HYDROGENERATORS
Ansaldo Energia
Hydrogenerators
A sustainable future in terms of energy must involve a reduction in CO2 emissions and our dependence on fossil fuels, which at present satisfy
most of the world’s energy needs.
Hydro energy delivers both of these benefits, besides it has low operating costs, it requires limited maintenance and is renewable.
In coming decades there will be significant growth
in hydro energy compared to traditional thermal
power plants.
Tailor made generators
Ansaldo Energia began working in the field of Power Generation with the installation of the first
hydroelectric plants at the start of the last century.
Since the second half of last century more than
500 hydrogenerators have been designed, built,
installed and started up in about 30 countries.
Most of all hydrogenerators ever manufactured
by Ansaldo Energia are still in operation.
By drawing on experience gained over more than
a century in this business, combined with constant product improvement, we can now offer our
Clients a comprehensive range of hydrogenerators, in conjunction with after sales assistance
services that maximise the investment made in
plant construction.
Ansaldo Energia currently produces three basic
types of hydrogenerators:
•generators for river flow (low/medium speed)
•generators for high-head plants (medium/high speed)
•motor-generators for pumped storage systems
Generator design features
With our “Tailor made” approach for hydrogenerators, we have always preferred to
design generators based on plant characteristics in order to guarantee maximum performance in terms of efficiency,
reliability and maintenance.
The process of optimising the hydrogenerator, based on the features of the plant,
begins with electromagnetic design to define the active parts of the machine. Design data (power output, voltage, speed,
etc.) is used to identify the ideal machine
configuration based on existing benchmark models, by balancing maximum
performance with transport and erection
constraints.
The generator project is then verified using advanced computational tools to analyse its electromagnetical, mechanical and thermal behaviour.
The heart of the generator is the stator winding,
and the quality of stator bar insulation is a deci-
sive factor for machine reliability. The new 4657
Resin Rich insulation system, which is derived
from our turbogenerators, has made it possible to
double the thermal conductivity of the insulation
compared with the previous generation and, other
conditions being equal, to lower the thermal level
of the stator bar, which is beneficial to the lifespan
and reliability of the generator.
Our generators are designed with a redundant,
closed-circuit cooling system. Based on the type
of generator involved, axial fans with adjustable
angle blades are used, or solutions with radial
ventilation or electric fans for motor-generators
which rotate in both directions.
In the case of vertical hydrogenerators for very
high vertical load (i.e. for Kaplan Turbine), we can
provide proven solutions with hydrulically equalised thrust bearings and, if required, a self-pumping thrust collar.
These solutions are available in non driving end
(NDE) thrust bearing configuration with a singlepiece thrust collar, and in driving end (DE) thrust
bearing configuration with a two pieces thrust
collar.
Generators are designed to withstand the heaviest duty operating conditions, frequent start-up
and shut-down cycles, and accidental operating
conditions such as short circuits.
An advanced quality system covering all phases of
work, from design to start-up, ensures that generators comply with internal and international benchmark quality standards.
Ansaldo Energia has two centrifugation facilities,
one of which under vacuum, to balance and overspeed test the generator fly wheel effect up to
over 6,000 tm2 and rotor weight over 400 tons. All
tests are performed in compliance with IEEE and
IEC standards.
Our comprehensive, reliable, after-sales service
is reviewed regularly to capitalise on operating
experience.
Product-oriented R&D guarantees constant, gradual evolution in line with Client needs.
Generator test and Inspection
The inspection and maintenance programmes developed by Ansaldo Energia for power plants, from continuous online assessment to major inspections,
are also available for the Hydro Generator line.
Ansaldo Energia has the organisational capabilities to perform all the electrical and mechanical
tests needed to verify generator conditions on
site, providing the Clients with a report on the
status of the machine that allows to estimate its
life cycle and to plan maintenance work.
The diagnostic instruments available include
the loop test (EL CID) stator core inter laminar
fault test system, high voltage winding tests, design verifications with Bump Tests and vibration
measurement campaigns, the full range of Non
destructive tests (NDTs), and alignment checks
and dimensional checks with the help of digital
contact-free instruments.
Generator refurbishment, reconditioning
and repowering
More than a hundred years’ experience in building
generators, combined with the use of advanced
reverse engineering tools, allows us to perform refurbishment, reconditioning and repowering work
on generators based on any technology.
Main supplies
In the field of reversible motor-generators units,
Ansaldo Energia was already a technological leader in 1938 with the Provvidenza hydro plant (60
MVA, 375 rpm).
Ansaldo Energia’s main high speed generatormotor references are Presenzano (Italy, 3 units,
300 MVA, 428 rpm) and Chiotas (Italy, 4 units,
170 MVA, 600 rpm).
The most important low-speed generators manufactured and designed by Ansaldo Energia are
Itaparica (Brazil, 3 units, 290 MVA, 82 rpm), Betania (Colombia, 3 units, 211 MVA, 128 rpm) and
El Caracol (Mexico, 3 units, 208 MVA, 128 rpm).
Other important low speed generators, including
ITA’ (Brazil, 5 units, 305 MVA, 128 rpm), Salto
Caxias (Brazil, 4 units, 345 MVA, 90 rpm) and
Machadinho (Brazil, 3 units, 418.5 MVA, 120
rpm), were designed and manufactured on a consortium basis with other companies.
Petergraf
05/2012
Stampa: Microart Recco - Genova
Ansaldo Energia Hydrogenerators
References in the World
ITALY (350)
11,558 MVA
FRANCE (21)
200 MVA
GREECE (2)
SPAIN (2)
42 MVA
DOMINICAN
REPUBLIC (2)
60 MVA
56 MVA
234 MVA
10 MVA
PHILIPPINES (3)
SIERRA
LEONE (2)
624 MVA
EGYPT (6)
MVA 101
67 MVA
NICARAGUA (2)
206 MVA
TURKEY (4)
TUNISIA (1)
MEXICO (3)
MIDDLE EAST (8)
116 MVA
535 MVA
COLOMBIA (11)
63 MVA
1,455 MVA
ECUADOR (6)
COTE
D’IVOIRE (3)
650 MVA
INDONESIA (5)
185 MVA
155 MVA
BRAZIL (38)
7,155 MVA
PERU (10)
1,088 MVA
VIETNAM (2)
ARGENTINA (26)
1,176 MVA
CHILE (3)
225 MVA
CONGO (8)
CAMEROON (5)
420 MVA
SUDAN (5)
14 MVA
123 MVA
MAURITIUS (2)
34 MVA
Total number of Hydrogenerators (26,500 MVA)
530
References here represented are the ones since 1950. Ansaldo Energia produces Hydrogenerators since the beginnig of XX century.
16152 Genova - Via N. Lorenzi, 8 - Italy
Tel: +39 010 6551 - Fax: +39 010 655 3411
E-mail: ansaldoenergia@aen.ansaldo.it
ansaldoenergia.com