Tr a d i t i o n I n o v a t i o n Q u a l i t y. Renewable energy and efficiency. elprom zem

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1 Renewable energy and efficiency

2 Patented Technological Innovation by Elprom ZEM Co. for Generator Stator Coil for High Voltage and Manufacturing Procedure for the Same Gold Medal and Diplom from the International Fair Plovdiv 2006 for New insulation system of the stator winding of Hydro generators. This innovation guarantees improvement of the Energy Efficiency of the rehabilitated generators up to 14,2%. Dipl. Eng. Valentin Filipov Executive director Elprom ZEM Co Is an inheritor of STZ Vasil Kolarov, which was founded in The company is the founder of the electric machines industry in Bulgaria and currently is the biggest manufacturer of rotating electric machines in the region. Since 1997 Elprom ZEM Co is a private company in the group of Industrial Holding Bulgaria. The processes in Elprom ZEM Co are certified by the ISO authorized company SGS: ISO 9001:2008, ISO , and OH- SAS Elprom ZEM has a patent for development of a New insulation system for stator winding HV for Hydro generators, which guarantees increased energy efficiency of the rehabilitated machines up to 14.2%. At the official presentation of the patent at the Plovdiv Technical fair in 2006 Elprom ZEM was awarded with a Golden medal and a Diploma. Elprom ZEM unites highly qualified specialists as well as ambitious young team of professionals. We take advantage of not only our abundant 60-years experience, constant strive for elaboration and development, but also the potential of the latest technologies and materials of highest quality, made by the leading suppliers aimed to provide continuous optimizing of the parameters of the manufactured machines by us. In Elprom ZEM s growth plan we have set investments in a few directions in order to improve the quality of our product line and services manufacturing technologies, technical equipment, controlling technologies and equipment, human resources, labor conditions and environment. Hydro generators made by Elprom ZEM operate in more than 200 HPP on 5 continents. In the last decade Elprom ZEM, using aggressive customer-orientated marketing, impetuously extends outside Bulgaria. We work on partnership basis with leading world companies, resulting in accomplishing number of largescale hydro-electric projects. Some of them are hydro generators for newly built HPP in Armenia, Czech Republic, Uganda, Canada and India, HPP Studen kladenets in Bulgaria, and especially the biggest Hydro Power Plant on the Balkan Peninsula Tsankov kamak. Rehibailitated by us hydro generators are distinguished by long operational life, accompanied by increased energy efficiency. TRADITIONS. INNOVATIONS. QUALITY. The established good traditions alongside with continuous implementation of innovations in various ways guarantee a quality by Elprom ZEM. We firmly stand behind our slogan by maintaining the deserved reputation over the years and permanent strive for improvement. We proudly declare that in Elprom ZEM you could recognize your loyal and professional partner.

3 The produced in ELPROM ZEM rotating asynchronous and synchronous electrical machines are based on classical, repeatedly verified in production design and operation schemes and the latest developments in technology. HPP Yegesis Armenia Stator frame for hydro generator 50 MVA Stacking of stator core lamination 25 MVA STATOR FRAME The stator frames of the manufactured rotating machines are welded construction made of rolled structural steel for the large dimensions. The sufficient mechanical strength is reached by using transverse and longitudinal ribs, which forms channels for the cooling air. Welds are performed by highly qualified specialists, using latest welding equipment and best technology and the quality control is done by specialized X-ray and ultrasonic equipment. In certain cases, after the performance of welding operations, tempering or vibration of the housings is done in order to remove residual mechanical stresses. Machining of the base surface is carried out by vertical and horizontal drills and lathes which are capable of handling stator frames of rotating machines with a capacity of 250 MVA. Stator core is installed on the stator frame by means of guiding beams with T-heads and tightening bolt connections. For the smaller dimensions frames of iron castings are used. STATOR CORE Stator core is built up from laminations (steel punching) made of high grade steel with low specific losses and high magnetic conductivity and cover the requirements of the International Standard of Electrical Machinery efficiency EN The factory has high quality machines for bilateral varnish coating with a thickness of 4 to 2 μm, which allows to achieve good filling with steel of the stator package with guaranteed insulation between segments. Technology used to built up the stator core allows to achieve high accuracy of geometric dimensions and guaranteed excellent magnetic properties. The ready stator core is checked for local areas of overheating by thermal vision, control of the inner cylindrical surface by laser teraker. Stator frames 50 MVA; 35 MVA

4 INSULATION SYSTEMS Stator winding, depending on the capacity of the electrical machine is done like coils or stator bars. ELPROM ZEM has the equipment and technology for the implementation of the winding insulation with heat resistance class F and H. Insulation systems are made on technology lines for hydro-vacuum pressing or Global VPI for voltage of hydrogenerators and other rotating electrical machines up to 20kV. The company has established its own Know-how as it is obvious from registered patents N Based on this patent Elprom ZEM has rehabilitated twenty four hydro generators with power output from 4,5 MVA up to 235 MVA, rated voltage from 6,3 kv up to 19,5 kv so far, and increased their efficiency up to 14, 2 %. Resin Rich insulation system is used for large dimensions and production of high voltage stator bars. Consolidation of the tapes is carried out in a deep vacuum process and under HVP. Cross section of insulation system image from a magnetic microscope Picture of dam Ticha overflow weir Cross section of insulation system image from an electronic microscope Stator bars 20 kv Preparation for installation of a hydro generator in Canada VPI technology is used for electric machines with medium and small dimensions. Both technologies use special insulation tapes, supplied by leading manufacturers in this sphere. ELPROM ZEM use machine application of the main insulation in the active part and the coils front parts. Automated preparation of insulation system ensures even distribution of input materials along the section and even strength which leads to the production of main insulation homogeneous distribution which guarantees equally distributed in the volume electrical field. Depending on the operating voltage there is crown protection made by selecting conductive and semiconducting tape with suitable V / A characteristic. The both technology insulation systems are characterized by low levels of partial discharge and leakage current, high dielectric strength, coefficient of stock ks = 2 3, ks =Ubr.v/Utest),(Utest=3.5*Unom). When we put all in one it predetermined operational resources of about years. For its long-term successful operation and high performance and quality of insulation systems, Elprom ZEM was awarded with a gold medal and a diploma at the Plovdiv Technical Fair. VPI treated stator Elprom ZEM has an oxygen free pyrolysis furnace for combustion of old insulation systems for repair and rehabilitation of rotating electrical machines, which is environment friendly and ensuring complete safety of the environment. Global VPI systems

5 Producing a shaft ROTOR The manufacturing rotors in Elprom ZEM are salientpole and non-salient poles types with short-circuit rotor cage. Depending on the power output of the hydrogenerators the rotor might be implemented with rotor spider which is welded construction, made by rolled structural steel or rotor ring built up by segments. Poles are laminated construction. They are jointed to the rotor body. For manufacturing the the segments for the rotor spider Elprom ZEM use a precise laser cutting machine, allowing to achieve high accuracy of manufacture of the elements ( mm). Coils of the rotor poles are made of copper strip with a purity of 99.99%, insulated with high quality materials and temperature resistance class F and H delivered by the leading companies in the industry. Exciter s winding is made of a copper strip with rectangular section. It is pressed by 2000 tons press, providing constructive withstand of the worst emergency regimes such as over speed and short-circuit. Damper coil winding is made of copper or brass. Preparation of a rotor for installation in HPP in Canada BEARINGS Pole coils for a hydro generator 50 MVA Rotor 235 MVA from HPP Chaira, Bulgaria Our electrical rotating machines are equipped with bearings, supplied by reputable manufacturers, guarantying reliable operation in heavy duty environment, handling various radial and axial intensions from water turbines and others. Depending on the design requirements, our machines are being equipped with rolling bearings, sleeve bearings with babbit or teflon contact layer. The lubricant systems are designed in order to guarantee long operational life, possibility for effortless maintenance and controlling the condition of the bearings and their cooling. In manufacturing of hydro generators with higher rated power we use slide bearings with oil pressure lubrication, while in the process of making generators with lower rated power we inbuilt the bearings inside bearing shields.

6 TEST PROCEDURES Brushless exciting system EXCITATION SYSTEM The power supply of the rotor exciter coil, depending on the client application, is implemented in two versions: with slip rings mounted on the shaft and brushes, supplied by static converter and using the inbuilt-exciter with rotating rectifier. Elprom ZEM has developed a wide range of exciters with rotating rectifier, characterized by high reliability of operation due to lack of rotating electrical outlet. As for performance are embedded in the body of the generator for external mounting for vertical and horizontal mounting. Elprom ZEM Co is certified under International standard for quality management ISO 9001:2008 and applies its System for quality management in the manufacturing process. We are also certified under ISO 14001:2004 and OHSAS 18001:2007. In the manufacturing process of the hydro generators, at all stages of the execution of the separate components, there are control tests held to ensure the quality. A subject of control tests are: geometrical measurements of the details and units of the construction, the performance of the welds, the condition of the insulation of the separate details and produced windings. We pay a special attention of the insulation of the windings by holding a full 100% control of their elements on every technological level from their producing to their installation. The mandatory tests include: high-voltage testing in accordance with the nominal power of the windings and the requirements of the standards. Upon finalizing the installation we take off the performance data from the hydro generator and cautiously verify them with the technical data set in the project. Tests of bars and sections Training of our specialists to work with the 3D Laser Tracker Brushless exciting system Dynamic balance of a rotor Experimental installation of a hydro generator 11

7 Elprom ZEM Co owns latest technology digital measurement and control equipment: 3D laser tracker for precise control of geometrical measure accurate to 5 µm/35 m and 17 µm/70 m; thermo vision cameras for control and measurement of temperatures; three-phase combined meter of electrical parameters all types I, U, cosφ, rated and nominal power, analyzing harmonics, pie charts and others, vibrations measurement and balance, including balance in operating mode. HPPs with installed hydro generators, manufactured and rehabilitated by Elprom ZEM Co. All electrical machines, manufactured by Elprom ZEM Co, cover the requirements and are according to IEC 60034, covering all the requirements of the standard. Assembling into test plant HPP Studen kladenets, Bulgaria HPP Konal, India SHPP Yahinovo, Bulgaria THE FUTURE AND ELPROM ZEM Installation of a rotor in stator in a HPP Our investment policy is focused on constant development and implementing of the latest technological achievements in the world. Elprom ZEM Co will continue its active participation in developing and implementing of new, modern manufacturing technologies aiming to offer to its clients reliable products which correspond to or exceed the requirements of all international standards. We will keep our researches in the field of the natural forces and possible methods for transforming them into energy in order to provide a better and cozier world to us and our children. 13

8 ELPROM ZEM WORLDWIDE North America Canada Cuba Europe Czech Republic Macedonia Germany Italy Hungary Africa Algeria Morocco Egypt Asia Armenia China India Indonesia Iran Iraq Kosovo Poland Switzerland Ukraine Tunisia Uganda Kazakhstan Pakistan Russia Syria Uzbekistan Vietnam The dam wall Tsankov kamuk, Bulgaria 15

9 W h e n w a t e r a n d t e c h n o l o g y c o m b i n e 41, Rozhen Blvd., 1271 Sofia, Bulgaria tel.: , fax: zem@elprom-zem.com