Keep your generator running with a rotor exchange from GE Vernova
When your generator rotor is due for servicing, GE Vernova’s rotor exchange program provides a fast, reliable, and cost-effective solution to reduce outage time and extend asset life.
Fast, tested, ready to install
How does the rotor exchange program work?
GE Vernova’s rotor exchange program allows you to replace a generator rotor needing maintenance or repairs with a fully refurbished, tested, and ready-to-install exchange rotor. For planned outages, these rotors can be delivered well in advance to help ensure a smooth and efficient outage schedule. With a rotor exchange, you’ll see removal and replacement in only 7 – 10 days—up to 40 days faster than an in-shop rotor rewind. On average, each day of reduced downtime translates to a savings* of $30,000 to $130,000, depending on the time of year the outage is performed.
*Average savings based on 100 to 175 MW units
Save time and money
Up to 40 days faster
Reduced uncertainity
Fully tested on delivery
Peace of mind
We know your generator equipment
250+ exchange rotors
delivered to customers globally
> 2 million
operating hours
Plan ahead
Reduce uncertainty
You can order a rotor exchange as far in advance as you need to, substantially reducing the risk of schedule extensions and execution challenges due to late rotor parts, winding delays, or test failures that are common with an on-site generator. Your generator's new replacement rotor will arrive:
Advanced technology and reliability
Key features of our exchange rotors
GE Vernova’s exchange rotors are engineered with upgraded materials, enhanced durability, and rigorous testing to help ensure seamless installation and long-term performance.
1
Upgraded materials:
Latest insulation, blocking, and wedge configurations.
2
Enhanced durability:
Modifications for cyclic duty, main terminal stud replacement, and amortisseur winding.
3
High-speed balanced and tested:
Ensuring full thermal and electrical reliability before installation.
4
Engineering-backed fit assurance:
A detailed assessment ensures compatibility with your generator.
5
Dedicated oversight:
A project manager will work with you to manage quality control throughout the process.
Faster turnaround, fewer lost MWh
Reduce downtime and increase output with a rotor exchange
When time is critical, a generator rotor exchange is the faster, more efficient alternative to a rotor rewind. Instead of waiting for lengthy repairs, our fully refurbished, high-speed balanced exchange rotors get you back online quickly, reducing downtime and avoiding lost MWh. With rapid installation and proven reliability, GE Vernova’s rotor exchange solution helps you maintain performance while keeping outage costs under control.
OEM expertise
Why choose GE Vernova’s rotor exchange program?
Did you know that GE Vernova is the OEM for thousands of generators? That includes many sub-models that most other vendors don’t have experience servicing, so we can work with you to make sure your new rotor is interchangeable with your old one.
- Trusted experience: More than 250 exchange rotors delivered worldwide.
- Proven performance: More than 2 million operating hours on our exchange rotors.
- Broad application: Over 30 repeat customers, covering 20+ generator versions.
- Inventory readiness: More than 10 rotor models available at any given time.
- Competitive pricing: A cost-effective alternative to a full in-shop rotor rewind.
Available for the following models: 7FH2, 7FH2B, 7A6, 324, 7H2, 330H, BDAX 7-290ERJT, TRLI 115-36, TRLI 115-36, TRLI 115-52, 9A
Frequently asked questions
Our generator rotor exchange program
Process and timeline
What is the process used for a remaining life assessment (RLA) of rotors and accuracy rate?
GE Vernova performs comprehensive assessments using electromagnetic testing, visual inspections, and material analysis to determine rotor condition and estimate remaining life. Our proven diagnostic methods provide high accuracy in evaluating stress levels, insulation degradation, and potential failure risks.
How long does it take to perform a rotor exchange versus a full rewind?
A rotor exchange typically takes 7 to 10 days, while a full in-shop rewind can take 30 days or more. The faster turnaround of an exchange helps reduce downtime and operational losses.
How long does it take to repair a generator rotor winding?
The repair timeline varies depending on the extent of work required. A full field rewind typically takes about 30 days, depending on the generator model and scope of work. However, some repairs can be completed in as little as 1-2 weeks. GE Vernova assesses each case individually to determine the fastest and most effective repair solution.
What is the process for removing and replacing a generator rotor?
GE Vernova’s generator rotor exchange involves removing the existing rotor, installing a fully tested, high-speed balanced exchange rotor, and performing alignment and verification checks—all within 7 to 10 days to ensure minimal disruption.
Cost and savings
How much downtime can I expect for a rotor exchange versus a full rewind?
A rotor exchange saves up to 30 days compared to an in-shop rewind. Less downtime translates to $30,000 to $130,000 in savings per day, depending on unit size and outage timing.
What cost savings can I expect with a rotor exchange?
By eliminating extended outage time, rotor exchanges prevent lost revenue and reduce labor costs, making them a cost-effective alternative to rewinds.
Does GE offer financing or flexible payment options for rotor exchanges?
GE Vernova works with customers to offer customized payment plans, financing solutions, and long-term service agreements to fit budgetary needs.
Technical and compatibility
Can GE determine if an exchange rotor is compatible with my unit?
Yes! GE Vernova has extensive experience conducting interchangeability studies to ensure an exchange rotor will fit your unit. As the OEM, we have access to original unit records, repair history, and outage reports to verify compatibility.
In some cases, we may require additional information from the customer to supplement our records and ensure a precise match. Our team works closely with operators to confirm a seamless installation.
What rotors are available in stock—and does the list include OOEM generators?
GE Vernova maintains a wide range of exchange rotors, but availability varies depending on the outage season and demand.
Common models included in our program are:
✔ 7FH2
✔ 324
✔ 7A6
✔ 330H
✔ 7FH2-B
✔ 9A5
For other models, including OOEM generators, our team can assess availability and explore solutions tailored to your unit’s needs.
What testing and quality checks are performed on exchange rotors before delivery?
Exchange rotors undergo extensive testing, including:
✔ Electrical testing for insulation integrity
✔ High-speed balancing for smooth operation
✔ Retaining ring inspections to detect stress corrosion cracks
✔ Dimensional checks to confirm precise fit
✔ Final certification to ensure compliance with OEM standards
What happens to my old rotor after an exchange?
Customers can return their removed rotor for refurbishment or reuse as a spare. GE also offers recommendations for repair or repurposing based on its condition.
What is the process used for a remaining life assessment (RLA) of rotors and accuracy rate?
GE Vernova leverages historical records, operational data, and advanced modeling tools to assess rotor condition and risk levels. While the exact process and data are proprietary, customers can contact their local sales account manager for further discussion and a detailed evaluation.
Are there any other generator components or accessories that need to be replaced or upgraded with the rotor?
GE Vernova assesses the exchange rotor against your unit’s current configuration to determine if any additional components or modifications are required. While some units may not need any modifications, common replacements include:
✔ Oil deflectors
✔ Bearing liners
✔ Hydrogen seals
✔ Excitation system settings
Our experts ensure seamless integration by identifying necessary upgrades before installation, reducing the risk of unexpected issues during the outage.
Performance and reliability
What are the most common signs of a faulty generator rotor?
Common indicators of rotor issues include:
✔ Shorted turns affecting electrical performance
✔ Increased vibration levels
✔ Higher excitation current needed to maintain output
✔ Excitation limitations causing an inability to maintain power output
These issues can often be detected while the rotor is still running. More severe conditions, such as a grounded field, can lead to a unit trip. Using GE’s Generator Health Monitoring enables continuous tracking and trending of potential rotor issues, helping operators take proactive maintenance actions.
How does GE Vernova ensure rotor reliability and longevity?
Our exchange rotors incorporate advanced repair technologies, such as:
✔ Copper-finned ventilation ducts for better cooling
✔ Retaining ring material enhancements to resist cyclic stress
✔ Rotor FlexPack solutions to handle cyclic operations and prevent premature failures
Can a rotor exchange help improve generator efficiency or capacity?
Yes! Our rotors include design and material enhancements that improve cooling efficiency, reduce energy losses, and in some cases, increase power capacity.
Are there upgrade options available with a rotor exchange?
Yes. GE Vernova offers performance upgrades, including:
✔ Advanced insulation materials for durability
✔ New end-winding blocking for enhanced mechanical stability
✔ Improved slot armor protection to prevent wear
Logistics and installation
How does GE Vernova support logistics and installation for the rotor exchange?
GE Vernova provides end-to-end support, including:
✔ On-site technical advisors to oversee removal and installation
✔ Global logistics coordination for timely delivery
✔ Precision alignment and testing for optimal performance
What emergency response or expedited services are available for urgent rotor replacements?
GE Vernova maintains a global network of specialists and strategically placed inventory for rapid rotor deployment in emergent outage situations.
How does GE Vernova’s inventory management ensure quick availability of exchange rotors?
With strategically located warehouses and pre-positioned rotors, we can reduce lead times and help ensure quick response to both planned and unplanned outages.
Service and support
What warranty or service guarantees come with an exchange rotor?
GE Vernova provides comprehensive warranty coverage for workmanship and materials. Customers can also opt for extended service agreements, including periodic inspections and maintenance.
Can GE Vernova’s rotor exchange be combined with other generator maintenance services?
Absolutely! Customers can integrate rotor exchange with:
✔ Full generator inspections
✔ Stator rewinds and upgrades
✔ Onsite generator repairs
✔ Lifecycle management solutions
By combining services, customers can reduce future outages, optimize maintenance costs, and improve long-term reliability.
Consider your options
Is a generator rotor exchange right for you?
There are a number of things to consider when planning your outage, from the age and future operation mode of your generator to the best timing for an outage for your plant and customers. GE Vernova can perform a risk assessment to determine the condition of your rotors, identify the ones most at risk and the type of rotor, and any spare generator rotor parts you might need.
Services
Explore our other generator rotor upgrades and services
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