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.
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 decisive factor for machine
reliability. The new 4675 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.
Ansaldo Energia currently produces three basic types of Our generators are designed with a redundant, closed-circuhydrogenerators:
it cooling system. Based on the type of generator involved,
• generators for river flow (low/medium speed)
axial fans with adjustable angle blades are used, or solutions
• generators for high-head plants (medium/high speed)
with radial ventilation or electric fans for motor-generators
• motor-generators for pumped storage systems
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 single-piece 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
IEC and IEEE 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 generator-motor 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.
Ansaldo Energia
Hydrogenerators
ITALY (350)
11,558 MVA
FRANCE (21)
200 MVA
GREECE (2)
SPAIN (2)
DOMINICAN
REPUBLIC (2)
234 MVA
10 MVA
MEXICO (3)
PHILIPPINES (3)
SIERRA
LEONE (2)
624 MVA
EGYPT (6)
MVA 101
67 MVA
NICARAGUA (2)
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
206 MVA
TURKEY (4)
TUNISIA (1)
60 MVA
VIETNAM (2)
56 MVA
42 MVA
Stampa: Microart Recco - Genova
02/2014
Petergraf
Reference
in the World
ARGENTINA (26)
1,176 MVA
SUDAN (5)
CONGO (8)
CAMEROON (5)
14 MVA
420 MVA
123 MVA
CHILE (3)
225 MVA
MAURITIUS (2)
34 MVA
2014 1Q Summary
Total number of Hydrogenerators (26,500 MVA)
>40
16152 Genova - Via N. Lorenzi, 8 - Italy
Tel: +39 010 6551 - Fax: +39 010 655 3411
E-mail: ansaldoenergia@aen.ansaldo.it
ansaldoenergia.com