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GE Power and Water
November 2015
New Generator Products
©2015 General Electric Company. All Rights Reserved. This material may not be copied or
distributed in whole or in part, without prior permission of the copyright owner.
Generator User’s
Conference
Anthony Arrao
John Yagielski General Electric Company
Schenectady, NY USA
GE Restricted - Distribute to named individuals only.
Generator Product Overview
©2015 General Electric Company. All Rights Reserved. This material may not be copied or
distributed in whole or in part, without prior permission of the copyright owner.
3
©2015 General Electric Company. All Rights Reserved. This material may not be
copied or distributed in whole or in part, without prior permission of the copyright
owner.
GE Generator Portfolio
0 100 200 300 400 500 600 700
H6X H2-cooled
H8X H2-cooled
W8X Water-cooled
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
9HA.02
SS
9HA.02
SS
7HA.02
SS 9HA.02 9HA.01 7HA.02
7HA.01 7F.05
7F.0
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9F.05 9F.03 SS
9F.05 SS
H33 (7FH2)
H35 (7FH2B)
H53 (324)
H55 (330)
H73 (390H)
H75 (450h)
9F.03
Generator Output (MW)
Modular
Generator
Products
Legacy
Generator
Products
GE Restricted - Distribute to named individuals only.
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Modular Generator Philosophy (H6X and
H8X)
H8X H6X
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distributed in whole or in part, without prior permission of the copyright owner.
• 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
590 MW
550 MW
510 MW
470 MW
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©2015 General Electric Company. All Rights Reserved. This material may not be copied or
distributed in whole or in part, without prior permission of the copyright owner.
• Highly efficient
• Reduced site assembly
• Enhanced cooling capability
• Improved serviceability
• Increased reliability
Benefits Key features
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
Generator Overview
©2015 General Electric Company. All Rights Reserved. This material may not be copied or
distributed in whole or in part, without prior permission of the copyright owner.
Extended Foot (double end drive)
Top line
lead exit
4 post
vertical
coolers
* Trademark of General Electric Company
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©2015 General Electric Company. All Rights Reserved. This material may not be
copied or distributed in whole or in part, without prior permission of the copyright
owner.
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
7 ©2015 General Electric Company. All Rights Reserved. This material may not be copied or
distributed in whole or in part, without prior permission of the copyright owner.
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
Heritage and Experience – Hydrogen and Water Cooled
Experience profile
Proven technology for service reliability
GE Restricted - Distribute to named individuals only.
Generator Features
©2015 General Electric Company. All Rights Reserved. This material may not be copied or
distributed in whole or in part, without prior permission of the copyright owner.
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©2015 General Electric Company. All Rights Reserved. This material may not be
copied or distributed in whole or in part, without prior permission of the copyright
owner.
Stator Winding and Core
Leak-free, corrosion-proof stator bar
clip (H2O-only)
Reliability & availability through service proven configurations
Iron clamping
flange with
ventilated flux
shield
Silicon steel core
* Trademark of General Electric Company.
• 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
Image is for water-cooled bars – support system
same for conventionally cooled bars
End windings Connection rings
10
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copied or distributed in whole or in part, without prior permission of the copyright
owner.
• Slot support restraint accomplished by top and side ripple springs; tapered wedge
and slide
• H2O-cooled windings include molded conforming filler material
Stator Slot Support System
Provides radial and tangential restraint while allowing axial expansion
11
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copied or distributed in whole or in part, without prior permission of the copyright
owner.
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
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copied or distributed in whole or in part, without prior permission of the copyright
owner.
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
13
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copied or distributed in whole or in part, without prior permission of the copyright
owner.
H2 Generator Cooling Circuit
Once–through ventilation optimized for uniform cooling
without air gap baffling
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copied or distributed in whole or in part, without prior permission of the copyright
owner.
Packaging Ribs integrated to the bearing cap
Increased axial clearance for removal
Double tilt-pad bearing with dual insulation
Field supported
by sling with
upper and lower
half end shield
in place
Endshield engineered for robust operation &
maintainability
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copied or distributed in whole or in part, without prior permission of the copyright
owner.
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
Double-end drive Single-end drive
Integral GT
turning gear
Standardized collector design for Single & Double End
Drive
16
©2015 General Electric Company. All Rights Reserved. This material may not be
copied or distributed in whole or in part, without prior permission of the copyright
owner.
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
17 GE Proprietary Information—Class III (Confidential)
Export Controlled—U.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.
Seal Oil System
• Automated system control … eliminate need for human intervention
• Digital bus communications … added system diagnostics and controls
• Continuous real time monitoring
©2015 General Electric Company. All Rights Reserved. This material may not be copied or
distributed in whole or in part, without prior permission of the copyright owner.
18
©2015 General Electric Company. All Rights Reserved. This material may not be
copied or distributed in whole or in part, without prior permission of the copyright
owner.
Stator Cooling System
©2015 General Electric Company. All Rights Reserved. This material may not be copied or
distributed in whole or in part, without prior permission of the copyright owner.
• 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
* Trademark of General Electric Company
Modernized with on-line maintenance & monitoring
Operability for combined-cycle operation
Validation and Test
©2015 General Electric Company. All Rights Reserved. This material may not be copied or
distributed in whole or in part, without prior permission of the copyright owner.
20 GE Title or job number
11/18/2015
Validation
Automated
retaining ring
assembly
Generator armature
development lab
Generator endurance test
stand
Connection
ring insertion
fixture
2007-
2009 Non-metallic and materials labs
• Insulation systems development
Generator armature development lab
• Bar force limits
• Slot component testing
2010
Repair technology COE and MFG tooling
• Field rewind process automation … full-scale
validation
• New repair center
• 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
validation
GE has invested $22.5MM into labs and test facility
Multi-year investment in validation capability for new products
21
©2015 General Electric Company. All Rights Reserved. This material may not be
copied or distributed in whole or in part, without prior permission of the copyright
owner.
Validation Progression
* Trademark of General Electric Company
Thermal cycling & endurance to simulate 1st year operation
22
©2015 General Electric Company. All Rights Reserved. This material may not be
copied or distributed in whole or in part, without prior permission of the copyright
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
23
©2015 General Electric Company. All Rights Reserved. This material may not be
copied or distributed in whole or in part, without prior permission of the copyright
owner.
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
On-Line Monitoring
©2015 General Electric Company. All Rights Reserved. This material may not be copied or
distributed in whole or in part, without prior permission of the copyright owner.
25
©2015 General Electric Company. All Rights Reserved. This material may not be
copied or distributed in whole or in part, without prior permission of the copyright
owner.
Monitoring and Diagnostics – Available modules
Generator Health Monitor (GHM)
(knowledge based analysis of data)
Enhanced Partial
Discharge Analysis
Auto Shorted Turn
Analysis
Stator Leak Monitoring
System – High
Performance
(H20 only)
Flow Circuit Analysis
(H2O only)
Advanced Monitoring
Systems
End winding
Vibration Monitor
Collector Health
Monitor
Summary
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distributed in whole or in part, without prior permission of the copyright owner.
27
Summary
©2015 General Electric Company. All Rights Reserved. This material may not be copied or
distributed in whole or in part, without prior permission of the copyright owner.
• 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
© 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
written consent of GE, including, but without limitation, in the creation,
manufacture, development, or derivation of any repairs, modifications, spare
parts, or configuration changes or to obtain government or regulatory approval
to do so, if consent is given for reproduction in whole or in part, this notice and
the notice set forth on each page of this document shall appear in any such
reproduction in whole or in part. The information contained in this document
may also be controlled by the US export control laws. Unauthorized export or
re-export is prohibited.
GE Power and Water
All relative statements are with respect to GE technology unless otherwise noted.