Precision Rewinding of a 1125 kVA Marine Generator

The process began with a controlled burn-off treatment. The generator was placed in our burn-off oven and subjected to 390°C for 14 hours, effectively removing the old winding without compromising the core structure.

Following this, the unit was carefully cleaned and primer-painted, setting the stage for electrical testing and new winding preparation.

The stator was then readied with precision: each slot was cleaned, treated, and prepared for the insertion of new coils, custom-designed to match the original performance specifications.

Parallel to this, the exciter stator underwent a complete overhaul, ensuring the supporting systems met the same high standards.

After the coil insertion, all windings were interconnected, and a specially designed internal cylinder was inserted. This ensures optimal varnish distribution during the Vacuum Pressure Impregnation (VPI) phase, maximizing insulation quality and durability.

The generator was then cured in our oven to harden the varnish and secure all components. Once the curing process was complete, the unit was assembled and reinstalled onboard, fully prepared for seamless marine operation.