CERB GROUP has successfully completed the first phase of the rehabilitation of a 40 MW hydrogenerator featuring a massive stator core with a diameter exceeding 5 meters and a height of more than 3 meters. The project is large-scale and technically complex, requiring high precision and close coordination among multidisciplinary teams of specialists.

The process began with a comprehensive inspection of the stator, including a detailed condition assessment, cleaning, and inspection of all welds. A new stator magnetic core made of high-quality electrical steel was then manufactured, carefully stacked and press-fitted to ensure accuracy, structural integrity, and long-term operational reliability.

All required measurements and tests of the stator magnetic core were performed by CERB’s High-Voltage Laboratory in full compliance with the client’s specifications. These included geometry and core pressing checks, as well as inspections for potential localized overheating. The test results were documented in official reports and confirmed the equipment’s readiness for the next stage.

The second phase of the rehabilitation will involve the installation of a new stator winding. It will be fitted with upgraded end-winding and slot components, reinforced wedges to ensure secure fixation of the windings, and modern insulation systems designed to protect against overheating and vibrations.

For enhanced safety and operational control, a resistance temperature detector (RTD) monitoring system will be installed, enabling continuous temperature monitoring of both the copper windings and the magnetic core steel.

During this phase, all prescribed electrical measurements and tests of the stator winding will be carried out, including insulation testing and verification of electrical parameters.

Upon completion of the rehabilitation, the generator, with an active power output of 40 MW, will be fully restored and ready to deliver stable and efficient power generation for many years to come.

This project is part of a series of similar rehabilitation projects successfully delivered by CERB GROUP in the field of large-scale energy equipment repair and modernization, demonstrating the company’s technical expertise, careful planning, and precise execution at every stage.