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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



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

4

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


4

Modular Generator Philosophy (H6X and

H8X)

H8X H6X



• 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

5



• 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



Extended Foot (double end drive)

Top line

lead exit

4 post

vertical

coolers

* Trademark of General Electric Company

6



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


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


Generator Features



9



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



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



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

12



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



owner.

H2 Generator Cooling Circuit

Once–through ventilation optimized for uniform cooling

without air gap baffling

14



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

15



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



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



18



owner.

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

Validation and Test



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



owner.

Validation Progression


Thermal cycling & endurance to simulate 1st year operation

22



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



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



25



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



27

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

© 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.

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