
It takes 4 Bar are baked in the
TAPE & hours to autoclave oven for
4
Employees climb into stator frames where they stack
PUNCHINGSONE
electrical steel laminations
BY ONE INTO THE SIDE OF A FRAME.
Punchings hold the stator bars in place and are the internal
backbone of the generator.
RACK &
STACK Number of up to Time it takes
punchings in
each Generator: 250,000 to fully stack
a Generator:
7 WEEKS
6
WEDDING
COME TOGETHER
Stator bars sit in the
There are
of a Generator
7
Rotors are carefully positioned INSIDE THE CORE
of the stator-filled frame. The Generator is encased in a metal
shroud and PAINTED.
PIECES OF
1 coat of primer
POWER Most popular
PUZZLE 24 2 coats of final paint color?
gallons of
WHITE
paint per unit
How to Make a GE Steam Turbine in
TEN (GIANT) STEPS
1
Steel forgings the size of TREE TRUNKS (think California
large Redwood) are shipped from Europe and Asia to form
THE CORE OF THE TURBINE.
FORGING Rows of metal blades are hung
from these huge metal disks.
These forgings can weigh up to 250 tons.
They cost a ton of money
AHEAD UP TO $400K!
2
Heres where the WHEEL FUN STARTS.
Machinists cut grooves Steam turbine rotor dovetails are
into the smooth core machined to tolerances of .0005.
and they know how to THATS 8X THINNER
GROOVING CUT IT CLOSE! THAN A HUMAN HAIR.
ALONG
3
THE BUCKET
They come in
From Pinetree to
Finger Dovetail to
DIFFERENT SIZES AND SHAPES.
Precision Machined,
checked for defects
4
ASSEMBLE
Now its time put the
50-250
buckets per stage
THE TROOPS metal casing. on average.
5
MAKE
Now its time for a really CLOSE SHAVE
Over 20,000lbs of steel is removed from the
D650 outer shell for the sole purpose of
facilitating bolting the two halves together.
YOUR CASE
6
The turbine is transported VIA TRAIN across
the parking lot.
7
Time to take a SPIN IN THE BUNKER.
Just like balancing
a tire, but to
3000-3600 RPM
Fast enough to melt the metal, if we didnt spin it in a vacuum.
BUNKER .001 Tips of the last stage buckets travel up to 1600 miles per
DOWN of vibration. hour during spin2x the speed of sounds or a speeding bullet.
METAL
8
The now bucketed rotor is encased in a
CASTING WHICH HOLDS THE
STEAM inside the turbine. This is one turtle that is
always showing its headlooking for the generator.
10
READY, SET,
White
COLOR
ME READY,
RUNNING,
AND ABLE.
PAINT!