HYDROGENERATORS

Ansaldo Energia
Hydrogenerators
A sustainable future in terms of energy must in-
volve a reduction in CO
2
emissions and our de-
pendence on fossil fuels, which at present satisfy
most of the worlds energy needs.
Hydro energy delivers both of these benefts, be-
sides it has low operating costs, it requires limi-
ted maintenance and is renewable.
In coming decades there will be signifcant growth
in hydro energy compared to traditional thermal
power plants.
Tailor made generators
Ansaldo Energia began working in the feld of Po-
wer Generation with the installation of the frst
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 con-
stant product improvement, we can now offer our
Clients a comprehensive range of hydrogenera-
tors, 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 fow (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 hydro-
generators, we have always preferred to
design generators based on plant cha-
racteristics in order to guarantee maxi-
mum performance in terms of effciency,
reliability and maintenance.
The process of optimising the hydrogene-
rator, based on the features of the plant,
begins with electromagnetic design to de-
fne the active parts of the machine. De-
sign data (power output, voltage, speed,
etc.) is used to identify the ideal machine
confguration based on existing bench-
mark models, by balancing maximum
performance with transport and erection
constraints.
The generator project is then verifed using advan-
ced computational tools to analyse its electroma-
gnetical, 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 benefcial 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 equali-
sed thrust bearings and, if required, a self-pum-
ping thrust collar.
These solutions are available in non driving end
(NDE) thrust bearing confguration with a single-
piece thrust collar, and in driving end (DE) thrust
bearing confguration with a two pieces thrust
collar.
Generators are designed to withstand the hea-
viest 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 genera-
tors comply with internal and international bench-
mark quality standards.
Ansaldo Energia has two centrifugation facilities,
one of which under vacuum, to balance and over-
speed test the generator fy wheel effect up to
over 6,000 tm
2
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, gra-
dual evolution in line with Client needs.
Generator test and Inspection
The inspection and maintenance programmes deve-
loped by Ansaldo Energia for power plants, from con-
tinuous online assessment to major inspections,
are also available for the Hydro Generator line.
Ansaldo Energia has the organisational capabili-
ties 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, de-
sign verifcations 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 re-
furbishment, reconditioning and repowering work
on generators based on any technology.
Main supplies
In the feld of reversible motor-generators units,
Ansaldo Energia was already a technological lea-
der in 1938 with the Provvidenza hydro plant (60
MVA, 375 rpm).
Ansaldo Energias 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 ma-
nufactured and designed by Ansaldo Energia are
Itaparica (Brazil, 3 units, 290 MVA, 82 rpm), Be-
tania (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 con-
sortium basis with other companies.
16152 Genova - Via N. Lorenzi, 8 - Italy
Tel: +39 010 6551 - Fax: +39 010 655 3411
E-mail: ansaldoenergia@aen.ansaldo.it
ansaldoenergia.com
Ansaldo Energia Hydrogenerators
References in the World
INDONESIA (5)
155 MVA
PHILIPPINES (3)
116 MVA
VIETNAM (2)
206 MVA
MIDDLE EAST (8)
535 MVA
ARGENTINA (26)
1,176 MVA
NICARAGUA (2)
63 MVA
ECUADOR (6)
650 MVA
DOMINICAN
REPUBLIC (2)
60 MVA
BRAZIL (38)
7,155 MVA
COLOMBIA (11)
1,455 MVA
MEXICO (3)
624 MVA
PERU (10)
1,088 MVA
CHILE (3)
225 MVA
SPAIN (2)
42 MVA
ITALY (350)
11,558 MVA
FRANCE (21)
200 MVA
COTE
DIVOIRE (3)
185 MVA
SIERRA
LEONE (2)
67 MVA
CONGO (8)
420 MVA
CAMEROON (5)
123 MVA
MAURITIUS (2)
34 MVA
GREECE (2)
56 MVA
TURKEY (4)
234 MVA
SUDAN (5)
14 MVA
EGYPT (6)
MVA 101
TUNISIA (1)
10 MVA
S
t
a
m
p
a
:

M
i
c
r
o
a
r
t

R
e
c
c
o

-

G
e
n
o
v
a




0
5
/
2
0
1
2





















































P
e
t
e
r
g
r
a
f

References here represented are the ones since 1950. Ansaldo Energia produces Hydrogenerators since the beginnig of XX century.
530
Total number of Hydrogenerators (26,500 MVA)