New Generator Products

Transcription

1 GE Power and Water New Generator Products Generator User s Conference Anthony Arrao John Yagielski General Electric Company Schenectady, NY USA November 2015 copied or distributed in whole or in part, without prior permission of the copyright

2 Generator Product Overview copied or distributed GE in whole Restricted or in part, - Distribute without prior to named permission individuals of the copyright only.

3 GE Generator Portfolio H33 (7FH2) H35 (7FH2B) H53 (324) H55 (330) H73 (390H) H75 (450h) Legacy Generator Products Modular Generator Products W8X Water-cooled H8X H2-cooled H6X H2-cooled 7F.0 4 9F.03 9F.05 SS 9F.05 9F.03 SS 7HA.01 7F.05 7HA.02 9HA Hz 60 Hz 7HA.02 9HA.02 SS 50 Hz 9HA.02 SS 60 Hz 9HA.02 SS 60 Hz 50 Hz Generator Output (MW) copied or distributed in whole or in part, without prior permission of the copyright 3

4 Modular Generator Philosophy H8X) (H6X and 470 MW 510 MW 550 MW H6X 6 leads up or 6 leads down GTE for Leads-up 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 H8X 3 leads up / 3 leads down Unit-mounted GNTE only 4 copied or distributed GE in Restricted whole or in - part, Distribute without to prior named permission individuals of the copyright only.

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

6 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 copied or distributed in whole or in part, without prior permission of the copyright 6

7 Heritage and Experience Hydrogen and Water Cooled Experience profile Units shipped Operating hours GE water-cooled generators ,160,000 - SS CC water-cooled 33 4,237,000 Phosphorus free braze bars 132 6,430,000 GE hydrogen-cooled generators ,316,600 - H73/ H75 improved end winding support system 76 5,052,600 Radial-cooled C-coil fields ,419,900 Proven technology for service reliability copied or distributed in whole or in part, without prior permission of the copyright 7

8 Generator Features copied or distributed GE in whole Restricted or in part, - Distribute without prior to named permission individuals of the copyright only.

9 Stator Winding and Core 3 phase, 2 or 3 circuit configuration Class F 155(C) insulation End windings Connection rings Tetraloc* end-winding support Encapsulated monolithic structure for minimum maintenance units in service Leak-free, corrosion-proof stator bar clip (H2O-only) Image is for water-cooled bars support system same for conventionally cooled bars Silicon steel core Iron clamping flange with ventilated flux shield Reliability & availability through service proven configurations copied or distributed in whole or in part, without prior permission of the copyright * Trademark of General Electric Company. 9

10 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 copied or distributed in whole or in part, without prior permission of the copyright 10

11 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 copied or distributed in whole or in part, without prior permission of the copyright 11

12 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 copied or distributed in whole or in part, without prior permission of the copyright 12

13 H2 Generator Cooling Circuit Once through ventilation optimized for uniform cooling without air gap baffling copied or distributed in whole or in part, without prior permission of the copyright 13

14 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 copied or distributed in whole or in part, without prior permission of the copyright 14

15 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 copied or distributed in whole or in part, without prior permission of the copyright 15

16 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 copied or distributed in whole or in part, without prior permission of the copyright 16

17 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 GE Proprietary Company. Information Class All Rights Reserved. This III (Confidential) material may not be copied or distributed in whole or in part, without prior permission of the copyright 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. 17

18 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 copied or copied or distributed distributed in whole in whole or in part, or in without part, prior without permission prior permission of the copyright of the copyright 18

19 Validation and Test copied or distributed in whole or in part, without prior permission of the copyright

20 Validation GE has invested $22.5MM into labs and test facility Generator armature development lab Automated retaining ring assembly Connection ring insertion fixture Generator endurance test stand Non-metallic and materials labs Insulation systems development Generator armature development lab Bar force limits Slot component testing 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 Generator validation and testing facility 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

21 Validation Progression * Trademark of General Electric Company Thermal cycling & endurance to simulate 1 st year operation copied or distributed in whole or in part, without prior permission of the copyright 21

22 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 copied or distributed in whole or in part, without prior permission of the copyright 22

23 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 copied or distributed in whole or in part, without prior permission of the copyright 23

24 On-Line Monitoring copied or distributed in whole or in part, without prior permission of the copyright

25 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) Enhanced Partial Discharge Analysis End winding Vibration Monitor Generator Health Monitor (GHM) (knowledge based analysis of data) Collector Health Monitor copied or distributed in whole or in part, without prior permission of the copyright 25

26 Summary copied or distributed in whole or in part, without prior permission of the copyright

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

28 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 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. All relative statements are with respect to GE technology unless otherwise noted.