GENERATORS

OPERATION
& SERVICING
 GENERATOR SHAFT
LINE
Ansaldo Energia has focused on turbo-generators since the early 1920s,
when we began the production of our first air-cooled turbine generator.
Since then, Ansaldo Energia has continuously enhanced its OEM and
non-OEM services portfolio.
Today Ansaldo Energia’s Generator Shaft Line offers complete solutions for
turbo and hydro generators over a range of applications, leveraging internal
resources, proprietary know-how and technologies, and a global network of
external suppliers. We can also offer complete maintenance, restoration and
modification services on non-proprietary, third-party turbogenerators.

We Know Our Job

The Ansaldo Energia’s know-how and experience as an OEM (Original Equipment
Manufacturer) derives from the design and manifacturing of:
• About 500 air-cooled units in the 10-330 MVA range
• More than 200 units in the 40-1220 MVA range, cooled by hydrogen and hydrogen+water
• Approximately 40 years of technological agreements with GE and ABB
• More than 500 salient-pole generators, manufactured since 1950
• A present large product and services portfolio combining all types of turbogenerators,
including different cooling mediums and plant types (fossil, gas, geothermal, nuclear), and
hydro units with low-medium-high speed

Our team can provide Customers with the technological know-how of an OEM on every type
of technology. By merging a flexible approach, a pro-active structure and highly specialized
competencies over different technologies, we build upon our knowledge and leverage our
organizational expertise, to achieve the know-how to work both on the OEM fleet and on non-
OEM generators.

Total
Range Installed
Type Applications Power
(MVA) Units
SYNCHRONOUS CONDENSERS

MVA
All Generators can operate as

HYDROGEN/WATER-COOLED Up to >60 >31,000

TURBOGENERATORS 1,200
Gas turbines, Steam turbines
HYDROGEN-COOLED Up to >160 >29,500
TURBOGENERATORS 740

AIR-COOLED Up to Gas turbines, Steam turbines, >590 >68,000

TURBOGENERATORS 450 Geothermal turbines

HYDROGENERATORS Up to Hydroelectric plants >530 >26,500

420
>1,400 >155,000
Ansaldo Energia’s Service Portfolio
for Generators
Ansaldo Energia’s Service organization provides worldwide, overall and
life-cycle technical assistance in the fields of generators maintenance and
operation, by adopting ad-hoc and high technology solutions and repairs.
We are able to service a wide range of generator technologies for planned
and unplanned service outages:
• Air-cooled turbogenerator
• Indirectly H2- cooled turbogenerator
• H2- H2O cooled turbogenerator
• Hydrogenerator

Ansaldo Energia’s Service can also provide Clients with in-house or remote
personnel training, supported by tailored digital materials.

Generator Shaft Line offers services in the

following areas:
Shaft Line Solutions
• Generator capacity enhancement (upgrades)
• Maintenance and operation optimization
• Entire unit replacement
• Generator rehabilitation
• Auxiliaries renovation
• Excitation system improvement (from analog to digital, from rotating to static)

Repair
The majority of repair and field activities are completed on-site at the
Customer’s location. Necessary repairs and/or improvements are performed
at our Genoa (Italy) Repair and Manufacturing Facility. If required, our Abu
Dhabi Repair Workshop and Middle East Service Hub (MESH) in Dubai (UAE)
can support repair activities with a network of qualified local suppliers.
On Site
We offer the following on-site capabilities:
• Machining repairs
• Low Speed Balancing and alignment assessment
• Partial or total stator re-winding including RR (Resin Rich), VPI (Vacuum
Pressure Impregnation) and GVPI (Global Vacuum Pressure Impregnation)
technologies
• Turbogenerator rotor re-insulation
• Hydrogenerator salient-pole replacement
• Magnetic core repair, including partial restacking

Machining, such as rotor journals lathing, including metal spray to recreate

original diameters, slip rings rectifying, and coupling holes honeying, is
possible due to fully skilled mechanics/operators and a wide set of portable
equipment, such as: Drilling Machine, Lathe, Vertical Turning Lathe, Line
boring, Horizontal boring and milling.

A special tool, designed and developed by Ansaldo Energia, permits in

addition a fast and reliable dismantling of stator bars insulated as per the
GVPI technology.

Maintenance
We provides every type of maintenance: from a Short Inspection to a Major
Overhaul, covering the machine, its auxiliaries (seal oil system, gas system,
demi-water system, braking system on hydro) and the excitation/starting
systems, regardless of the technology and the manufacturer.

Pre-outage activities:
• Elaboration of Scope of Works (SOW)
• Elaboration of Inspection and Test Plan (ITP)
• Planning Elaboration
• Pre-outage meetings
• Method Statement
• Risk assessment
• Tools preparation
• Spares definition
On-site activities: Post-outage activities:
• On-site mobilization • Final Report issue
• Mechanical dismantling • Data base fertilization
• Fact Finding / Non-Destructive Tests (NDT) • Engineering feedbacks
• Non-Compliance (NC) report and resolution • Technical Information Letter (TIL)
• Failure analysis / Troubleshooting
• Remedials implementation In case of fault, fast intervention to diagnose
• Generator re-boxing the extent of the issue, a troubleshooting RCA
• Start-up assistance and balacing (Root Cause Analysis) and repair are included
• On-site demobilization in the offered services.

Short inspection Minor inspection Major inspection

• Inspection of components • Dismantling of frontal end • In addiction to activities

outside generator frame covers in order to allow visual performed during a Minor
(make-up filter, slip ring, inspection on end-windings Inspection, rotor is pulled out
brushless check) from the generator to allow a
• Dismantling and inspection of
detailed visual inspection and
• Electrical checks on rotor and the bearings
electrical tests
bearing NDE insulation
• Air gap robotic inspection
• Every component of the
(“Magic Inspection”) in the
generator is checked and
stator core with rotor inside
restored

Diagnostics
Diagnostic tools are available to continuously monitor turbogenerator
parameters and behavior, in order to detect aging trends and to address
maintenance activities. We offer a preventive maintenance program,
ensuring that Customers are in the best position to achieve optimum
operation and to reduce costs.

Ansaldo Energia is leader in developing tools and methods to check

the operation of turbogenerators and to assess the state of mechanical
components. Our portfolio includes different tests aimed to minimize
maintenance cost and increase availability of the plant, avoiding the risk of
unplanned outages.

Non-Destructive Testing:
Ansaldo Energia continuously develops
specifically tailored non-destructive testing
of the generator components. We offer high
reliability and repeatability of the tests, as well
as reduced testing time by avoiding long and
expensive dismantling of components.

Life Assessment:
We provide different procedures to analyze
the expected remaining life of capital and
strategic generator components, as well as
the characterization of material exposed to
high temperature and thermal cycles.
Remote Monitoring:
Ansaldo Energia monitors the health of generator cycles 24/7 by the remote
acquisition of vital parameters (typically temperature and vibrations).
The acquired data and specific feedback are returned to the Operator to
provide for planning and predictive intervention and optimize the list of
necessary spare parts.
In particular, DIAGEN® is an integrated diagnostic proprietary system,
designed and developed by Ansaldo Energia: it can be installed on existing
units, regardless of the size, model and OEM.

Integrated Plant Support

Integrated Plant Support (IPS) increases reliability and availability of your
generator, while improving plant efficiency and flexibility. Our Remote
Monitoring & Diagnostics centres of Genoa (I) and Abu Dhabi (UAE) offer:
• 24/7 experts support for data analysis and supervision of plant parameters
• Troubleshooting, event analysis, recommendations through ADA
(Advanced Diagnostic Analysis) system for vibrations analysis and
Distributed Control System (DCS) connection

DIAGEN
DIAGEN® allows real-time measurements, evaluation of trends and Fast
Fourier Transform (FFT) analysis, which can be connected to our monitoring
centres in Genoa and Abu Dhabi.
Several benefits can be achieved by the Customer:
• Easy data reading and assessment with only one instrument
• Support by Ansaldo Energia generator specialists
• Predictive diagnostics to reduce fault risks
• Easy implementation to connect with already installed probes by Ansaldo
Energia or other OEMs
• Cost saving
Long Term Service Agreements
Ansaldo Energia provides Long Term Service Agreements (LTSA) that
incorporates optimized outages planning, state-of-the-art technologies,
skilled permanent monitoring and best-in-class expertise in a customizable
format, which allows:
• Anticipation of technical issues
• Optimization of scheduled and unscheduled interventions and inspections.
• Optimization of spare parts management
• Supply, installation and commissioning of upgrades
• Maintenance and operation day-by-day

Parts
As a generator OEM, and based on our extensive experience in the Servicing
and Maintenance of our own fleet, Generator Shaft Line manufactures and
continually develops capital parts and all other spares for turbogenerators
and hydrogenerators.

Leveraging today’s capacities with a history of knowledge and technological

agreements with different manufacturers, Ansaldo Energia is able to supply
a wide spectrum of parts for third parties’ machines.
As needed, Generator Shaft Line is able to rapidly implement a Reverse
Engineering process, based on a team of well-proven experts in the design
of generator parts, equipped with up-to-date digital tools for 3D scanning
and prototyping.
For more information, please visit www.ansaldoenergia.com
Follow us on Linkedin www.linkedin.com/company/ansaldo-energia

Ansaldo Energia, all rights reserved. Trademarks mentioned in this document are the property of Ansaldo Energia, its affiliates, or their
respective owners in the scope of registration. The information contained in this document is merely indicative. No representation or
warranty is provided, nor should be relied on, that such information is complete or correct or will apply to any particular project. This will
depend on the technical and commercial circumstances. Said information is provided without liability and is subject to change without
notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Via N. Lorenzi, 8 - 16152 Genoa - Italy

Ph: +39 010 6551 - Fax: +39 010 655 3411
202303

Linkedin: www.linkedin.com/company/ansaldo-energia
ansaldoenergia.com