12 FIELD REPAIRS 22 OVERVIEW

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1 PRODUCTS & SERVICES

2 GLOBAL SUPPORT 24/7 Our Aftermarket support spans the globe, covering Europe, The Americas, The Middle East, The Far East and Australia. Teams of highly qualified and experienced field service engineers operate out of our main facilities, with additional expertise available from our Aftermarket facility in Houston, USA. Sales and technical support is further strengthened by our regional offices in Abu Dhabi, UAE and Kuala Lumpur, Malaysia. All providing an interactive global Aftermarket sales support network for all our core products, providing a direct link between our clients and our service bases. Being the largest independent turbogenerator manufacturer in the world doesn t just come from selling more products. It s to do with 125 years of finely honed experience, exacting standards and innovative thinking. Constantly striving to outperform the most challenging demands from diverse industry sectors. It s about being a truly global player. More than that, it s to do with seeing ourselves as a partner, rather than just an Original Equipment Manufacturer (OEM). With the dedication and drive to think long term and provide ongoing, comprehensive support that maximizes the operational life of our products and minimizes risk, downtime and outlay for our customers. BRUSH design and manufacture turbogenerators for gas turbine and steam turbine drives, as well as synchronous motors and power management systems for every energy production sector, including nuclear and hydro electric. We lead the way in the manufacture and servicing of electrical equipment for industrial, marine and offshore applications. With a special focus on solar and geothermal energy, we re leading the way in service, maintenance and support of green energy power generation across the globe. All of our equipment complies with the relevant European, American and International standard specifications, and we re registered to ISO 9001 and ISO14001, which govern the quality of design, manufacture and service. Our manufacturing facilities are located in Loughborough, England; Ridderkerk, The Netherlands; Plzen, Czech Republic and Pittsburgh, USA. 02 CONTENTS 04 INSTALLATION & COMMISSIONING 14 FACTORY REPAIRS 06 MAINTENANCE 16 REPLACEMENT PARTS 08 INSPECTIONS 18 UPGRADES & MODIFICATIONS 10 MAJOR INSPECTIONS 20 CUSTOMER TRAINING 12 FIELD REPAIRS 22 OVERVIEW

3 INSTALLATION & COMMISSIONING INSTALLATION No one understands our machines quite like our own people. Whatever the product, whatever the function, location or application, our experienced and highly trained specialists will handle the installation with professionalism and adeptness. Their experience and knowledge of our products is unrivalled. They use the latest technologies in shaft alignment and bedplate levelling to ensure accuracy. They also manage the complex activities involved with meticulous efficiency, maintaining electrical and mechanical compatibility with the existing plant and minimizing outage times. In short, they make sure it s done quickly and accurately, so you re back up and running as soon as possible. COMMISSIONING With extensive experience across the utility and industrial power, oil and gas, marine and railway sectors, our support teams include highly trained electrical commissioning engineers who can analyze and understand your specific requirements, then commission and test your complete power plant installation, including tasks such as: Generator compliance testing Setting up of excitation systems Equipment protection Grid synchronising. Well versed in the complexities of full scale operations across varied and challenging environments, they can also commission entire power management systems, which are designed to provide management and control of complete generation, distribution and load networks. If you have an onsite team already in place, instead of a full end-to-end commissioning service, we can offer a supervisory service to help co-ordinate the project. 04

4 MAINTENANCE Our philosophy that prevention is better than cure helps you maximize the life of your equipment, minimize downtime and prevent the inconvenience and cost of unplanned outages due to equipment failure. The best way to ensure the continuous operation of your power generation equipment is with an ongoing maintenance programme. We ll carry out thorough inspections at regular intervals, monitor performance and identify and address issues before problems occur. Our Lifecycle Management Programme means we schedule inspections at convenient times in the equipment s operational cycle. To make things easier and quicker, we can predetermine the scope of the work and outage period. Replacement parts are readily available from our extensive and comprehensive parts facility, keeping potential downtime to a minimum. We aim to identify when parts will need replacing, from minor parts to major assemblies, we can help you budget for maintenance costs too. We provide short and long term maintenance contracts for our own products, and we can service other manufacturers products too. We ll tailor your contract to your specific installation and requirements, which can include programmed service visits, emergency call outs, spares holding and, if necessary, exchange/loan units for key pieces of equipment. 06

5 INSPECTIONS If such vital equipment were to go wrong, outage time could have far reaching consequences for your business. But regular, structured inspections as part of an ongoing, comprehensive maintenance plan means: Outage time is reduced to a planned minimum The equipment is continually appraised Potential problems can be addressed before they result in serious failure BRUSH have the capabilities to inspect all other non OEM generators and equipment. Whatever your installation or equipment, whether it s manufactured by BRUSH or a third party, we can tailor an inspection programme to suit your facility. The inspections are classed as either major or minor inspections, then further categorized into levels representing the life of the equipment, dependent on age and running hours. For each level, we define a number of inspection points to be carried out within a specified time frame, and our experienced service engineers will provide a materials kit and appropriate tooling to support each inspection. MINOR INSPECTIONS These generator inspections are carried out with the rotor in-situ during typical outage periods of the prime mover. 8,000 HRS OR 1 YEAR* TYPICALLY INCLUDES BASIC CHECKING OF PROTECTION AND MONITORING DEVICES 08 25,000 HRS OR 3 YEARS* 50,000 HRS OR 6 YEARS* 75,000 HRS OR 9 YEARS* TYPICALLY INCLUDES ADDITIONAL CHECKING OF EXCITER, RECTIFIER AND COOLING SYSTEMS ALSO COMPLETED WITH THE ROTOR IN-SITU, THIS TYPICALLY INCLUDES THE MINOR INSPECTIONS AND ADDITIONAL CHECKS OF THE BEARING AND STATOR END WINDING SIMILAR TO 25,000 HOURS INSPECTION. * Frequency of inspection may be adjusted to suit the customer s maintenance schedule and the number of starts.

6 MAJOR INSPECTIONS Carried out at specified times, major inspections are more in depth and we ll provide a report of the findings with a recommended course of action. We may be able to take care of minor repairs during the inspections, however, if major repairs or replacement parts are needed, we ll need to forward plan the work to minimize outage time. Following each inspection, we ll provide a report to recommend the appropriate course of action relating to preventative maintenance and consider how to minimize its impact on normal plant operation ,000 HRS OR 12 YEARS* SIMILAR TO 25,000 HOURS INSPECTION THIS IS THE MOST COMPREHENSIVE GENERATOR INSPECTION AND INCLUDES THE REMOVAL AND INSPECTION OF THE ROTOR. ROTOR ENDCAPS (ENDRINGS) MAY BE REMOVED AND WE MAY COMPLETE A BOROSCOPE INSPECTION, DEPENDING ON YOUR EQUIPMENT. WITH THE ROTOR REMOVED, A THOROUGH STATOR CORE INSPECTION CAN BE COMPLETED TO CHECK STATOR COIL, WEDGE AND INSULATION CONDITION.

7 FIELD REPAIRS The quickest way to keep your installation or equipment functioning as normal is to carry out any possible repairs, major or minor, on site. With our ongoing maintenance and inspection service, it s usually possible to identify necessary repairs before a critical issue occurs, which allows us to schedule repairs to minimize outage and downtime. Our trained and skilled engineers have a huge amount of experience of working onsite, in vastly different environments, onshore and offshore. In addition to our service bases in key global locations, we also use trusted local companies to support our repair services, who work to our high standards and can provide a speedy response. Our comprehensive field repairs service includes: Engineering design expertise, offering technical solutions BRUSH certified parts and materials Local repair facilities, using trusted affiliates, for manufacturing and assembly, logistic or labour support GENERATORS BRUSH service engineers on site to direct and perform repairs BRUSH service base project teams overseeing the work and ensuring you re happy with the end result. BRUSH have the capabilities to repair all other non OEM generators and equipment. Typical generator field repair services include: Stator end winding refurbishment Stator rewedge Stator rewind Rotor overhaul and end winding refurbishment Rotor-end cap/retaining rings Rotor rewind bearing replacement Oil seal replacement Cooler repair. CONTROL SYSTEMS Typical power management and generator control systems services include: 12 Excitation controller fault finding and calibration Power management system fault finding and calibration Generator protection relay testing Synchronizer testing if we don t think it s economically viable to repair major assemblies, such as rotors, stators and exciters, we can supply parts that are mechanically and electrically interchangeable.

8 FACTORY REPAIRS It may not always be possible to carry out repairs on site, owing to space constraints, unsuitable environments or lack of resources. If this is the case, we would transport the equipment to the factory facilities at one of our manufacturing bases. With a combination of trained engineers, technical equipment and project managers on hand, repairs and overhauls can be carried out quickly and professionally. Our factory-based facilities in the UK, USA, The Netherlands and Czech Republic include: Workshops with cleaning facilities and vacuum drying ovens Modern machining and fabrication facilities Coil manufacturing and vacuum pressure impregnation facilities Assembly workshops including large capacity cranage GENERATORS Typical generator factory repair services include: High voltage test facility 3D measuring facilities Decontaminating processes required for handling hazardous materials including asbestos based insulation found in older products. Stator core replacement Stator rewind Bearing replacement or refurbishment Rotor overhaul and end winding refurbishment Rotor-end cap/retaining rings Rotor rewind Rotor high speed balancing including over speed High voltage testing. CONTROL SYSTEMS Typical power management and generator control systems services include: 14 Excitation controller fault finding and maintenance Power management system fault finding and maintenance.

9 REPLACEMENT PARTS To extend the life of your equipment, whether manufactured by BRUSH or a third party, we have a replacement parts support service which provides a complete range of high quality parts including: Individual components such as diodes and fuses Integral parts such as wedges and coils, laminations, retaining rings Major equipment assemblies such as replacement rotors, stator and exciters, which are mechanically and electrically interchangeable with existing equipment. SPARES Because it s so important that your equipment remains operational, we recommend that you keep a basic spares stock in supply at all times. As well as supporting maintenance programmes, having spares to hand can reduce outage time if a breakdown occurs. We ll offer advice about which parts should be kept as spares. WORLDWIDE AVAILABILITY All common parts for BRUSH products are stocked at our extensive parts facility in the UK, and we can quickly transport them around the globe as required. Common BRUSH DAX generator and PRISMIC Excitation Controller parts are also stocked in the USA. ONLINE PARTS IDENTIFICATION At our online parts identification website, you ll be able to enter your product serial numbers to find recommended parts lists, along with up to date information on stock availability, prices and lead times. Part data for DAX and PRISMIC products is available online, and PRISMIC software updates can be downloaded. To register and access our online parts identification, visit 16

10 UPGRADES & MODIFICATIONS BRUSH products are manufactured to deliver high performance, year after year. BRUSH Aftermarket helps maximize the operational life of your equipment, and because our solutions are carefully engineered and planned, we minimize downtime and the risk of power outages. One important part of the success of our Aftermarket sales support lies with our ability to upgrade and modify equipment to keep your plant functioning well and at peak performance levels. PRODUCT UPGRADES Replacing major assemblies, such as stators and rotors, in both BRUSH and third party products can improve the operation of your plant and extend the life of your equipment. We offer engineered solutions for the following upgrade packages: MW output Equipment cooling system Machine excitation system Retrofit rotor earth fault monitor Generator auxiliary equipment Analogue to digital excitation controller Power management system. PLANT UPGRADES Because of our extensive knowledge of your existing equipment and design, we can tailor fully engineered solutions which are electrically and mechanically compatible with the existing units and power system. MODIFICATIONS If the demands of your business change and you need your equipment to respond, we can carry out modifications to your existing BRUSH equipment, such as power management systems and exciter systems, which bring it up to date and enable you to optimize operations. RE-ENGINEERING AND REVERSE ENGINEERING Our expert BRUSH engineers don t just specialize in our own products. They have comprehensive technical skills and are able to carry out extensive work on equipment produced by third party manufacturers, such as reverse engineering, re-engineering and servicing. 18 Their extensive engineering capabilities include: Mechanical engineering Electrical/electromagnetic engineering Thermal engineering Insulation engineering Control and protection Spare parts.

11 CUSTOMER TRAINING To get the most out of your newly installed BRUSH equipment, your staff need to know how to operate and maintain it effectively. With a well trained operations team, you ll get maximum value from your investment, with improved operating efficiency, productivity and safety. Your team will have full confidence in their equipment and, by understanding its processes and workings, they ll help prevent problems and recognize issues that could cause large scale failure. What s more, if they re able to identify and deal with minor problems themselves, through their in-depth product knowledge, they ll help reduce service call-outs, maintenance and downtime costs. BRUSH TRAINING SCHOOLS Our wide range of courses provide the highest level of training in generator, power management, excitation control and synchronizer systems, for current equipment and older heritage models that are still in active service. The courses are tailored to your specific situation and involve a practical hands-on approach in a relaxed environment to make sure your staff get as much out of the session as possible. Our European in-house training facility is located in Loughborough, England. We find that being away from the normal working environment allows maximum information to be retained. The training center is equipped with working examples of BRUSH power management products, excitation controllers and a power plant simulator. Our training facility in Houston, Texas, is also able to offer full training for the range of BRUSH excitation controllers and attendees are able to control a real generator, including synchronizing to a grid. ON SITE TRAINING Although we prefer to give comprehensive training at one of our facilities, we can also provide on-site training courses if that s more convenient. These courses focus on your specific equipment and can be held during the equipment commissioning stage or later. 20

12 OVERVIEW SALES SUPPORT 24/7 WORLDWIDE COVERAGE TURBOGENERATORS FIELD REPAIRS TURBOGENERATORS CONTROL SYSTEMS LIFECYCLE MANAGEMENT BRUSH LIFECYCLE MANAGEMENT IS A COMPLETE RANGE OF PRODUCTS AND SERVICES DESIGNED TO SERVE YOUR INDIVIDUAL REQUIREMENTS AND COVERING EVERY ASPECT OF AFTERCARE. MULTI POLE GENERATORS EXCITATION & POWER MANAGEMENT SYSTEMS SYNCHRONOUS MOTORS AND GENERATORS MAINTENANCE TRANSFORMERS LIFECYCLE MANAGEMENT 24/7 REPLACEMENT PARTS BRUSH PERFORMANCE UPGRADES When we replace your conventionally cooled rotor with a radially cooled rotor, combined with the replacement of some parts such as the heat exchanger, an increase of power to your BRUSH machine by up to 33% is achievable. Upgrades are also available for excitation systems, cooling systems, ground fault monitor retrofits, lubricating oil systems, sealing oil systems and cooling gas systems. DC MOTORS AND GENERATORS TRACTION MOTORS AC SQUIRREL CAGE INDUCTION MOTORS FACTORY REPAIRS MAINTENANCE SPARES KIT LOUGHBOROUGH, UK RIDDERKERK, THE NETHERLANDS BRUSH ASSURED BRUSH and its customers have generators and other machinery in some of the most harsh and isolated environments in the world, which can often make the delivery of essential parts difficult. In the power industry time is invaluable, which is why BRUSH Assured allows the customer to hold vital parts for their machines at their nearest holding warehouse, so the customer can always be prepared for the unpredictable. INSTALLATION AND COMMISSIONING SUBMERSIBLE MOTORS TRANSFORMERS GENERATOR COMPLIANCE TESTING SETTING UP OF EXCITATION SYSTEMS GRID SYNCHRONIZING UPGRADES PLZEN, CZECH REPUBLIC PITTSBURGH, USA MW OUTPUT EQUIPMENT COOLING SYSTEMS MACHINE EXCITATION SYSTEMS BRUSH OPTIMUM PERFORMANCE PLAN BRUSH PARTS DIRECT BRUSH Optimum Performance Plan allows customers to maximize the life of their machine by choosing a three tiered service plan completely tailored to your needs. With the flexible service options of Bronze, Silver and Gold Performance plans, you can maximize the return on investment considerably and minimize costly downtime. Our Parts website allows customers to browse the recommended parts for their machine and order instantly online. With your own individual account and a wide range of stock held, it is a quick and easy way to ensure your spares are delivered with maximum efficiency to reduce downtime. INSPECTIONS EQUIPMENT PROTECTION MINOR INSPECTIONS (1,3,6,9 YEARS) MAJOR INSPECTIONS (12 YEARS) RETROFIT ROTOR EARTH FAULT MONITOR GENERATOR AUXILIARY EQUIPMENT ANALOGUE TO DIGITAL EXCITATION CONTROLLER BRUSH CONDITION MONITORING BRUSH Condition Monitoring measures Partial Discharge Activity (PDA) within electrical equipment. PDA provides an early warning of degradation of the electrical insulation system, and how quickly that deterioration is progressing. The data produced, along with an accurate assessment of operating conditions, provides top quality diagnostics and a reliable analysis of a machine s health and performance. 22 CUSTOMER TRAINING POWER MANAGEMENT SYSTEM BRUSH ACADEMY, LOUGHBOROUGH ON SITE TRAINING BRUSH MAINTENANCE KITS BRUSH understands the need to have essential maintenance spares close to hand. With this in mind, BRUSH have created kits that contain all mechanical and electrical spares needed for regular maintenance, plus a number of spares that see high replacement. The kits come in robust packaging to withstand the rigours of onsite use. All of this delivered at competitive lead times and considerably discounted prices.

13 BRUSH AFTERMARKET NOTTINGHAM ROAD, LOUGHBOROUGH, LEICESTERSHIRE, LE11 1EX, UNITED KINGDOM T E SERVICEUK@BRUSH.EU BRUSH AFTERMARKET T. EDVARDA BENEŠE 39/564, PLZEN, CZECH REPUBLIC T E SERVICECZ@BRUSH.EU BRUSH AFTERMARKET RINGDIJK 390B, 2983 GS, POSTBUS 3007, 2980 DA, RIDDERKERK, THE NETHERLANDS T E SERVICENL@BRUSH.EU T E SERVICE24@BRUSH.EU BRUSH AFTERMARKET 601 BRADDOCK AVE, TURTLE CREEK, PA, 15145, USA T E SERVICEUS@BRUSH.EU BRUSH AFTERMARKET LOT PT , JALAN TELUK DATUK 28/40, OFF PERSIARAN SEPANG SEKSYEN 28, SHAH ALAM SELANGOR D.E., MALAYSIA T E SERVICEMY@BRUSH.EU