GEFL3688B

GE Power Generation
GE Generators - An Overview
James J. Gibney, III
GE industrial & Power Systems
Schenectady, NY
GER-3688B
GE GENERATORS - AN OVERVIEW
J. J. Gibney, III
GE Industrial & Power Systems
Schenectady, NY
INTRODUCTION
The history of GEs design, manufacture and
development of electric generators has been a
long and varied one. Since the early 1900s more
than 10,000 GE generators have been shipped
and placed in service at utility companies and
industrial plants, and as ship service units. The
designs have evolved from slow-speed vertical-
shaft units to high-speed horizontal shaft air-
cooled units, through indirect hydrogencooled
units to direct water-cooled units.
During the 1950s through the mid-1970s much
emphasis was placed on developing units to sup
port the rapid growth in unit ratings, which
increased from 100 MW to more than 1100 MW.
It was during this time frame that such innovative
design features as direct water-cooled armature
windings, gap-pickup rotor winding cooling,
Micapal II TM stator insulation, Class F rotor and
stator insulation, advanced TetralocTM stator end-
winding support systems, and the side ripple-
spring armature bar slot support structure were
developed.
In the early 1960s packaged gas-turbinedriven
generators were introduced. These applications
were characterized by the ambient-temperature-
following nature of the gas turbine output and the
ability of the gas turbine to provide peaking capa-
bility for short periods. Generator designs were
developed which were tailored to gas turbine
applications. As new gas turbines were intro-
duced, or as older designs were uprated, genera-
tor designs were introduced to match the new gas
turbine ratings.
Over the course of the past decade, the empha-
sis in new electric power generation installations
has swung away from large units delivering major
blocks of power to smaller units operated not only
by utilities, but by cogenerators or other smaller
independent power production companies. In
response to this change, GE is placing a major
emphasis on the design and development of gen-
erators suited to these applications.
Excluding marine service applications, GE cur-
rently has more than 6400 generators in service
(Figure 1) . These generators can be placed in three
major design classifications based on the cooling
medium used: air, hydrogen and liquid cooled. This
NUMBER OF UNITS IN SERVICE -
BY COOLING TYPE
Air Cooled
Liquid Hydrogen Open
Cooled Cooled Ventilated TEWAC Total
___ ~
Steam
rurbine-Driven 520 3,006 2 1,164 4,712
Gas
Turbine-Driven 1 214 1,340 151 1,706
Totals 521 3,220 1,342 1,335 6,416
Figure 1. GE generator experience
paper will give an overview of each of these basic
design classifications.
DESIGN CONSIDERATIONS
The design of synchronous generators is an
optimization process. A generator design engi-
neers challenge is to develop a final design that,
as best as is practical, optimizes the overall size,
efficiency, performance capabilities and electrical
parameters, while maintaining mechanical, ther-
mal and magnetic limits. In addition, the designer
must be aware of the need to minimize the overall
cost impact of the design.
The development of modern analytical calcu-
lation methods, including finiteelement analysis,
supplemented with the use of improved materi-
als, building upon component testing, has aided
the generator designer in the pursuit of an opti-
mal design.
AIR-COOLED GENERATORS
Air-cooled generators are produced in two
basic configurations: open ventilated (OV) and
totallyenclosed water-to-air-cooled (TEWAC) . In
the OV design, outside air is drawn directly from
outside the unit through filters, passes through
the generator and is discharged outside the gener-
ator. In the TEWAC design, air is circulated within
the generator passing through frame-mounted
air-to-water heat exchangers.
The recent emphasis in the marketplace on
steam and gas turbinegenerators in the 20- to lOO-
MVA size has provided GE with the impetus to
GER-3688B
restructure its aircooled machines. A consequence
of the historical development of the turbinegener-
ator market was that two lines of generators
evolved, one for steam turbine applications and the
other for gas turbine applications, with little stan-
dardization between the designs. As GE embarked
on this design restructuring, it took the opportunity
to look at other issues which GE judged were criti-
cal to its ability to maintain leadership in the design
and manufacture of this size generator. Among
these issues were performance parameters, avail-
ability of features, cycle time and cost effectiveness.
MARKET NEEDS
The basic design of a generator, while influ-
enced primarily by material and electromagnetic
properties, is also impacted by market require-
ments. Hence, customer discussions as well as
recent market trends are used in the development
of a final generator design. Some of these include:
winding temperature rise, industry standards, gen-
erator ratings, etc.
TEMPERATURE RISES
In the early 1970s GE introduced insulation sys-
tems capable of operating at class F temperatures
(155 C, 311 F) for the life of the generator. This
enabled a significant uprating of generator designs
(about 10%) with a minimal increase in cost. To
capitalize on this technical capability, GE designed
generators with Class F insulation and Class F rises.
Many such generators built by GE are in service
and operating successfully at Class F temperatures.
However, the trend in recent specifications has
been toward Class F insulation systems operating at
Class B temperatures. In order to be responsive to
these requirements, the new designs will operate at
Class B temperatures according to ANSI and IEC
standards.
GENERATOR RATINGS
In a rapidly developing technology, such as that
of the combustion turbine, it is inevitable that the
output of a given gas turbine frame size will be
increased from time to time. This has required
redesign of the generator to keep pace with the
rise in turbine output. The ratings of the genera-
tors designed to match the gas turbine frame sizes
have been set so that the generator will meet or
exceed the gas turbine capability over the full
operating temperature range, taking into account
the expected turbine upratings duriiig the life-
time of the design.
Another important consideratioil that affects
the generator rating which must be taken into
account is the use of steam and water injection for
NO, control. The output of the gas turbine can
increase by 5% or more above its dry IS0 rating,
depending on the level of steam or water injection
required to meet the emission requirements. An
approach that results in the generator having suf-
ficient capacity to match the gas turbine at the
required NO, requirements has been factored
into the generator rating.
STANDARDS
All new designs will meet the requirements of
the applicable ANSI and IEC standards, as did the
older designs.
RELIABILITY
Particular attention has been paid to known
problem areas based on inservice generator experi-
ence. The new designs strive for a high level of relia-
bility and availability through attention to detail
design and to the problems that have caused down-
time on older designs. In addition, the reliability of
the product will improve through design simplifica-
tion and standardization, discussed below.
PRODUCT
STANDARDIZATION
Standardization of the product line has signifi-
cant benefits both to the user and to the manufac-
turer. From the users viewpoint, the standardiza-
tion of the product line translates into a simpler
machine with fewer unique parts, easier spare
parts access and the reliability benefit of a larger
fleet of identical machines, with the rapid identifi-
cation of any performance problems that this
brings. The benefits to the manufacturer are that,
with fewer unique parts to track and check, fewer
different assemblies to build and fewer drawings
to keep up to date, the job of building a highqual-
ity machine becomes simpler.
Standardization is being implemented at three
levels. At the highest level, the number of differ-
ent designs can be reduced by careful selection of
generator ratings and the use of common designs
for gas and steam turbines. At the time the
redesign project was begun, there were 17 unique
air-cooled generator designs between 12 MVA and
100 MVA. With careful choice this has been
reduced to six basic electromagnetic designs.
The second level of standardization is illustrat-
ed in Figure 2. This shows the high level of stan-
dardization achieved in covering the basic config-
urations of the generator for the Frame 6 gas
turbine (designated 6A3), 50 Hz or 60 Hz, open
2
GER-3688B
Design Option Design Option
6A3 6A3
6OHz 5oHz 6OHZ 6OHZ
Generator Component Generator Component
TEWAC TEWAC ov ov TEWAC TEWAC ov ov
BSBSBSBS BSBSBSBS
Frame.. Frame.. ............................................... ............................................... . . .. .. . , . ,
Core.. Core.. ............................................... ............................................... . . . . .. .. . . . . . . . .
Base Base ................................................. ................................................. . . . . . . . . ll . . ll
Slator Bar 50 Hz.. Slator Bar 50 Hz.. ............................... ............................... . . . .
Stator Bar 60 Hz Stator Bar 60 Hz ............................... ............................... ll . . t f t f
Brushless Exe Brushless Exe .................................... .................................... * * . .
Static Ext.. Static Ext.. ........................................ ........................................ * * 1 1 . .
ov ov Roof.. Roof.. .......................................... .......................................... t t * l * l
TRNAC Roof.. TRNAC Roof.. ...................................... ......................................
Rotor Forging.. Rotor Forging.. .................................. .................................. - - ... ... . . . . ll
Rotor Copper Rotor Copper ................................... ................................... ll . . ll ..... .....
Rotor Edg. 60 Hz Rotor Edg. 60 Hz ............................. ............................. . . ll .. ..
Rotor Wdg. Rotor Wdg. 60 60 Hz.. Hz.. ............................. ............................. , , . .
Rotor Slot Width Rotor Slot Width ............................... ............................... . . . . . . .... ....
Rotor Slot Depth 50 Hz Rotor Slot Depth 50 Hz .................... .................... t t t t ll . .
Rotor Slot Depth 60 Hz Rotor Slot Depth 60 Hz .................... .................... l * t l * t . .
* .%me Canp~nent Applied to Deoign Option
B - Brushless Excitation
S - Static Excitation
Figure 2. Generator standardization
GT164SOA
ventilated (OV) or totally enclosed (TEWAC) , and
brushless or static excitation. For example, the sta-
tor frame, core and base, and the rotor forging
and rotor copper cross section are identical for
any combination of these features. The only dif-
ference between the 50-Hz stator and the 60-Hz
stator is the different stator bar. Everything else is
the same. This component standardization can be
extended to other ratings when the same compo
nent is used for two different machines. For exam-
ple, the generator base is the same for the Frame
5 generator as it is for the Frame 6 generator. In
addition, while the gas turbines are the primary
application of the new air-cooled generators, they
can and have been applied with steam turbine
drives as well (Figure 3).
The most detailed level of standardization is
with hardware such as fasteners and small compo
nents. A carefully constructed list of preferred
hardware has been developed and the number of
different nuts, bolts and similar items has been
drastically reduced.
The impact of standardization is illustrated in
Figure 4, which shows the reduction in the num-
ber of parts and drawings required to build a sin-
I-
REL. # OF
PARTS
REL. # OF
DRAWINGS
,
OLD DESIGN NEW DESIGN
1.0 0.6
1.0 0.7
GT19263 GT1649
Figure 3. Air-cooled steam turbine generator
Figure 4. Impact of standardization
3
GER-3688B
gle new design as compared to its predecessor.
When these gains are compounded by the
reduced number of unique designs, there is a pro
found effect on the productivity and quality of the
manufacturing operation.
One of the potential adverse effects of stan-
dardization can be a loss of flexibility to meet an
individual customers needs. This has been
addressed first by building into the design those
features that are frequently specified. An example
is the use of stainless steel oil feed piping. This fea-
ture is not requested by every customer, but it is
asked for often enough such that it is easier to
build every unit with the stainless steel piping. The
second way in which individual needs have been
met is through standard options. These are pre-
engineered options commonly requested for
which drawings have been prepared ahead of
time.
These options can be readily incorporated in
the machine, within normal material procure-
ment and manufacturing cycles. An additional
group of options is available that have not been
pre-engineered due to the low frequency of
request. These are available but with longer lead
times since the necessary engineering work must
be accommodated.
DESIGN AND
CONSTRUCTION FEATURES
The design teams involved were organized with
representation from all the major business func-
tions, and members of the design teams visited
some representative customers to better under-
stand user needs. In this way, the technical
requirements of the designs were influenced by
the needs of all the functions involved in the
design, manufacture, marketing and maintenance
of the generator. Features were incorporated into
the design specifically to aid producibility. Visits to
and discussions with potential vendors influenced
the design of components both for improved per-
formance and to suit vendors capabilities. Careful
cost comparisons were made of alternative design
approaches to ensure that the final configuration
was cost effective.
ELECTROMAGNETIC DESIGN
To achieve the reliability objectives of the pro
ject, no new electromagnetic design limits have
been used. The designs are based on proven tech-
nology used in generators already in service.
Where appropriate, the technology used in larger
units has been drawn upon to improve the
designs of these machines. In reaching the final
configuration, a large range of design alternates
was considered, and the final choice of design
reflects the optimization of the types of considera-
tion described herein.
STATOR DESIGN
The stator frame is divided onto an inner and an
outer section, both of which mount on a single
base fabrication. The inrrer frame is a very simple
structure designed to support the stator core and
winding while providing some guidance to the air
flow in the machine. The stator core, made from
grainoriented silicon steel for low loss and high
permeability, is mounted rigidly in the inrrer frame.
Isolation of the core vibration from the remainder
of the structure is accomplished through the use of
flexible pads between the feet on the inner frame
and the base structure. The combined core and
inner frame are designed to have a four-nodal natu-
ral frequency well removed from 100 Hz or 120 Hz,
and tests on the assembled inner frame confirmed
the predicted natural frequencies.
The outer frame is a simple fabricated enclo-
sure, which supports either the air inlets and
silencers if the unit is open ventilated (Figure 5)
or the roof and cooler enclosure if the unit is
totally enclosed, water-to-air-cooled. The outer
frame further acts as an air guide to complete the
ventilation paths and as a soundproof enclosure
to keep noise levels low. Since the rotor is pedestal
mounted, the end shields are very simple struc-
tures. As with the inner frame, the outer frame
was designed to be free of resonances below 80
Hz, and again, tests of the completed structure
confirmed the design analysis.
The entire generator is mounted on a single
fabricated base, which supports the pedestals, the
inrrer and outer frames, and the brush rigging or
the exciter. The base contains piping for oil sup
plies, conduit for wiring and a number of compo
nents associated with the main leads, such as light-
ning arresters and surge capacitors. The structural
vibration of the base was also confirmed by test to
be well away from any frequency of concern.
The stator winding is a conventional lapwound
design. The insulating materials are those used
since the early 1930s thus maintaining the proven
reliability record. The materials are all designed
and tested to provide reliable performance at
Class F temperatures for the life of the machine.
The stator bar copper is stranded and insulated
with Class F materials and is Roebelled for mini-
mum losses. The ground wall insulation is Micapal
HT, a proven Class F system (Reference 1). This is
a resin-rich tape system, with the volatiles removed
under vacuum, which is then cured under pres-
4
GER-3688B
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GENERAlOR CGMPIRTYEN,
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Figure 5. Generator packaging
GT18560
FILLER BETWEEN
CROSSOVERS
VERTICAL
SEPARATOR
GLASS TAPE
-E
ARMOR
I
TOP RIPPLE j
SPRING
f
FILLER/ J
/ INSULATED TOUGH PITCH
COPPER WIRE WITH
ROEBEL TRANSPOSITION
EPOXY IMPREGNATED MICA
A TAPE GROUND WALL
\RTD OR
FILLER
SIDE RIPPLE
SPRING
\
WEDGE
STATOR SLOT ASSEMBLY
Figure 6. Stator slot section
GT18494A-1
GER-3688B
! - STATOR
i
FLANGE
r BINDING
/ BAND
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;I SUPPORT
STAT01
KEYBA.. \
STATOR
PUNCHINGS--,
\
VENTILATION -
DUCT
. . . . .
BETWEEN BAR
FILLER
_---- \
-- \
- GLASS
\
ROVING
?
TIES
WFDCXS
.------
\ \ M&END
\
BLOCK
BINDING
(FINGER) RAND
TION
GTlW!SA
Figure 7. Stator end winding section
sure to a solid, void-free structure. The exterior of
the bar is taped with a conducting armor in the
slot section, and a semi-conducting grading sys-
tem is applied to the end arms. In this way the bar
is fully protected from the effects of high electri-
cal voltage gradients.
The bars are secured in the slots (Figure 6)
with fillers and top-ripple springs to restrain the
bars radially, and with side-ripple springs to
increase friction between the bar and the slot wall.
The side-ripple springs are also conducting to
ensure proper grounding of the bar surface.
The end winding support system is the proven
approach used on conventionally-cooled stators of
all sizes built by GE. This system utilizes resin-
impregnated glass roving ties (Figure 7).
One design improvement made in response to
problems experienced on some designs manufac-
tured in the late 1970s is in the manner in which
the series connection between top and bottom
bars is made. Until recently, this was accomplished
by brazing individual strands together and then
solidifying the package with an epoxy. The
improved system is to braze all the strands togeth-
er in a solid block and then to braze top and bot-
tom bars together with solid copper plates. This
provides a solid electrical connection and a
6
rugged mechanical joint.
The complete end winding structure has been
vibration tested to ensure freedom from critical
resonances, and vibration levels measured during
running tests were found to be low.
ROTOR DESIGN
The rotor (Figure 8) is a simple single-piece
forging, pedestal mounted, with tilting-pad bear-
ings for smooth operation. On smaller units, the
rotor is sufficiently short that the second critical
speed is above running speed, thus simplifying
balance. The retaining ring is nonmagnetic 18 Cr
18 Mn stainless steel for low losses and good stress-
corrosion resistance. The rings are shrunk onto
the rotor body, thus eliminating any risk of top
turn breakage. The retaining ring is secured to
the rotor body with a snap ring, a design which
minimizes the stresses in the tip of the retaining
ring.
Radial-flow fans are mounted on the centering
ring at each end of the rotor. The fan is a high-
efficiency design, and when tested prior to use in
the generator proved to have satisfactory margins
compared to the design requirements. The fans
provide cooling air for the stator winding and
Fan
Ring
Fan
GTlWX
Figure 8. Generator field
/
:YIR OUTLE
1
1
1
s,,k%ls~
AIR FILTER
s
1
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I
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INLET
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I
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GENERmJR
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A,R INLET
tie --....
t .--
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-- -- ..--
BEARING
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DRIVE
-_, ;;ib- l-y;dA 7;:
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TR;:;aEFls ^:;g$g=
GT18561
Figure 9. Generator cross section and ventilation paths
core. The rotor winding, which is a directlycooled
radial flow design, is self-pumping and does not
rely on the fan for air flow. The overall ventilation
pattern is shown in Figure 9.
The rotor winding fits in a rectangular slot
(Figure 10) and is retained by a full-length wedge
on the shorter machines. Where cross slots are
required on longer rotors, several wedges are used
in each slot. The rotor slot insulation, turn insula-
tion and other materials in contact with the wind-
ing are full Class F materials and have proven reli-
ability through use on other generator designs.
7
GER-3688B
COll Wedge
creepage BlWk
Field COll
Turn lSlatlOn
slot Armor
- Sub sot
Channel
GI1lU!M
Figure 10. Section through coil slot
PACKAGING DESIGN
The objective in the packaging design has been
to reduce the number of sections (Figure 5) to
simplify the structure and to improve the piping
and wiring design for fewest parts and ease of
assembly. The lesser number of package sections
leads to a stronger structure, but, more important-
ly, results in fewer feet of joint through which
unfiltered air can leak, thus aiding cleanliness in
the generator. Depending on the design, a num-
ber of components have been relocated from the
auxiliary cubicle into the base, simplifjring the
design of the auxiliary cubicle. Components in the
base are low-maintenance items, and are accessible
through covers in the collector compartment.
A great deal of attention has been paid to cus-
tomer requirements in this area, as the prefer-
ences of individual users frequently require pack-
aging changes. Ease of addition or removal of
features and hardware is critical to meeting these
needs within the normal cycle times.
TESTING
Extensive prototype testing of each of the new
designs, both in the factory and under load at a
customers site, has proven that the designs meet
Electrical Testing
l Excitation Requirements
l Short Circuit Ratio
l Temperatures
Mechanical Testing
l Rotor Vibration
l Stator Frame Vibration
l Noise
l Stator Winding Vibration
l Ventilation
GT22940
Figure 11. Factory and load test objectives
Journal Probe
Location
and Orientation
Turbine End Horizontal
Turbine End Vertical
Collector End Horizontal
Collector End Vertical
Measured Vibration
Mils Peak-to-Peak (MM)
Broadband Filtered - l/Rev
0.90 (.023) 0.37 (.009)
1.00 (.025) 0.46 (.012)
0.60 (.013) 0.19 (.005)
0.50 (.013) 0.23 (.006)
Figure 12.6A3 journal vibration maximum val-
ues observed for all speed and operat-
ing conditions
all the expected performance requirements
throughout the load range. Some of the key test
objectives are listed in Figure 11.
Loss measurements confirmed the prediction
of generator efficiency at the generator rated out-
put, and heat runs both in the factory and under
load confirmed that the generator would meet
both NASI and IEC standards for Class B tempera-
ture rise.
At the design stage, a great deal of attention
was focused on achieving a smooth running rotor.
Figure 12 shows the levels measured on a 6A3 at
the site. These levels are significantly lower than
those required by API, and also are much lower
than those in a recently issued draft international
standard (7919/3). The API requirements for sep
aration margins of rotor lateral critical speeds
from operating speeds were also fully met.
A noise survey was conducted during startup of
the first 6A3, using the sound intensity method
which compensates for ambient noise effects. The
average generator near-field sound pressure was
determined from the measurements to be 85.7
dBA, which is very satisfactory, and compares
favorably with the design target of 85 dBA.
CURRENT STATUS
Three new machines have been designed to
match the GE Frame 5,6 and 7 gas turbines. More
than 130 generators of these new designs have
been shipped through the end of 1992, with
approximately one-half in service.
The air-cooled generator product line is contin-
uing to evolve. The generator that is being
applied with the LM6000 aeroderivative gas tur-
bine (Figure 13) was tested and shipped in 1992.
Its basic configuration is open ventilated (with a
TEWAC option), brushless exciter, pedestal-
mounted bearings, on a single-lift base, rated 60
GER-3688B
Figure 13. LM6000
RDC26475-2 GO2A-00.044
Figure 15. Hydrogen-cooled generator
FluId
Relative
Spectfic
HEat
Relative
Denstty
Relative
Practical
Vol Flow
Approx.
Rel Heat
Removal
Abihty
1 1.0 1 1.0 1 10 I 1.0 )
Hydrogen 30 pslg
(2.07 bar) 14.36 0.21 10 3.0
Hydrogen 45 psig
(3.10 bar) 14.36 0.26 IO 4.0
Water 4.16 1000.0 0 012 50.0
GT21022A
Figure 14. Air, hydrogen, water heat removal
comparison
MVA at 0.8 pf. In 1993, a 160 MVA, 50-Hz air-
cooled generator, to be used primarily with the
frame 9E gas turbine, will be tested as well.
HYDROGEN-COOLED
GENERATORS
As the rating of steam turbines rose in the
1930-1950 time frame, it became clear that in
order to keep the size, weight, ability to ship and
cost of a generator within reason, a more optimal
cooling medium needed to be used. Hence the
introduction of hydrogen.
How well the armature winding of a generator
is cooled has a significant influence on the overall
size of a synchronous generator. The cooling of
the armature winding is dependent on a number
of factors: cooling medium (air, hydrogen, water) ;
insulation thickness; and overall electrical losses
(12R + load loss). As Figure 14 shows, relative heat
removal capability improves from air to hydrogen,
with increased hydrogen pressure, and even more
significant with the use of water cooling.
Conventional hydrogen cooling can be utilized on
generators rated approximately 300 MVA and
Figure 16.7F generator
RDC26126.21-3
below, while direct water cooling of armature
windings is applied to units above 250 MVA. This
division results from design optimization. While it
is possible to apply water cooling on machines
rated below 250 MVA, the cost/performance ben-
efit suffers. Water cooling adds manufacturing
complexity, as well as requires the need for an
auxiliary water cooling and deionizing skid, plus
associated piping, control and protection features.
At higher ratings, the cost of this complexity is off-
set by the advantage of producing a generator of
significantly smaller size than a comparable con-
ventionallycooled generator.
Hydrogen-cooled generator construction
(Figure 15)) except for the frame, is very similar
to that of air-cooled generators. The stator slot
and end winding support designs are essentially
like those shown in Figures 6 and 7. Most designs
use direct radial flow cooling similar to that
shown in Figure 10. The stator frame, on the
other hand, because of the need to contain 30
psig (2.07 bar) to 45 psig (3.10 bar) hydrogen,
uses thick plate cylindrical construction. End
shields are appropriately more rugged, and con-
tain a hydrogen seal system to minimize leakage.
Conventional hydrogen cooling, while available
9
GER-3688B
-
/
G02A-00-043
Figure 17. Water-cooled generator F
POP35782
@we 19. Water-cooled stator winding
arrangement
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systarri
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ioao Cycrlng
f-1 hom?ai Expanslan)
Normar
Fiunnmg
FBC%S
1 -
i
L-. ---L ..-.--.-L-.-L-
7 102 d 4 1010 302
Total ~*~~~ of Cycles
w a .3t?-bar 4ime Span
GO4A-00-019
Figure 18. Hollow copper strand construction
GT21019
Figure 20. Cyclic duty on stator winding in
30 years
for generators rated below 100 MVA, is most
often applied to steam-turbinedriven units above
100 MVA, as well as with the frame 9 and 7F
(Figure 16) and frame 7FA and 9F gas turbines.
HYDROGEN/WATER-COOLED
GENERATORS
Even more compact generator designs are
achievable through the use of direct water cooling
of the generator armature winding (Figure 17).
These designs employ hollow copper strands
(Figure 18) through which deionized water flows.
The cooling water is supplied via a closed-loop
auxiliary-base-mounted skid. The cool water
enters the winding through a distribution header
on the connection end of the generator and the
warm water is discharged in a similar manrrer on
the turbine end of the generator (Figure 19).
The armature voltage and current of hydro-
gen/watercooled generators are significantly high-
er than those of air- or hydrogencooled units. As a
result, the insulation voltage stress and forces on
the armature windings can be several orders of
magnitude larger than those experienced on lower-
rated units. These present unique design require-
ments must be addressed if high reliability and
long life of the equipment is to be maintained.
Insulation
The stator insulation material used in modern
GE water-cooled generators consists of an epoxy-
mica-based system called Micapal. Micapal I was
introduced in 1954, partially as a solution to tape
migration and girth cracking problems associated
with the then almost universally applied asphalt-
insulation-based system.
In 1975, an improved epoxy-mica system was
introduced (Micapal II). This all-mica paper insu-
lation has improved mechanical toughness (15%)
and voltage endurance (12%). While these prop
erties were developed to meet the requirements
of very large ratings, the application of Micapal II
on small and midsize units permits further opti-
mization opportunities. Micapal II has excellent
thermal cycling capability, and is particularly suit-
ed for the daily start/stop duty required of many
units today.
10
GER-3688B
GT17109
Figure 2 1. Armature bar restraint in stator slot
Forces on Stator Winding-s
There are two sources of force on the stator
windings: high-level, short-duration transient
forces due to system or misoperation faults, as well
as those that result from normal load currents
and load cycling.
Figure 20 charts frequency of occurrence against
relative magnitude for these forces. Each type of
force requires careful consideration during the
design process. High-level fault currents can cause
very high forces, which will cause major winding
damage if not suitably restrained. Load cycling, and
the thermal expansion which accompanies it, is a
daily event that causes expansion and contraction
of the entire windings. If components are not suit-
ably designed, or if windings are unduly restrained
in the axial direction, lowcycle fatigue damage may
occur. Finally, the electromagnetic forces at twice
system frequency due to normal load currents may
cause fretting or highcycle fatigue of components,
particularly if a component has a mechanical reso
GT17110
Figure 22. Stator and winding support cross
section
11
nance close to double frequency.
These forces require the design engineer to
closely examine the detail design of the endwind-
ing and stator slot sections.
Stator Slot Support System
The key elements of the stator-slot support
system design (Figure 21) are:
Careful assembly of the stator core to ensure
a uniform slot dimension and avoid high
areas.
Use of side ripple springs full length along
each bar to ground the bar armor to the slot
and provide permanent friction damping
against tangential and radial motion.
A top-of-slot, radial force wedge designed to
securely hold the armature bars down to the
bottom of the slot, preventing potential
destructive bar motion.
Freedom for axial movement to accommodate
thermal expansion without component stress.
Endwinding Support Structure
Because the endwindings are suspended
beyond the core, shortcircuit or faulty synchroniz-
ing current forces are much more difficult to
restrain than those in the stator slots. In addition,
the structure itself has many more degrees of free-
dom complicating the process of avoiding detri-
mental resonant frequencies. As with the stator slot
support system, the endwinding support system for
a watercooled armature design is more complex
than that for a conventionally-cooled winding.
However, each of the support systems evolved from
the same heritage, and both have provided
extremely reliable service since their introduction.
The advanced TetralocTM endwinding support
system (Figure 22) is used on all water-cooled
designs and features:
l A support basket consisting of axial supports,
supported from the stator flange, and contin-
uous circumferential epoxy fiberglass rings.
l Glass filament ties to secure the armature
bars to the fiberglass rings.
l Conformable, resin-impregnated, between-
bar blocking to maintain bar spacing and
provide mechanical support.
Rotor Electrical Design
The generator rotor contains the field windings
that produce the magnetic flux, which, in turn,
produces the stator current and voltage. Proper
cooling of the field winding is another challenge
GER-3688B
Creepage
Block
Copper
Wmdmg
Gas Flow
GT21018
Figure 23. Slot section of generator rotor wind-
ing with radial-flow direct cooling
that the generator designer must overcome.
All hydrogen/water-cooled generators use
direct conductor cooling of the rotor winding for
heat removal. Smaller two-pole and all four-pole
generators use the radial-flow design (Figure 23).
At the end of the rotor body, hydrogen enters the
windings through full-length subslots and is dis-
charged along the length of the rotor body
through radial slots, machined or punched, in the
copper conductors. The hydrogen passes from
the conductors through the creepage blocks and
wedges to the air gap, where it is directed
through the stator core to the hydrogen coolers.
As generator ratings, and consequently rotor
body length, increase even further, the gappickup
diagonal-flow cooling method is employed
(Figure 24). In this scheme, cold hydrogen is
scooped up in the gas gap and driven diagonally
through the rotor copper to directly remove the
heat. At the bottom of the slot, the gas is turned
and passes diagonally outward to the gas gap in a
discharge stator core section. The stator core ven-
tilation is coordinated with the rotor-cooling gas
flow, thus creating an in-and-out flow of hydrogen
through the stator core, through the rotor, and
returning to the hydrogen cooler through the
core. This cooling method produces a tempera-
ture profile, as shown in Figure 25, and results in a
design which maintains the same average copper
temperature, independent of rotor length.
Rotor Mechanical Design
There are significant challenges to be faced in
producing an optimal generator rotor mechanical
design. The following describes some of those
challenges and features that have been incorpo-
rated to meet those challenges.
Retaining Rings
The generator retaining rings, which support
the rotor winding end turns against centrifugal
force, are the most highly stressed components of
the generator. On most designs they are shrunk on
to the end of the generator body, as shown in
Figure 26. Locking of the retaining ring to the gen-
erator body is required to ensure the ring is not
pushed off its fit surface due to the axial force gen-
erated by thermal expansion of the field winding.
Important design requirements of retaining
rings are that they be tolerant to high stress levels,
possess adequate low-cycle fatigue capability and
have acceptable separating speeds. Therefore, a
design is required where careful attention is paid
to minimize stress concentrations. Large shrink-fit
interferences are required to prevent separation
under overspeed conditions, which result in rela-
tively high stress levels at standstill. In most cases,
INSULATING
CREEPAGE BLOCK INLET WEDGE
I
WARM GAS r OUTLET WEDGE
OUT 8, COOL GAS IN
\
INSULATING CREEPAGE STRIP
D COPPER CHANNEL
SUB-DIVIDED
FIELD CONDUCTOR
\
- SLOT INSULATION
\
. TURN INSULATION
GT17110A
Figure 24. Air gap-pickup diagonal-flow rotor cooling scheme
12
)A c-,..(.*rln~
CI I I lC,l
Temperature Rise From Bottom
OF OC
140 60
/ A
II \I
122 50
/ -
-
Copper Temperature
A
104
t
40
I
T
) Gas Temperature Rise
,INi kt-ti
Rotor
Baftle
GEK3688B
I
GTZlOZOA
Figure 25. Diagonal-flow cooling field winding temperature profile
Figm-e 26. Arrangement of locking key and
shrink fit
the ring material must be nonmagnetic to mini-
mize the end leakage flux and reduce heating of
the core end structure.
For many years, nonmagnetic retaining rings
have been made from an 18Mn-5Cr steel alloy.
However, it was not until the mid-1970s that the
susceptibility of 185 retaining rings to stress-corro
sion cracking became known. As a result of coop-
erative programs with retaining ring suppliers, a
different alloy, 18Mn-18Cr (originally proposed by
GE), was selected as a better retaining ring materi-
al. This material has the required properties,
including high resistance to stress-corrosion crack-
ing in the types of environments of which rings
may be exposed during the service life of the gen-
erator. GE now supplies 18-l 8 retaining rings on
its generators.
Rotor Balance
One of the most critical rotor manufacturing
requirements, after all the parts are accurately
machined and carefully assembled, is the final bal-
ance operation. This ensures that the rotor vibra-
tion will be within acceptable limits and that the
rotor remains straight within very close tolerances
at all running speeds up to and including the
maximum specified overspeed.
The design work initially includes the accurate
calculation of all shaft stiffness and critical speeds. To
correct for the double frequency vibrations which
would otherwise occur, cross slots of appropriate
depth and number are specified in the pole centers
of most twopole rotors to equalize the bending stiff-
ness between the direct and quadrature axes.
Provisions are incorporated for making balance
weight corrections. Each GE hydrogencooled gen-
erator field is supported in its own pair of bearings.
Balancing and overspeed testing are per-
formed in GEs factory balance facility. A high-
speed multiplane modal balancing procedure is
used. This procedure is done to ensure minimum
vibration levels at every speed up to the maxi-
mum specified overspeed.
CONCLUSION
While this paper has focused mainly on the
flange-to-flange generator, the successful opera-
tion of a steam or gas turbine generator involves
other systems as well. Discussion of excitation,
lube oil, hydrogen and stator cooling water sys-
tems, as well as generator protection and opera-
tion, can be found in other GE publications.
13
GER-3688B
The design of modern generators, whether
they are air, hydrogen or hydrogen/water-cooled,
requires a blend of time-proven, as well as innova-
tive, design concepts. This successful integration
of time-proven concepts with modern technology
produces generators that can be expected to pro
vide efficient, trouble-free service through years of
baseload or cycling operation.
REFERENCE
1. Galpern, H.N. and Vogt, G.H.,A New Class F
Armature Insulation System for Turbine
Generators, presented at the 13th Electrical /
Electronics Conference, September 2529, 1977.
IEEE Publication Number 77CH12732-FL.
0 1994 GE Company
14