GE Energy

Problem
Solved.
How can I improve
flexibility for new and
existing plants?

2010 GE Energy Customer Solutions Conference

GE Energy

Generator
Problem Solved.
Uprates
<<insert customer challenge
here>>
Presenter
Karl Tornroos

2010 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.
 Watts & Vars

Two Important Commodities Produced

by a Turbine Generator Unit

Megawatts

GEN

Megavars

2010, General Electric Company

Reactive Capability Curve (RCC)
Consider the present
operation of the Direction
of Field
generator and potential Uprate
future operation
MW and MVAR needs of
the
power System Direction
of Stator
Anticipated operation for Uprate
both
lagging and leading
power factors Constant
MVA Curve
Thermal limits on
generator output:
Armature winding
Field winding
Core end
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2010, General Electric Company

 Uprate of the Generator System Generator Core End Design
T-G Coupling & Shaft Considerations
Coolers Stator Core End

Generator Rotor and

Field Winding

Collectors and Excitation

Generator Stator Winding System Connections
Retaining Rings

Bushings

The Complete Generator System Is Evaluated Using:

Modern Design Tools
Extensive Fleet Experience GE is Uniquely Qualified to Study
Factory and station tests of GE generators the Entire Generator System
(example: core end capability tests)
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2010, General Electric Company

GE Continues to Invest in Uprate Technology
GE has invested in New Product Introduction
programs aimed at generator uprates
Core end capability
Stator winding design
Armature Development Laboratory
GE has completed over 60 detailed
uprate studies of GE generators since 2003

2010, General Electric Company

 Generator Uprate
Considerations for
Individual Generator Sub-
Systems
What part of the RCC does each component impact?
Reactive Capability Curve

500 A
400

300
B
200

100

MVAR
Cross -Slot Flux
Created by Current in 0
Stator Bars 0 100 200 300 400 500 600 700 800
-100
Stator Bar Currents

-200
C
-300
D
-400
Direction of 2/rev
vibratory bar
MW
force

Fan Collector
Coil Slot
Ring
Coupling

Balance
Retaining Plug
Ring Collector Fan

2010, General Electric Company

 Typical Component Capability Analysis (example only)
750 MVA @ 0.90 PF original rating
MWe 600 650 675 700 725 750 775 800 825 850 875 900
% MWe 89% 96% 100% 104% 107% 111% 115% 119% 122% 126% 130% 133%
Limit
Stator Bars: Driven By:
Thermal Limit MVA 2
Mechanical Limit MVA 2
Stator Core End:
Thermal Limit MVA 2
Rotor:
Field Thermal Limit I field2
Coupling Mech Limit
MWe
Uprate at 0.9 power factor:
MVA @ 0.9 pf
667 722 750 778 806 833 861 889 917 944 972 1000
% MVA
89% 96% 100% 104% 107% 111% 115% 119% 122% 126% 130% 133%
MVAR
291 315 327 339 351 363 375 387 400 412 424 436

Some limits can be overcome through installation of a re-designed & upgraded component
Physical constraints of the existing generator geometry can prevent the uprate of some
components
Due to age, some components may be less capable than their as-new capability and
replacement may be necessary to achieve an uprate
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2010, General Electric Company

Stator Winding
Uprate Considerations - Armature Winding Design
Higher bar vibratory force
increases as the square of the
MVA uprate
Bar force is determined by slot
width and stator current and
cannot be changed by a
redesign of the winding
Retention of a zero clearance,
zero vibration design is critical
to long term reliability
Thermal expansion of stator
winding should be considered

Direction of 2/rev
vibratory bar force

Focus of GEs new Armature Development Laboratory

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2010, General Electric Company

Armature Bar Electromagnetic Review
Optimized Solid-Hollow Strand Ratio
Increases Capability, Reduces Losses
Apply New Armature Bar
Developments to Optimize Bar
Design
Strand mechanical stresses
Modern, Optimized
Water velocities Strand Configuration
Current densities
Improves Stator Bar Capability,
Efficiency

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2010, General Electric Company

Stator Core
Stator Core Uprate Considerations
Heating of the ends of the core increases with the
square of the % increase in MVA
A loose or damaged core can cause an early
failure of a new stator winding
Overfluxing of the core ends can lead to local
arcing or overheating -- possibly severe damage
The core end assessment must be performed as a
part of an uprate
Core End Analysis Leverages Extensive GE
Experience & Factory Tests with end iron TCs

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2010, General Electric Company

High Voltage Bushings, CTs, & Lower Frame
Extension
Higher stator currents require an
evaluation of the thermal capability
of the high voltage bushings
Higher currents also lead to
increased proximity heating (induced
heating) of lower frame extension
Capability and cooling of the Lower Frame
Extension
lower frame extension (bushing
box) require evaluation
Thermal evaluation of High Voltage Bushings
(Inner Cooled)
connections to iso-phase bus
and neutral
Ambient air temperatures below the CTs
generator should be evaluated can
impact CTs and connections

Neutral Connections & Iso-Phase Bus Connections

Neutral Enclosure (Not Shown) (Not Shown)
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2010, General Electric Company

 Field Winding and
Related Components
Uprate considerations for the Field Winding
Increased Field Temperatures
Coil Thermal Expansion
Assessment of Present Condition:
Vibration Performance & Thermal
Sensitivity
Shorted Turns & Field Grounds
Coil Distortion
Endwinding Blocking Movement

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2010, General Electric Company

Parts of a Rotor

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2010, General Electric Company

Rotor Shaft Mechanical
Evaluation
Rotor Shaft Mechanical Introduction
Mechanical evaluation of up-rate involves
coupling and shaft
Coupling Flange Capability at:
Steady State
Minor Transient
Major Transient
Shaft Capability at:
Steady State
Minor Transient
Major Transient
Shrink Fit & Keys
Evaluation of fatigue life at
Keyway/Shaft Step
Special tools have been developed by GE
for evaluating Nuclear shrunk-on
couplings 19

2010, General Electric Company

Typical Torsional Response at Turbine Generator Coupling
1
Full Load Dump

0.8
1.0 pu
Response Torque [% Rated]

0.6

0.4

0.2
endurance
0 strength
LP C - GEN
0 0.5 1 1.5 2 2.5

-0.2

-0.4

-0.6

-0.8

-1

-0.81 pu Time [sec]

Response above endurance strength, hence fatigue damage

accumulated until damping reduces response below endurance20

2010, General Electric Company

 Replacement Field may be required
1. Modern materials
2. Modern forging
3. Addresses all TILs
4. 18 MN-18 Cr retaining rings
5. Balanced, fully tested
6. Aluminum wedges all coils (TIL 1292)
7. Class-F insulation system
8. New copper windings
9. Field winding blocking
10. New collector rings
11. Asbestos-free construction

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2010, General Electric Company

When uprate goal cannot be achieved consider
a replacement generator
Replacement Generator
Rating and Size of Generator Can Be Chosen to
Meet Any Uprate Goal Higher Uprate Likely
Uprate of Present Generator
Rating of Generator is Limited by Capabilities and Size
of Key Major Components

All new components with Full Generator Life -- Some Components May Have Reduced Life
30 to 40 Years Expectancy & Reliability Due to Past Operating History

Higher Cost Lower Cost

Foundation Modifications May Be Required No Impact on Foundation

Modern Technology Is Applied to All Components Modern Technology is Applied to Replaced Parts
Such as Generator and Digital Excitation System

Torsional & Lateral concerns Limited Torsional & Lateral concerns

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2010, General Electric Company

Replacement Generator Experience
GE has replaced 2 nuclear generators
(quantity 10 plus other sized T-Gs)
Included foundation modifications
All interfaces completed such as:
Coupling
Bus work
Cooling systems
Lube and seal oil systems
Included new auxiliaries
Extensive pre-planning is key
Project management
Field engineering support

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2010, General Electric Company

Key questions to ask during an uprate study
What is the uprate MWe goal?

What is the uprate MVAR goal or transmission system

requirement?
What stability studies have been performed to evaluate the
higher MWe rating?

What major components have experienced degradation that

in time may have reduced their original capability? (Stator
core, frame, stator winding, rotor forging, field winding, etc. )
What components require replacement for reliability & life
extension reasons?

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2010, General Electric Company

 Thank You
Questions Please