135MW 13.8kV 360? Transposed Turbo bars

Every job is a challenging one, but this one in particular (manufacture and supply of entire stator bars with full rewinding on site) is very challenging. Being insulated under the GVPI scheme, originally, we have been awarded to do a resin rich rewind for this stator even though we have the facility to handle this job in house. (200ton in house crane and 5 x 12Metre VPI chamber and hot chamber)

We had already rewound another 1x135MW, in a record time, for the same customer but with the available spare coils. Understanding our workmanship and quality, the customer chose to rewind all of their generators (4 x 135MW) during off season and eventually awarded us with the above job. we competed with a very reputable MNC OEM and still managed to convince the customer to execute this job.

The wall insulation space available is very low to withstand surge voltages, if any. Hence we adopted a very specific insulation scheme for these bars and just to be sure, we tested these bars at 3U+1 = 41KV.

The bars (66 Top + 66 Bottom) are ready for random final inspection by the customer and waiting to be packed and despatched thereafter.