GEK 116371

March 2009

GE Energy

Hydrogen–Cooled Generators
Electrical and Mechanical Features Axial Fan – Conventionally Cooled –
2-Pole

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes the
matter should be referred to the GE Company.
© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.
GEK 116371 Hydrogen–Cooled Generators

The below will be found throughout this publication. It is important that the significance of each is thoroughly
understood by those using this document. The definitions are as follows:

NOTE

Highlights an essential element of a procedure to assure correctness.

CAUTION

Indicates a potentially hazardous situation, which, if not avoided, could result in

minor or moderate injury or equipment damage.

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR
SERIOUS INJURY

***DANGER***
INDICATES AN IMMINENTLY HAZARDOUS SITUA-
TION, WHICH, IF NOT AVOIDED WILL RESULT IN
DEATH OR SERIOUS INJURY.

2 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Hydrogen–Cooled Generators GEK 116371

TABLE OF CONTENTS

I. GENERAL DESCRIPTION OF GENERATORS ...................................................................... 4

II. STATOR FRAME AND SPRING MOUNTING......................................................................... 4

III. STATOR CORE ............................................................................................................................. 5

IV. STATOR WINDING ...................................................................................................................... 6

V. RESISTANCE TEMPERATURE DETECTORS ...................................................................... 8

VI. HIGH–VOLTAGE BUSHINGS AND CURRENT TRANSFORMERS................................... 8

VII. GAS COOLERS............................................................................................................................. 8

VIII. STATOR VENTILATION........................................................................................................... 8

IX. GENERATOR ROTOR (MECHANICAL AND VENTILATION) .......................................... 10

X. FIELD WINDING AND RETAINING RINGS .......................................................................... 11

XI. COLLECTOR AND COLLECTOR CONNECTIONS ............................................................. 11

XII. BRUSHES AND BRUSH HOLDER RIGGING......................................................................... 11

XIII. END SHIELDS AND BEARINGS ............................................................................................. 11

LIST OF FIGURES

Figure 1. Typical Hydrogen–Cooled Turbine–Generator........................................................................ 4

Figure 2. Typical Stator Punching ........................................................................................................... 5
Figure 3. Stator End Winding Structure .................................................................................................. 6
Figure 4. Typical Stator Winding End Turns and Connections for a Two–Pole, Hydrogen-Cooled Gen-
erator ........................................................................................................................................ 6
Figure 5. Armature Conductors Assembled in a “Roebel” Bar............................................................... 7
Figure 6. Once-through Flow Ventilation System for Hydrogen–Cooled Generator.............................. 9
Figure 7. Forward Flow Ventilation System for Hydrogen–Cooled Generator ...................................... 9
Figure 8. Typical Assembled Rotor ......................................................................................................... 10
Figure 9. Rotor Slot Assembly ................................................................................................................ 10

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 3

GEK 116371 Hydrogen–Cooled Generators

I. GENERAL DESCRIPTION OF GENERATORS

The conventionally–cooled hydrogen turbine–generator is completely enclosed for operation with hydro-
gen gas as the cooling medium. The ventilation system is completely self-contained including gas coolers
and fans. The separately excited rotating field, driven by the turbine, rotates inside the stationary armature
and is supported by bearings located in the end shields mounted on the generator frame. See Figure 1.

Figure 1. Typical Hydrogen–Cooled Turbine–Generator

The machine is designed to operate continuously, delivering power from the armature terminals, with pro-
visions being made for maintaining the hydrogen pressure and purity and for supplying cooling water and
lubricating oil. Temperature detectors and other devices are installed in and connected to the machine to
permit the measurement of the winding and hydrogen temperatures, and the hydrogen pressure and purity.
The generator is constructed to withstand all normal conditions of operation without harm. The stator cas-
ing is constructed to limit the destructive effects of an internal hydrogen explosion.

II. STATOR FRAME AND SPRING MOUNTING

The stator frame consists of a gastight cylindrical casing of welded plate construction, reinforced internally
in the radial direction by stationary web plates, and in the axial direction by key bars and braces.

The stator core punchings are held permanently under pressure in the axial direction of the generator. The
stator core is also spring mounted to isolate both radial and tangential vibration of the stator core from the
outer frame. With core motion limited to safe magnitudes, this results in low frame vibration and quiet
operation.

The stator frame is supported on the foundation by either of two methods – leveling devices (‘fixators’) or
plates and shims. Leveling devices serve the dual purpose of uniformly supporting the generator and pro-
viding adjustable vertical alignment capability. Heavy structural end shields which contain the generator
bearings are bolted to the ends of the frame. The frame also serves as the support and enclosure for the
gas coolers. All end shields, coolers, access ports, etc., are carefully sealed to prevent leakage of hydrogen
from the generator. Lifting trunnions bolted to the sides of the frame are provided for attachment of lifting
slings to rig the generator. These trunnions are removeable to meet transportation and site installation space
requirements.

4 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Hydrogen–Cooled Generators GEK 116371

III. STATOR CORE

The stator core is made up of segmented, insulated punchings of high-quality, electrical grade silicon steel.
These punchings are assembled in an interleaved manner on dovetail–shaped keys integral with the key bars
and are separated into packets by space blocks to provide ventilation ducts. The punchings are stamped
from thin steel sheets and contain open-end slots for the armature bars with dovetail slots for wedges to hold
the armature bars in place as shown in Figure 2. The assembled punchings are clamped into a stiff cylin-
drical core by pressure applied through ductile cast–iron end flanges from nuts torqued onto the threaded
ends of the key bars. Pressure is applied to the teeth by nonmagnetic steel fingers located under the end
flanges. In order to reduce heating from rotor end leakage flux and its associated electrical losses occurring
at the ends of the stator core, the end packets of punchings are stepped back to increase the gap between the
punchings and the rotor. The punching insulation is a thermo-setting varnish which maintains its insulating
properties at temperatures above the normal operating range of the generator.

CAUTION

Since the keybars, in effect, short across the back edges of the punchings, it is
essential to avoid damaging the core at the inside diameter or tooth tips. If the
punchings are burred or shorted together at the tooth tips, this would permit cir-
culating currents, induced by the magnetic flux in the core, resulting in a hot spot
and possible damage to the core.

Figure 2. Typical Stator Punching

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 5

GEK 116371 Hydrogen–Cooled Generators

Figure 3. Stator End Winding Structure

IV. STATOR WINDING

The stator winding, Figure 4, is composed of insulated bars assembled in the stator slots, joined at the ends
to form coils, and connected in the proper phase belts by connection rings. Each phase is split into groups
of coils.

Figure 4. Typical Stator Winding End Turns and Connections for a Two–Pole, Hydrogen-Cooled
Generator

6 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Hydrogen–Cooled Generators GEK 116371

The phases are electrically spaced every 120 degrees. The stator bars are composed of insulated copper
conductors (strands) transposed by the “Roebel” method so that each strand occupies, for an equal length
along the bar, every radial position in the slot. This arrangement avoids circulating current loss which
would otherwise be present under load conditions due to the self-inductive distribution of magnetic flux in
the coil slot. See Figure 5 for details of the transposed bar. The armature bars are held in the core slots by
Textolite wedges driven into the dovetail slots also shown in Figure 5.

The stator bar is composed of several individually insulated transposed strands. A micapal insulation sys-
tem is applied to form the main “ground wall” insulation of the stator bar. This insulation system consists of
several layers of mica tape bonded with a thermosetting binder. The result is a high density, high dielectric
strength system which has high mechanical strength throughout the operating range of temperature. The
bars, with a composite buildup of layers of tape applied, are placed in a tank and subjected to vacuum,
pressure, and heating cycles, to remove the volatiles, compact the system to eliminate voids and cure the
binder.

Armor tape is applied to the core portion of the stator bar to protect the bar from abrasion in the slot. Corona
suppressors control the voltage gradient along the outer surfaces of the stator bars between the end of the
conductive slot armor and the series loops.

Suppressors are designed to eliminate electrical tracking and discharges at normal operating voltages and
at test voltage levels. A high resistance semi-conductive cross grading paint is applied to the end arms to
suppress corona activity in the end winding during high potential tests and during operation.

Stator coil ends are covered either with mica insulation (phase straps) or a cap (series loops), after which
they are sprayed with epoxy paint. These end turns are securely restrained by the binding bands, which are
molded fiberglass rings supported from the stator core flanges (Figure 3). The fiberglass ties, space blocks,
and conformable material are bonded with thermosetting resin.

Figure 5. Armature Conductors Assembled in a “Roebel” Bar

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 7

GEK 116371 Hydrogen–Cooled Generators

V. RESISTANCE TEMPERATURE DETECTORS

Resistance type temperature detectors (RTDs) are located between top and bottom bars in each phase of
the armature windings to measure the temperature of the windings at the points of highest operating tem-
perature.

Gas temperature detectors are provided to measure the inlet and outlet gas temperatures of each of the
coolers. The leads from the detectors are brought out through a gastight gland in the generator frame
and connected to DIN connectors in outdoor rated junction boxes for connection to the turbine-generator
control. A more complete description of the resistance temperature detectors, their locations, and their
connections in the electrical junction boxes is provided in separate drawings and instructions listed in the
Table of Contents of the composite book for the set.

VI. HIGH–VOLTAGE BUSHINGS AND CURRENT TRANSFORMERS

The main armature leads typically exit the top of the generator frame (through the terminal plates by means
of gastight, high-voltage bushings) for gas turbine applications, and the bottom of the frame for steam tur-
bine applications. On most generators, connections are provided at the collector end (opposite the turbine
coupling).

The bushings consist of one–piece porcelain insulators containing a copper conductor. The terminals at
each end of the bushing are silver–plated. To minimize induced current losses and heating caused by load
current in the leads, the terminal plates are made of nonmagnetic material. Drains are provided to prevent
accumulation of oil or water around connections at the bottom of the frame.

Bushing–type current transformers, if used, are mounted on the high–voltage bushings. A more complete
description of these transformers is provided in separate instructions listed in the Table of Contents of the
composite book for the set if the generator is provided with bushing–type current transformers.

VII. GAS COOLERS

Generator gas coolers are mounted either vertically in the cooler towers at the four corners of the frame, or
horizontally in the base of the stator frame. Water pipe connections are made externally at the bottom of
each cooler (when vertically mounted). Hydrogen sealing is by a compression packing at the ‘floating’ end
and by a pumped seal at the ‘fixed’ end. A more complete description of these seals is provided in separate
instructions listed in the Table of Contents of the composite book for the set.

WARNING

SERVICING OR REPAIRING THE COOLER WHILE THE GEN-

ERATOR IS OPERATING WITH HYDROGEN IN THE CASING
IS EXTREMELY HAZARDOUS AND SHOULD NOT BE AT-
TEMPTED.

VIII. STATOR VENTILATION

The rotor fans provide the pressure rise required for the ventilation of the generator. The fans are axial flow
type with individual blades fastened to fan hubs near the ends of the rotor. Inlet nozzles may be used to
control the entrance condition of the gas to the fans.

8 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Hydrogen–Cooled Generators GEK 116371

The stator ventilating circuit is shown in Figure 6 and Figure 7. There are two types of circuits used on
conventionally cooled generators. The particular circuit utilized is based upon overall optimization of the
specific generator architecture.

1. In the ‘once-through’ ventilation scheme, hydrogen is forced by the fans into the gas gap and then
directed radially outward through the radial gas ducts between the punching packets all along the
stator core. Hot gas is directed to the coolers. After the heat is removed, cold gas returns to the rotor
fans and recirculates.

Figure 6. Once-through Flow Ventilation System for Hydrogen–Cooled Generator

2. In the ‘forward flow’ ventilation scheme, hydrogen is forced by the fans into the gas gap, and around
behind the stator core. The stator is divided axially into sections by the web plates so that in some
sections cold gas is forced from the outside of the core toward the gas gap through the radial gas ducts
between the punching packets, and in other sections it passes from the gas gap toward the outside of
the core through the radial gas ducts. Cooling gas is conducted through tubes or ducts to the proper
section, and hot gas is directed to the coolers. After the heat is removed, cold gas returns to the rotor
fans and recirculates.

Figure 7. Forward Flow Ventilation System for Hydrogen–Cooled Generator

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 9

GEK 116371 Hydrogen–Cooled Generators

IX. GENERATOR ROTOR (MECHANICAL AND VENTILATION)

The construction of the generator rotor is illustrated in Figure 8. The rotor is machined from a single alloy
steel forging which has passed extensive tests to ensure that the forging meets the required physical and
metallurgical properties.

Longitudinal slots, machined radially in the body, contain the field coils. Field coils are held in the slots
against centrifugal force by non-magnetic steel wedges. These wedges are driven into dovetail openings
machined in the rotor slots. The wedges and the coils they hold in place are designed with radial holes that
are aligned together to form numerous radial passages connecting the rotor subslot and the gas gap. Gas
flows axially under the rotor endwindings and on into the subslots and then radially outward through the
radial passages discharging finally into the gas gap. The radial flow of gas removes the heat generated in
the coils. The gas flowing along the gap over the rotor surface cools the rotor externally.

Rotor fans, provided for the ventilation of the generator, are assembled near the ends of the rotor.

Figure 8. Typical Assembled Rotor

Figure 9. Rotor Slot Assembly

10 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.

Hydrogen–Cooled Generators GEK 116371

X. FIELD WINDING AND RETAINING RINGS

The field winding consists of rectangular copper bars formed into coils. Several turns in one pair of slots
around one pole form a coil. Several coils are assembled around each pole to form the winding. The
individual turns are insulated from each other. Coils are insulated from the slot wall in the body portion by
molded slot liners, as shown in Figure 9. To provide maximum ventilation and cooling, the end portions
of the field coils are left bare. Molded ring insulation is provided between the coils and the retaining rings,
and epoxy glass blocking is provided in the end windings to separate and support the coils and restrict their
movements under stress from temperature and rotational forces.

The end turns are held in place against centrifugal force by heavy retaining rings machined from high
strength, heat–treated alloy steel forgings which are shrunk and locked onto the rotor body.

XI. COLLECTOR AND COLLECTOR CONNECTIONS

Current is supplied to the field windings through the collector rings which are electrically connected with
the field winding through insulated copper bars assembled in the bored–out center of the rotor forging.
At one end of the connection bars terminal studs, assembled in radial holes in the rotor shaft, connect the
winding to the bars. At the end of the shaft this connection is accomplished using collector studs. The
collector end connections use an elastomeric seal system to contain H2 pressure.

A more complete description of the collector is provided in separate instructions listed in the Table of
Contents of the composite book for the set.

XII. BRUSHES AND BRUSH HOLDER RIGGING

A more complete description of the brushes and brush holder rigging is provided in separate instructions
listed in the Table of Contents of the composite book for the set.

XIII. END SHIELDS AND BEARINGS

The generator rotor bearings, the hydrogen shaft seals, and oil passages for supplying oil to these parts
are contained in the outer end shields. The end shields are split on the horizontal centerline to facilitate
their removal. Joints between the shield halves and between the shields and the stator frame are fitted and
provided with grooves for the insertion of sealing compound to seal the gas in the machine.

The rotor bearings are provided with ball seats to allow accurate alignment of the bearings with the rotor
journal surfaces. A more complete description of the bearings is provided in separate instructions listed in
the Table of Contents of the composite book for the set.

The escape of hydrogen from the generator along the shaft is prevented by a shaft seal attached to each outer
end shield, inboard of the bearing. This arrangement permits inspection of the generator bearings without
removing gas from the machine. A more complete description of the shaft sealing system is provided in
separate instructions listed in the Table of Contents of the composite book for the set.

Both the bearing and the shaft seal housing at the collector end of the machine are insulated from the gen-
erator frame to prevent the flow of shaft currents.

Inner end or ‘gas’ shields are located between the ends of the armature windings and the outer end shields
to separate the gas discharged from the fans from the gas entering the fans.

© General Electric Company, 2009. GE Proprietary Information. All Rights Reserved. 11

GEK 116371 Hydrogen–Cooled Generators

GE Energy
General Electric Company
www.gepower.com

12 © General Electric Company, 2009. GE Proprietary Information. All Rights Reserved.