term changes in grid reactive power capacity are not balanced,

the result can lead to system voltage instability, islanding, voltage

collapse and, ultimately, system breakdown.
In the Northeast Blackout on Aug. 14, 2003, reactive power
shortages played a key role, according to a report from Cornell
Universitys Engineering and Economics of Electricity Research
Group. Also, a Power Systems Engineering Research Center report
noted that reactive power shortages played a key role in the 1996
western electric grid (WECC) blackouts.
Reactive power shortages are caused by a variety of factors:
plant retirements, plant trips, transmission line failures and peak
A
s gas and steam power generation plants approach
the end of their operational life, plant owners
face a challenging decision between upgrading
or retiring the plant. Retiring a power generation
unit can reduce a plants reactive power capacity,
possibly creating a defcit that directly affects the
local systems reliability. If a unit is retired, the
challenge will be to maintain grid voltage at or near the plant inter-
connection point to ensure grid reliability.
Solutions have involved installing new static volt-amperes reac-
tive (VAR) compensators, shunt capacitor banks and/or synchro-
nous condensers at or near the plant location. However,
there potentially is a more economical and effective solu-
tion: converting the existing synchronous generator into a
synchronous condenser.
There are considerable benefts to making this conversion.
Re-using the existing generator, its foundation and build-
ing, auxiliary systems and grid connections offers an eco-
nomical source of reactive power capacity. Typically, about
30 to 35 percent more reactive power can be produced via
the conversion because the unit can be overexcited in ac-
cordance with its capability curve that would not otherwise
occur in power generation mode. Reactive power produced
by a synchronous condenser is considered superior to static
VAR solutions; the condenser increases reactive power in
response to a system voltage drop while also supplying the
local system with signifcant short circuit support.
The conversion requires a system-level approach and cus-
tom engineering as conversion involves decoupling the tur-
bine from the generator, installing a starting means for the
condenser, designing and installing a new control system
and making minor mechanical modifcations to the genera-
tor. The resulting condenser will operate at nearly zero real
power, but can produce or consume reactive power com-
mensurate with the generators capability curve.
Reliability Considerations
Reactive power capacity is a critical feature of the electri-
cal infrastructure and research underscores its role in avoid-
ing power outages. The reliability of the system depends not
only on the generation and distribution equipment reliabil-
ity, but also the reactive power capacity, which is required to
stabilize local system voltage.
Reactive power has been defned by the U.S. Department
of Energy as the portion of electricity that establishes and
sustains the electric and magnetic felds of alternating-cur-
rent equipment. Reactive power, which must be supplied
to most types of magnetic equipment, such as motors and
transformers, is provided by generators, synchronous con-
densers, or electrostatic equipment such as capacitors.
Reactive power also supports the fow of real electrical
power throughout the grid. When short-term and long-

Converting Existing
Synchronous Generators into
Synchronous Condensers
By Dr. James M Fogarty, Consulting Engineer-Electrical Machines and Ryan M LeClair, Generator Growth Leader, GE Energy
Figure 1 SYNCHRONOUS CONDENSER
REACTIVE POWER CAPACITY
S
y
n
c
h
r
o
n
o
u
s

C
o
n
d
e
n
s
e
r

O
p
e
r
a
t
i
o
n
Lagging
Megavars
Leading
Megavars
Megawatts
Rates
0.30
0.60
0.80
0.90
0.95
1.00
0.95
0.70 0.30
+30%
electricity demand. Reliable sources of reactive power, like syn-
chronous condensers, are key to avoiding these shortages.
Conversion Considerations
Converting an existing synchronous generator to a synchronous
condenser requires a custom-engineered solution because each plant
will have a unique design and layout. The generator, electrical, cooling
and lubrication systems must be evaluated as a whole. The conversion
will require that the turbine be decoupled from the generator.
Starting means: In the conversion process, the frst step is se-
lecting the condensers starting means. The condenser must be
accelerated to a speed to allow synchronization with the grid. Be-
cause the turbine is decoupled and cannot accelerate the condenser,
synchronous or induction motors have been used for that purpose.
Typically, the collector end of the rotor shaft is not designed to
withstand the transient torques that a starting motor may impose
on the rotor during a fault. Therefore, the motor is typically cou-
pled to the turbine end of the condenser rotor, which requires a
new foundation for the drive motor, coupling and clutch.
GEs gas turbine static-start technology has been adapted for
this purpose providing the stand-alone condenser with its own
starting means. This static-start approach eliminates the motors
expense, cycle time and auxiliary equipment. Furthermore, the
turbine can be condemned in place, avoiding demolition and en-
vironmental expenses. Avoiding a drive motor on the rotor train
also simplifes the rotors dynamic behavior and its response to
incorrect synchronization, possibly eliminating the need for fail-
ure contingencies. In addition, the static-start equipment can be
equipped to start more than one condenser at the plant.
Prime mover: The next consideration is whether to remove the
turbine from its foundation or simply decouple it. GEs solution is
to decouple the turbine but keep it in place. That approach causes
minimal disruption in the turbine-generators lubrication system.
It also allows the condenser to be converted back and forth be-
tween generator and condenser modes, if desired. The turbine
could be removed without a substantial change to the synchro-
nous condenser conversion. If a starting motor is used, typically
Figure 2 METHOD FOR STATIC START AND CONTROL
Steady/thrust bearing
Mark VIe controller
Variable frequency drive
EX2100 exciter
Turning gear
it must be installed on
the turbine end of the
condenser, which re-
quires removing that
portion of the turbine.
Excitation: The
next step is evaluating
the present excitation
system for its ability to
reliably deliver the re-
quired excitation cur-
rent needed for full
reactive power genera-
tion. With GEs solu-
tion, the exciter will
also deliver the excita-
tion current necessary
for start-up. For maximum reactive power generation, the excita-
tion system and generator should be capable of operation at a feld
current commensurate with the nameplate power factor.
Mechanical: Mechanical components are generally designed
and installed to properly support the condenser rotor. Typically,
this involves a thrust bearing (the turbine that performed this
function is now decoupled) as well as a turning gear. A steady
bearing may also be installed, if required based on the rotor dy-
namics. GEs solution involves installing a single steady bearing,
thrust bearing and turning gear assembly on the collector end of
the rotor. In certain instances, it may be helpful to modify the
lube oil system to include high-pressure lift oil that reduces the
breakaway torque of the rotor at start-up.
Controls: At this point, the control of the synchronous con-
denser is assessed. Typically, a new supervisory control system is
designed and installed which controls the start-up sequence, the
excitation system, and synchronization to the grid. The control sys-
tem should also monitor the existing generator protection systems
as well as the breakers, auxiliary systems, and condenser status. Op-
timally, the control system should be integrated with the overall
plant controls to enable monitoring of the systems status.
Condition of the Existing Generator: The fnal step involves
evaluating the condition of the existing generator and determin-
ing its expected lifespan and reliability. If the synchronous con-
denser will have signifcant life expectations, it may be worthwhile
to consider replacement rotors, feld rewinds and stator rewinds.
These modifcations, along with a properly sized excitation sys-
tem, can also increase the condensers reactive power capacity.
Converting an obsolete synchronous generator to a synchro-
nous condenser is a viable, economical alternative to retiring the
unit. As the condenser is a rotating device, it can also provide
short circuit support in addition to reactive power capacity. While
converting the unit requires a system-level approach and custom
engineering, the result can greatly extend the generators useful
lifespan. For the community, a conversion to a synchronous con-
denser can provide electrical system voltage support resulting in a
stable source of electric power.
www.ge-energy.com
Reprinted with revisions to format, from the October 2011 edition of POWER ENGINEERING
Copyright 2011 by PennWell Corporation