Generators are the foundation of contemporary energy systems that light and heat homes, provide power to buildings and industrial facilities, and operate hydropower dams. Reliability is not a word you associate with water, but when it comes to mission-critical applications, and in particular power generation through hydro turbine generators, it’s a must!
And that’s where Generator Rewinding is so important. Rewinding not only rejuvenates a dying generator but also improves its performance, efficiency, and lifespan.
Whether inside a factory or at a hydropower station, re-machining of generator systems constitutes an affordable option that may extend the lifetime of equipment and minimize downtime.
What is Generator Rewinding?
Generator Rewinding Generator rewinding is the process of removing the copper windings found in the stator or rotor of a generator. These windings are essential in the generation of magnetic fields for electrical energy generation.
The windings, over time, also have the potential to become less efficient or damaged as a result of heat, vibration, and degradation of insulation, resulting in the loss of power and higher energy usage or the complete failure of the device in some cases.
There are several steps in the generator rewind process:
- Disassembling the generator
- Stripping off old or bad coils
- Core cleaning and inspection
- Rewinding With suitable insulation, we also offer to install new windings
- Testing and reassembling the generator.
This operation brings the generator into original factory specifications, or can sometimes improve a unit through the use of uprated materials or modern winding and insulation techniques.
Effect of Rewinding on the Efficiency of Generators
In industrial and hydropower applications, especially, efficiency is key, with energy losses correlating directly with profitability and sustainability. Worn or crossed windings have increased electrical resistance, therefore, they generate heat in the motor and reduce its output.
Wind Your Generator Rewinding
Rewinding of Generator can be beneficial in multiple ways:
- Minimized Electrical Resistances: New windings decrease resistance to current flow, resulting in less power loss and lower temperatures.
- Improved Insulation: New insulation material can bear higher temperatures and provide better protection.
- Optimized construction: Engineers can fix design issues or rearrange a winding for improved magnetic flux during rewinding.
- Hydro turbine generators: for hydro applications where stable power is required for grid support and power regulation, higher efficiency means high-grade execution with less maintenance.
Why is Rewinding Beneficial to Increase the Life of a Generator?
Generators are expensive and time-consuming to replace. Generator Rewinding is a well-established means to prolong the life of the generator by 10 to 20 years, depending on application and operating conditions.
Here’s how the repeat supports longevity:
It eliminated progressive deterioration, purchase replacement, and no more failures.
Better thermal stability due to improved insulation systems that withstand the breakdown of the insulation over time.
Minimizes mechanical strain by repositioning and optimizing winding configuration.
Preconditions the generator for greater capacity needs, when called upon, uprating during a rewind.
At hydropower stations, the turbine generators operate nonstop for several decades, and rewinding helps ensure they continue to run without requiring the whole generator to be carved out, preventing temporary outages and ecological disturbance.
Price Comparison: Re-webbing vs. New Webbing
“Rewind or replace” is a difficult question for operators to answer when faced with an underperforming generator. Here’s a comparison to think about:
- Cost Savings: Rewinding is generally 30–50% less expensive than a new generator.
- Quicker Turnaround: Rewinding can be performed in weeks, while replacement might require months.
- Life Increase: A generator’s life can be extended up to 10-20 years with good rewinding.
- Environmental Applicability: Rewinding recycles centre elements to alleviate material wastage and carbon impact.
- Customization Available: Performance upgrades are available during rewinding.
- Reduced Downtime: Faster repair means less time off production.
- Perfect for High-End Generators: Especially good for Hydro Turbine Generator, which are expensive to replace.
Sure, total replacement in the case of obsolescence or severe damage may sound like a good concept, but in the majority of cases, generator rewinding is the smart choice with a far better ROI…especially for high-capacity, hydro turbine generators, which may literally end up costing millions of dollars to replace.
The Quality of Gogoal Hydro in Generator Rewinding
Specialists should be considered when either preserving or improving hydropower systems. Gogoal Hydro has developed a strong name for generator rewinding, especially in large hydro and industrial generators.
Why Choose Gogoal Hydro?
- 20 years of Experience: Knowledgeable on different generator brands and models, and also a bunch of water turbine alternators.
- Advanced Diagnostics: Comprehensive electric and thermal testing to determine the precise extent of rewinding required.
- Special Rewinding Service: For the specific operation conditions and design characteristics of the generator.
- Material: The use of Class F or H insulation, high-quality copper wire, insulation, and sealing resin, corrosion protection, and stable and reliable performance.
- Quick Turnaround: Reduced downtime on site through effective project management and in-house skills.
- Compliance and Safety: IEC &60; IEEE &60; ISO All series are in line with or exceed IEC, IEEE, and ISO quality standards.
Gogoal Hydro provides reliable and durable solutions for industrial and hydropower plants – whether its partial coil replacement, full rewinding, or performance upgrades.
Conclusion
The generator’s performance can come with direct implications on the productivity and energy efficiency of any given operation, but particularly in some industries, such as hydropower, where the Hydro Turbine Generator plays a crucial role in the generation of electricity. A generator’s performance deteriorates over time due to electrical and mechanical wear and the loss of energy, overheating, and possible damage, the attacker can cause.
Need assistance with your hydro or industrial generator?
Get in touch with Gogoal Hydro now for uncompromising diagnostic and expert generator rewinding services to get you back to full power.