Modernization & Upgrades for Industrial Generators

Robotic inspection

Cost reduction

Reduced downtime

Robotic inspection

Cost reduction

Reduced downtime

Robotic inspection for onsite generator diagnostics

In-situ condition analysis of your 2-pole generators - without rotor removal

Generators are usually in use for many years. During operation, aging and grid effects may lead to severe damages on vital components such as rotor or stator.

Prolonged outages due to unpredicted repairs can be avoided with our advanced robotic in-situ inspection and condition analysis.

Your challenge

Due to the small air gap dimensions of (industrial) generators, it is recommended to disassemble the rotor at regular intervals for a thorough and professional inspection of all main components.

Depending on the complexity of the installation situation and the operating application of the generator, this disassembly is often associated with a high level of installation work and thus a long system downtime. Unforeseen maintenance or repair measures therefore can extend the downtime in an unplanned way.

Our Solution

By performing a robotic inspection prior to the scheduled major overhaul of the generator, we offer a comprehensive, combined inspection program consisting of visual findings and proven electrical diagnostic measurements that allow our experienced experts to make a valid assessment of the condition of your generator.

The results of the robot inspection serve as a solid basis to evaluate the generator condition.

Depending on the condition of the generator, a robot inspection replaces a time-consuming main inspection.

Up to 90 % cost reduction

if main inspection can be replaced with a robotic inspection (depending on condition and installation situation of the generator)

Shorter outage

by eliminating the need of rotor removal (up to 80% saved outage time)

Extended indication detection capabilities

reducing the forced outage risk by tracking of known defects, even during minor inspections

Analysis and recommendations

assessing the generator condition and shift necessary repair measures to planned outages with an optimized schedule

Learn more about our fast and efficient in-situ inspection solution

Our robotic inspection covers the same scope as a major inspection but eliminates the need to pull out the rotor and reducing disassembly to a minimum.*

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Robot Features specially developed for air-cooled generators

Ultra-low frame

Fits into smallest air gap of 2-pole generators

Fast and easy handling

Full freedom of movement on the rotor body with superior ease of operation

Hi-Res video capturing

Full HD video of rotor and stator with different lightning modes for optimal viewing conditions

Our service capabilities

for all air-cooled 2-pole, 4-pole generators and synchronous condensers

2-pole 50 and 60 Hz

4-pole 50 and 60 Hz

Whatever kind of industry your business is, whatever air-cooled generator you have. We offer comprehensive generator services tailored to your specific needs.

With years of experience on generators of current and former manufacturers our skilled field service reduces downtimes and costs to a minimum with cutting-edge tests and tools.

With repairs, rewinds and footprints, our engineering provides solutions that fit your needs and asset strategies. Our portfolio ranges from monitoring products to predictive maintenance and long-term service agreements to reduce your effort and increase the reliability of your generator assets.

As a company with global presence, we have a network of world-wide resources and workshops offering exclusive opportunities and solutions.

Your benefits

Global network

Gain access to a global network and a continuously improved, cutting-edge service portfolio

Experienced global team

Profit from an experienced global team servicing air-cooled generators in industrial applications

Planned maintenance schedules and downtime

Optimize planned maintenance schedules and downtime of your generator assets

Upgrading and uprating

Siemens Energy offers you a broad range of options

This includes

Rewinding the stator and rotor using state-of-the-art insulation technology
Optimizing i.e. reducing heat-up of various components
Optimizing the cooling system
Optimizing efficiency
Upgrading instrumentation and control systems to digital closed-loop control technology
Installation and commissioning of modern monitoring and diagnostics systems

Footprint generators

Tailor made generator replacement concept

This recently developed engineering approach combines the cutting edge in generator technology with the interfaces of legacy generator types while ideally catering to the operator's economic interests. The focus is on integrating state-of-the-art active parts as used in today's newly built units to engineer tailored replacement machines that will take over from the original machines within a foreseeable time frame.

The replacement machines are designed to mate with all relevant interfaces (i.e. shaft centerline height, foundations, etc.) of the legacy unit and to facilitate quick exchange.

The footprint approach can be applied to nearly all generators, irrespective of the model and type of cooling, and for all conventional designs on the 50-Hz and 60-Hz markets, for voltages of 6.3 kV, 10.5 kV or 13.0 kV.

Replacement of excitation system

The increasing cost and delivery times for replacement parts and servicing the generator's original excitation systems are economic incentives for upgrading. Replacing the original analog excitation systems with wear-free, state-of-the-art digital systems not only reduces running costs but also improves unit availability.

Our footprint approach offers many advantages:

Short outage times

because the design is tailored to the specific plant

Increased generator rating

can be achieved, especially if uprating of the entire turbine-generator set is in planning

Different types of configuration

for cooling, as well as on a structural level are possible, e.g. changeover to a closed-cycle ventilation system

Greater availability and dependability

thanks to newer components

Extended service life

Lower operational cost

thanks to reduction of wear parts (stock keeping), and the elimination of the excitation unit bearings

Do you need more information?

If you have any questions or would like to find out how we can help you, please let us know.