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1 Pag. 1.

2 Index of Subjects HISTORY OF MOTORTECNICA CERTIFICATES LOCATION INVESTMENTS AND FORECASTS SECTORS CONCERNED MAIN EQUIPMENT REFERENCE LIST PRODUCTS AND PROCESSING METHODS

3 History of Motortecnica A general profile of the Company The History Organization Chart

4 Pag. 4 A GENERAL PROFILE OF THE COMPANY MOTORTECNICA has been working in the electromechanic sector since It was born to repair electric machines, later, it extended its activity to the design and construction of motors and alternators of different kind. Today, the company, thanks to the high degree of professionalism characterizing it and to the higher and higher quality of the products and services it can offer, has got a leading position in the sector of construction, repair, overhaul and maintenance of hydraulic electric machines.

Pag. 5 THE HISTORY Founded in 1989 Since 1999 it has been collaborating with the main companies constructing electric machines Since 2003 it has got the

5 Pag. 5 THE HISTORY Founded in 1989 Since 1999 it has been collaborating with the main companies constructing electric machines Since 2003 it has got the qualification of ISO 9001 certified Company Since 2006 it has been constructing electric machines on its own Since 2013 it has been situated in the new seat

6 Pag. 6 MOTORTECNICA L.T.D. ORGANIZATION CHART

7 Certificates Quality Policy IQNet ISO 9001:2008 CSQ ISO 9001:

8 Pag. 8 QUALITY POLICY MOTORTECNICA L.t.d. has implemented and documented a system of quality management meeting the requirements of the international rule UNI EN ISO 9001:2008. The processes found and implemented by MOTORTECNICA are conforming with the requirements of this rule. The continuous improvement of processes, products and services to meet customers demands is necessary to guarantee continuity, solidity and flexibility to the company. In order to obtain this, some goals have been set with the help of the whole staff of Motortecnica: To always meet the customer s needs and fulfil his expectations; To consolidate and widen the company s position on the market; To develop the employers professionalism, to improve their approach to work and to increase their involvement in reaching the company s goals; To develop the management of processes, according to high quality standards; To improve the efficiency and effectiveness of the company s processes, thus reducing costs and waste.

9 Pag. 9 In order to carry out what has been above said we have decided to: monitor the trend of the process indexes and to set more and more motivating target values; improve the company s order management, from the point of view of the planning, advancing and traceability of works, by the acquisition of the suitable software and the right competences. Motortecnica is personally committed to: supporting and implementing such a policy; carrying out all the actions being necessary for spreading and implementing this quality policy; fostering and supporting training actions on the subject of quality, addressed to the whole staff; ensuring the availability of the resources being necessary for the setting up and preservation of the quality guarantee system.

10 Pag. 10 IQNET ISO 9001:2008 CSQ ISO 9001:2008

11 Location Plant Map 12 15

12 Pag. 12 PLANT

13 Pag. 13 PLANT

14 PLANT Innovative characteristics 50 ton Cranes Rotor runaway test bunker Innovative testing room VPI tank

15 Pag. 15 MAP

16 Investments and Forecasts Turnover and Investments 17

17 Pag. 17 TURNOVER AND INVESTMENTS TURNOVER INVESTMENTS FATTURATO INVESTIMENTI

18 Sectors concerned Desing Area Design and Production of complete electric machines

completed and approved by Electrical Engineers having a big experience in the sector. Then, the mechanic design is carried out.

19 Pag. 19 DESIGN AREA In general, the design draft is first analyzed from an electromagnetic point of view, by producing, with the use of a dedicated own calculation software, an electromagnetic draft card (also reporting, of course, the relevant mechanic data of the machine), and then the design is completed and approved by Electrical Engineers having a big experience in the sector. Then, the mechanic design is carried out. It is focused on the design itself and on the structural components check of the alternator, such as: the shaft, the stator housing, the bearings, the anchor clamps, etc. etc.

20 Pag. 20 After having checked the main components, their CAD design is carried out, in order to provide for the relevant supplies for the construction of the machine. The same procedure is followed as regards the secondary components.

Pag. 21 The project drawing up stage is periodically analyzed and checked, immediately intervening in case inconsistencies and mistakes may occur, thus keeping the utmost control over the development

21 Pag. 21 The project drawing up stage is periodically analyzed and checked, immediately intervening in case inconsistencies and mistakes may occur, thus keeping the utmost control over the development of the processes necessary for the optimum completion of works. The schedule of the project carrying out and supply of materials are continuously monitored by the Project Manager, who also is the unique customer s external interface, guaranteeing, in this way, univocal and efficient information.

Pag. 22 DESIGN AND PRODUCTION OF ELECTRIC MACHINES STATOR: FRAME The frame is

number of longitudinal and transversal ribs.

existing ribs are arranged in order that they can allow an optimum air flow.

22 Pag. 22 DESIGN AND PRODUCTION OF ELECTRIC MACHINES STATOR: FRAME The frame is made from quality steel sheets, which are welded and stiffened by a suitable number of longitudinal and transversal ribs. The inside of the stator frame is a part of the cooling ducts, therefore the existing ribs are arranged in order that they can allow an optimum air flow. If it is necessary, the frame is panelled inside with acoustic insulation panels for the reduction of noises in the engine room.

Pag. 23 STATOR: MAGNETIC CORE The magnetic pack or core is made from low loss digit sheets (2,7 W/kg at 1,5 T 50 Hz), duly deburred and insulated on both sides with varnish of class F or higher, a

23 Pag. 23 STATOR: MAGNETIC CORE The magnetic pack or core is made from low loss digit sheets (2,7 W/kg at 1,5 T 50 Hz), duly deburred and insulated on both sides with varnish of class F or higher, a class suitable to resist rubbing mechanic stresses and the aggression of vapours coming from hot lubricating mineral oils. The slots of the magnetic core are open type and the profile of the sheets tooth will be such as to ensure the utmost seal of the taper winding gibs, as regards radial stresses. Groups of sheets are joined together in order to form the different basic packs constituting the magnetic pack. Between the different packs, a suitable number of spacers are inserted, in order to create channels having the task to ensure the pack and the stator winding cooling, as well as to limit load losses. The end packs are suitably tapered and the press pack fingers are from non magnetic steel and are welded to the head sheet. The magnetic core is anchored between plates under pressure and is fixed to the housing by dovetails or similar devices. Both the conveyance and the external shields of the housing can be easily disassembled for the machine inspection and without removing the rotor.

Pag. 24 STATOR WINDING The stator winding is of the double layer shortened pitch kind. The turn is made from electrolytic, drawn, annealed copper metal straps with rounded edges.

24 Pag. 24 STATOR WINDING The stator winding is of the double layer shortened pitch kind. The turn is made from electrolytic, drawn, annealed copper metal straps with rounded edges. To obtain the insulation of the metal strap, a mixed yarn of glass and polyester fibres is wound round it, after having melted the yarn in the oven in order to glue glass fibres to the copper and to each other (Daglas). It is possible to carry out the stator winding by the help of two types of technology: Global VPI Resin Rich Metal straps are not too thick, in order to reduce losses due to the current concentration.

25 Pag. 25 GLOBAL VPI Porous tapes are used, which, during the idle impregnation process, absorb the injected resin, which then fills all holes, in order to make the insulation compact and resistant at best. The advantages of this technology are the short time in which this production stage can take place and the limited costs of it. However, since it is a global impregnation, after this operation, it is not possible to carry out any action (tests, repairs, replacements, etc.) on a single coil, since the whole winding has become a unique block. RESIN RICH Tapes pre-impregnated with resin are used. The resin, during a process of thermal pressing of the active sides of the coil, after pouring out, fills all the air pockets and makes the insulation compact and electrically resistant. One of the advantages of this technology is that it is possible to intervene, if necessary, on each single coil (tests, repairs, replacements, etc.), since each coil is insulated and thermally pressed singularly. The so obtained insulation is of a class F or H, according to the tapes being used.

Pag. 26 On the bottom of the magnetic core slot, a strip of insulating material is arranged, then the two coils are inserted and between them a separator is introduced.

On the side of each coil, a corrugated thick element completes the elastic assembly and the grounding system of the winding situated in slot.

26 Pag. 26 On the bottom of the magnetic core slot, a strip of insulating material is arranged, then the two coils are inserted and between them a separator is introduced. The external slot coil is protected by an insulating tape from the pressing action performed by the radial spring, being fixed flat below the slot wedge. On the side of each coil, a corrugated thick element completes the elastic assembly and the grounding system of the winding situated in slot. Then a locking system of coils is carried out, within the stator pack, which can compensate the inevitable dimensional adjustment of the insulation, taking place especially within the first years of the machine operation. The coils are characterized by a suitable inversion of head conductors (transposition), in order to reduce circulation losses. The coil heads are linked to anchor rings, which are suitably insulated by glass roving ties impregnated with polyester resin.

Pag. 27 The anchor rings, set on brackets fixed to press pack plates, are as regards their number and size, suitable to resist electrodynamic, even anomalous stresses, which may occur during the

27 Pag. 27 The anchor rings, set on brackets fixed to press pack plates, are as regards their number and size, suitable to resist electrodynamic, even anomalous stresses, which may occur during the machine operation. The connections between coils, carried out by the brazing of copper bars being suitably shaped, are insulated by glass taping-continuous mica-polyester felt, on which a thermal shrinking tape is fixed and then they are baked into a ventilated oven. Insulation is completed by varnishing with epoxidic resin. Such connections are then anchored to the housing with brackets, clamping brackets and spacing blocks, tightened with glass roving ties. Resistance electric thermometers are set in the stator pack slots, between the two coil sides, and they are arranged in a circumference, in a suitable number for each phase, in order to measure the winding temperature. Such thermal resistances are insulated, by a glass cloth sheath being pre-impregnated and polymerized. The connection cable of each thermal detector comes out from the winding by passing through the press pack fingers and, after having being fixed by fasteners, reaches the terminal board set on the housing.

All materials from which it is made are carefully selected, in order that it can resist the highest

28 Pag. 28 ROTOR: SHAFT The rotor shaft is made from a forging unit, having very good mechanic and magnetic characteristics. All materials from which it is made are carefully selected, in order that it can resist the highest stresses that may occur because of the centrifugal force, under conditions of runaway speed. For the mechanic sizing of the shaft, analyses of the torsional and bending critical frequencies are carried out.

29 Pag. 29 ROTOR POLES Poles are made of steel blank sheets, having marked mechanic and magnetic characteristics, their thickness is conforming with the machine characteristics. The polar pack is pressed by two front steel plates (press pole plates), having marked mechanic characteristics, by means of stout tie rods. The press pole plates are also meant for absorbing the centrifugal force exerted by the front sides of the coils. The transversal section of the pole consists of the pole body and the pole extension. The pole body is rectangle shaped. The pole extension consists of a profile made of a circumference arch, having a radius such as to be an air gap varying from the pole centre to the circumference, in order to practically obtain an outlet sinusoidal shaped wave. Pole extensions will be provided with a damping winding, made from low resistance bars, housed in slots made near to the external surface of such extensions and brazed in front of sectors made from the same material. Sectors are then connected with each other, in the interpolar space, by flexible bolted butt straps, in order to shape a closed ring. Then a damping cage of a continuous kind, will be obtained.

30 Pag. 30 The complete poles are fixed to the rotor body with hammer head or dovetail connections and shrinking wedge shaped keys. ROTOR WINDING The rotor winding consists of wound up spiral shaped electrolytic copper metal straps of one layer kind. The turns are obtained by brazing copper plates and the insulation between the turns of the coil is made from double-lacquered Nomex interlayers. Coils are suitably processed and hot pressed before assembly, in order to make them be compact and avoid yieldings, even under the maximum stresses caused by runaway speed. During the hot pressing of the coil, the impregnation resin of interlayers becomes fluid and performs a gluing action between the copper turns and the insulation itself.

Pag. 31 If it is necessary, the coils can have a suitable number of jutting turns, in order to increase the surface of thermal exchange between the copper and the cooling fluid.

31 Pag. 31 If it is necessary, the coils can have a suitable number of jutting turns, in order to increase the surface of thermal exchange between the copper and the cooling fluid. The coil setting on the pole pack is carried out in order to ensure a perfect insulation between the copper and the core. In order to obtain this, a layered cloth thermal stiffening glass and resin material, between the pole and the coil, is used, and insulating frames, also made from cloth-glass and resin, one below and the other one above the coil itself, are used. Pole coils are then connected in series with each other, with copper connections joined by screws. In order to allow the coils expansion, special devices will be provided, at the level of the contact surfaces between the upper turns and the insulating frames. Steel frames are fixed to the pole core with screws and they exert a continuous pressure on the coil by the means of springs. Brackets or wedges can be also provided. The setting of the coil on the pole is to be carefully carried out, in order to produce a component being mechanically suitable for resisting any temperature variations and the stresses due to centrifugal actions.

Pag. 32 BEARINGS The bearings will be able to support the weight of all the rotating parts of the synchronous machine and its possible residual axial thrusts and those of the corresponding hydraulic

32 Pag. 32 BEARINGS The bearings will be able to support the weight of all the rotating parts of the synchronous machine and its possible residual axial thrusts and those of the corresponding hydraulic turbine. The bearings are of the white metal type (sliding), with autonomous lubrication in oil bath and are provided with rigid seals, made from a material resistant to corrosion having the IP44 protection degree. All the active parts of bearings are assembled within a box. TERMINALS The terminals of each phase will be conveyed, by insulated bars, outside the alternator space, up to the step-up transformer and to the board of star point and grounding.

33 Main Equipment Our Equipment 34-42

34 Pag. 34 MPM 3000 Automatic Brazing Machine MPM 3000 Automatic Brazing Machine

35 Pag. 35 Numerical Control Machining Center - 3 Axes Numerical Control Machining Center - 5 Axes

36 Pag. 36 Vertical Lathe Electric Oven

37 Pag. 37 Cut and Skin Pulse Generator

38 Pag. 38 Zeiss Automatic Meter 50kV-200kVA AC Generator

39 Pag. 39 Ridgway Taping Machine Stator Coils Shaping Machine

40 Pag. 40 Dimensional Control Mockup Dimensional Control Mockup

41 Pag. 41 Equipment Thermal Press

42 Pag. 42 Laser Cutting Machine Waterjet Cutting Machine

43 Reference List Leading Works 44-47

44 Pag. 44 LEADING WORKS CLIENT DESCRIPTION POWER EXECUTION Ilva Spa Taranto Synchronous Motor 8210 kw 20 poles 10kV 8210 kw Horizontal Ilva Spa Taranto Synchronous Motor 5000 kw 20 poles 10kV 5000 kw Horizontal Ilva Spa Taranto Synchronous Motor 6000 kw 20 poles 10kV 6000 kw Horizontal Ansaldo Energia Rotor Poles for Alternator 31500kVA 31,5 MVA Horizontal Ilva Spa Taranto Three-phase Asynchronous Motor MCS800L4 5500kW 10kV 5500 kw Horizontal Ilva Spa Taranto Synchronous Motor MTS kW 10kV 3677 kw Horizontal Ilva Spa Taranto Three-phase Synchronous Motor MTS kW 10kV kw Horizontal Ilva Spa Taranto Three-phase Synchronous Motor MTS kW 10kV 8000 kw Horizontal B-TICINO S.P.A. Alternator MTS MVA 15 kv 35 MVA Horizontal Ilva Spa Taranto Three-phase Synchronous Motor MTS kW 10kV 3677 kw Horizontal Ilva Spa Taranto Three-phase Asynchronous Motor MCS kW-3kV 1550 kw Horizontal ENEL S.P.A. Alternator MTS11-6-1,45MVA-3kV 1,45 MVA Horizontal Alstom Power Italy Stator for Alternator 62,5 MVA 11 kv 62,5 MVA Vertical Ansaldo Energia Rotor Poles for Alternator ATBW kVA 28 MVA Vertical Ansaldo Energia Rotor Poles for Alternator ATBW kVA 27,5 MVA Vertical

45 Pag. 45 LEADING WORKS CLIENT DESCRIPTION POWER EXECUTION Ansaldo Energia Rotor Poles for Alternator ATBW kVA 42 MVA Vertical Ansaldo Energia Rotor Poles for Alternator TIBB kVA 61,25 MVA Vertical ENEL S.P.A. Alternator MTS ,6 MVA Horizontal ENEL S.P.A. Alternator MTS ,6 MVA Horizontal ZECO Alternator MTS-V ,6 MVA Vertical ENEL S.P.A. Alternator MTS ,5 MVA Horizontal ENEL S.P.A. Alternator MTS-V ,9 MVA Vertical ENEL S.P.A. Alternator MTS ,5 MVA Horizontal ENEL S.P.A. Alternator MTS ,5 MVA Horizontal Alstom Power Spain Rotor Poles for Alternator 82MVA 15,5kV 82 MVA Horizontal EON Alternator MTS-V ,4 MVA Vertical EON Alternator MTS-V ,25 MVA Vertical EON Alternator MTS-V ,5 MVA Vertical EON Alternator MTS-V ,7 MVA Vertical

46 Pag. 46 LEADING WORKS CLIENT DESCRIPTION POWER EXECUTION ENEL S.P.A. Alternator MTS MVA Horizontal ENEL S.P.A. Alternator MTS MVA Horizontal ENEL S.P.A. Alternator MTS-V ,5 MVA Vertical ENEL S.P.A. Rotor Poles for Alternator ATBV MVA Vertical ENEL S.P.A. Alternator MTS ,75 MVA Horizontal ANDINO - ENEL S.P.A. Alternator MTS-V ,65 MVA Vertical ANDINO - ENEL S.P.A. Alternator MTS-V ,65 MVA Vartical SEL Alternator MTS MVA Horizontal SEL Alternator MTS MVA Horizontal Voith - SEL Alternator MTS ,6 MVA Horizontal Voith - SEL Alternator MTS ,6 MVA Horizontal Impel System Alternator MTS-V MVA Vertical Andritz - Hydro Dolomiti Enel Alternator MTS-V MVA Vertical Andritz - Hydro Dolomiti Enel Alternator MTS-V MVA Vertical

47 Pag. 47 LEADING WORKS CLIENT DESCRIPTION POWER EXECUTION Voith - Cimo Alternator MTS-V ,3 MVA Vertical ZECO Alternator MTS-V ,95 MVA Vertical Andritz Alternator MTS ,1 MVA Horizontal Andritz Alternator MTS ,1 MVA Horizontal Voith Alternator MTS-V ,35 MVA Vertical

48 Products and Processing Methods Products and Processing Methods 49-90

49 Pag. 49 Horizontal Alternator (35 MVA) Vertical Alternator (1,6 MVA)

50 Pag. 50 Vertical Alternator (8,5 MVA) Vertical Alternator (0,9 MVA)

51 Pag. 51 Horizontal Alternator (24,5 MVA) Vertical Alternator (3,7 MVA)

52 Pag. 52 Vertical Alternator (12,5 MVA) Horizontal Alternator (3,5 MVA)

53 Pag. 53 Vertical Alternator (3,65 MVA) Horizontal Alternator (18,5 MVA)

54 Pag. 54 Stator Frame Stator

55 Pag. 55 Stator Frame Stator Frame

56 Pag. 56 Magnetic Pack Magnetic Pack

57 Pag. 57 Packed Stator Frame Packed Stator Frame

58 Pag. 58 Packed Stator Frame Stator Coils

59 Pag. 59 Stator Coils Stator Winding - Roebel Bars

60 Pag. 60 Stator Winding - Roebel Bars Stator Winding Up

61 Pag. 61 Stator Winding Up Stator Winding Up

62 Pag. 62 Wound Up Stator Stator Connections

63 Pag. 63 Complete Stator Frame Complete Stator Frame

64 Pag. 64 Complete Stator Frame Complete Stator Frame with Protection Devices

65 Pag. 65 Rotor Shaft Rotor Shaft

66 Pag. 66 Rotor Coils Rotor Coils

67 Pag. 67 Rotor Coils Rotor Coils

68 Pag. 68 Rotor Coils Polar Core

69 Pag. 69 Polar Cores Wound Poles

70 Pag. 70 Wound Pole Wound Poles

71 Pag. 71 Complete Rotor (14 poles) Complete Rotor (14 poles)

72 Pag. 72 Complete Rotor (4 poles) Complete Rotor (20 poles)

73 Pag. 73 Complete Rotor (28 poles) Complete Rotor (10 poles)

74 Pag. 74 Complete Rotor (14 poles) Complete Rotor (8 poles)

75 Pag. 75 Brushless Exciter Construction Brushless Exciter Construction

76 Pag. 76 Brushless Exciter Brackets

77 Pag. 77 Lower Bracket Amperometric Transformer Board (T.A.)

78 Pag. 78 Mechanic Processing Stage Mechanic Processing Stage

79 Pag. 79 Mechanic Processing Stage Mechanic Shop

80 Pag. 80 Electric Tests During Rotation Electric Tests During Rotation

81 Pag. 81 Electric Tests During Rotation Runaway Tests

82 Pag. 82 Assemblies within the Shop Assemblies within the Power Plant

83 Pag. 83 Assemblies within the Power Plant Assemblies within the Power Plant

84 Pag. 84 Assemblies within the Power Plant Assemblies within the Power Plant

85 Pag. 85 Assemblies within the Power Plant Assemblies within the Power Plant

86 Pag. 86 Assemblies within the Power Plant Assemblies within the Power Plant

87 Pag. 87 Assemblies within the Power Plant Assemblies within the Power Plant

88 Pag. 88 Transports Transports

89 Pag. 89 Transports Transports

90 Pag. 90 Transports Transports

91 MOTORTECNICA. - Via Zona Industriale Campigliano, San Cipriano Picentino (SA) - P.I./C.F Tel.: Fax: info@motortecnica.com

Design specifications

Design specifications Design To relevant standards: IEC, VDE, DIN, ISO, EN With squirrel-cage or slipring rotor Degree of protection IP 55 / IP 65 Cooling method IC511, suitable for both indoor and outdoor