NOTABLE PROJECTS

In the last 35 years Dr Znidarich headed engineering for many large electrical machine refurbishments, upgrades and uprates. 

 

As there is no large electrical machine manufacturing in Australia, Dr Znidarich had developed locally based engineering knowledge,

which was sucessfully applied and tested on many large machine projects  in Australasian region and worldwide.

​LIST OF NOTABLE PROJECTS
  • 1981 – First Turbo Generator Rotor Rewind by an Australian Company Including Design and In-House Manufacturing of the Windings – 100 MW Directly Cooled English Electric Design for Tallawarra PS/ELCOM NSW.  Project Included Complete Reverse Engineering, Design of New Winding and Elimination of Slot Liner Migration Problem;

  • 1983 – The First in Australia Design and Manufacture of Fully Transposed Bar (360˚ Roebel) for Liapootah Hydro PS (31 MVA, 11kV, 20 Pole) for Hydro Electric Commission Tasmania;

  • 1985 – Design and Manufacture Fully Transposed Bar (360˚ Roebel) for Tungatinah Hydro PS (31.25 MVA, 11kV, 10 Pole for 2 Machines) for Hydro Electric Commission Tasmania;

  • 1985 – Design and Manufacture 2 Sets of Windings for Wayatinah Hydro PS (15 MVA, 11kV, 24 Pole) for Hydro Electric Commission Tasmania.  Due to Correctly Implemented Winding Transposition, Windings Operated 25˚C Cooler when Compared to Competitor’s Windings;

  • 1988 – Design, Manufacture and Install Stator Windings for 60 MVA, 11 kV, 28 Pole Warragamba Dam Hydro Generator.  The Winding was Re-Designed to Roebel Bar Configuration and was the First Project in Australia Where an Outside Contractor (Transfield Tulk) was Fully Responsible for Dismantling, Refurbishment, Reassembly and Recommissioning of the Machine.

  • 1991 – Successfully Complete R&D Project to Locally Develop an Australian HV Insulation System Capable of Meeting Most Stringent Accelerated Ageing Testing (Voltage Endurance and Thermal Cycling);

  • 1994 – Design and Manufacture HV Winding for 60 MVA, 11 kV, 6 Pole Synchronous Condenser for Transpower NZ.  Winding Re-Designed to Single Turn Roebel Bar with Machine Output Uprated to 72 MVA.  Project Repeated in 2012 for Sister Machine;

  • 1994 – 1995 – Design and Manufacture 20 Sets of Hydro Generator Stator Windings for Seven Hydro Electric Power Stations in Indonesia (5 – 10 MW).  Project Carried Out in Partnership with ELIN from Austria.  In Most Cases Machine Output was Uprated.

  • 1994 – 1995 – Design, Manufacture and Install Stator Windings for 66.7 MVA, 11 kV, 40 Pole Eildon Hydro Generator in Victoria.  Two Turn Original Design was Converted to Single Turn Roebel Bar, which Resulted in Considerable Winding Loss Reduction and Lower Stator Winding Operational Temperatures;

  • 1999 – 2009 – Complete Engineering Design for Refurbishment, Upgrade, and Uprate of 8 Hydro Generators for Roxburgh PS, for Contact Energy, New Zealand.  Work Scope Included New Stator Cores, New Stator Windings, and Re-Insulation of Rotor Poles.  Stator Windings Were Subjected to the Most Stringent Accelerated Ageing Testing (Voltage Endurance and Thermal Cycling).  Generators Uprated from 44.44 MVA to 50 MVA;

  • 2003 – Design and Manufacture Complete Set of 167 MVA, 13.8 kV, 8 Pole Synchronous Condenser Stator Windings (360˚ Roebel Bars) for New York Power Authority;

  • 2003 – Design and Manufacture Complete Set of 162 MVA, 14 kV, 2 Pole Turbo Alternator Stator Windings (360˚ Roebel Bars) for Peterborough PS in UK.  End Winding Support Re-Designed to Allow for Axial Thermal Expansion and Mitigate Double Frequency Vibrations;

  • 2003 – 2006 – Complete Engineering Design for Refurbishment, Upgrade, and Uprate of 6 Hydro Generators for McKay PS, for Southern Hydro in Victoria.  Work Scope Included New Stator Windings, Re-Insulation of Rotor Poles, Provision of Solid State Excitation System, and New Up-Rated Sliprings.  Complete Power Station Output was Uprated from 96 MW to 150 MW (an Uprate of 56.25%);

  • 2004 – 2006 - Complete Engineering Design for Refurbishment, Upgrade, and Uprate of 4 Hydro Generators for Kareeya PS, for Stanwell Corporation in North Queensland.  Work Scope Included New Stator Windings, and Re-Insulation of Rotor Poles.  The Four Machines were Uprated from 22.5 MVA to 24.0 MVA;

  • 2006 – 2008 – Design and Manufacture Windings for Three 27 MVA MG Sets for AMTRACK in USA.  MG Sets are Used for DC Power Supply to AMTRACK Rail System.  Both Synchronous Motor, and Single Phase Generators Uprated by 30%;

  • 2007 – Design, Manufacture and Install Stator Windings for 12.5 MVA, 12.5 kV, 2 Pole Turbo Generator for University Campus in Hawaii.  Multi Turn2 Pole Coil Required Special Flexible Insulation System, which was Specifically Developed for this “One Of” Rewind.  Later On, this Insulation System was Subjected to Exhaustive Type Testing, and Developed Into Standard GE Insulation System Under Code Name GEGard 400 HVII;

  • 2007 – 2009 – Design and Manufacture Seven Improved Slipring Assemblies for 350 MVA Tumut 3 Hydro Generators, and Seven Improved Slipring Assemblies for 137.5 MVA Murray 2 Hydro Generators.  The Aim of the Projects was Reduction of Slipring Operational Temperatures, which was Successfully Accomplished;

  • 2008 – Complete Design Engineering, and Engineering Installation Consultation for Rewind and Refurbishment of 60 000 HP, 13.2 kV, 14 Pole Pump Motors for Mark Wilmer Pumping Station in Arizona USA.  Truly Multinational Effort, with Australian Engineering, Winding Manufacture in Canada, and Rewind by USA Crews.  TGE Energy Services Engineering Coordinated Project Execution and Received Highest Praises from Central Arizona Project Management;

  • 2008 – 2011 – Complete Engineering Design for Refurbishment, Upgrade, and Uprate of 4 Hydro Generators for West Kiewa PS, for AGL in Victoria.  Work Scope Included New Stator Cores, New Stator Windings, and Re-Insulation of Rotor Poles.  Although the Uprated Machine is Capable of 25 MVA, the Uprate was Limited to 18.1 MVA by Hydraulic System Constraints.

  • 2013 – 2014 - Engineering Design and Support for Refurbishment, Upgrade and Uprate of Tekapo A hydro generator.  The Work on the Generator Included Design, Provision and Installation of New Stator Frame, Design, Provision and Installation of New Low Loss Stator Core; Design, Provision and Installation of Uprated Stator Winding, Design, Provision and Installation of New Rotor Poles and New Rotor Field Winding.  The Machine was Successfully Commissioned and is Operating in Accordance with New Design Parameters;

  • 2015 - Engineering Support for an Overhaul of Tumut 1 U1 Hydro Generator, 101.0 MVA, 12.5 kV, 16 Pole/375 r/min.  The Work on the Generator Included, Complete Initial Inspection and Electrical Testing of Stator, Rotor and Exciters, Re-Tightening of Stator Core, Stator Core Testing, Slot Wedge Design and Partial Re-Wedging of Stator Slots, Stator Winding Repairs, Final Inspection and Electrical Testing;

  • 2015 – 2016 - Engineering risk analysis for SHL Guthega 33.33 MVA, 11.0kV, 14 Pole/428 r/min hydro generator.  The analysis included the Methodology of Cutting/Removing Single or Multiple Failed Coils Out of Circuit and the Detailed Analysis of Additional Heating Resulting from Stator Winding Imbalances Due to Removed Stator Coils;

  • 2017 - Engineering Design and Engineering Support for Pacific Hydro Ord River 19.5 MVA, 11.0 kV,16 Pole/375 r/min Hydro Generator.  The Work on the Generator included Mechanical Disassembly, Inspection and Electrical Testing, Design and Fitting of New Solid Copper Circuit Rings and Stator Leads to Replace Inadequate Cable Connections and to Implement HV/LV Leads Inversion, Design of Stator Slot Wedges and 100% Re-Wedge of Stator Slots, Fitting of New PD Couplers, Final Electrical Testing, Mechanical Re-Assembly and Re-Commissioning.  The Generator is Now Operating Virtually Free of Partial Discharges;

  • 2017 - Engineering Design and Engineering Support for Origin Energy Kangaroo Valley 93.33 MVA, 16.0 kV, 12 Pole/500 r/min Hydro Generator.  The Work on the Generator Included Design of Completely New Slot Wedging System to Accommodate Elastic Rubber Mid Slot Strip, Engineering for Stator Core Repairs and Stator Core Testing, Design of Stator Slot Wedging System and Complete Stator Slot Re-Wedging, Engineering for Stator Core Re-Tightening by Stator Core Stud Resonant Frequency Method, Engineering for Rotor Rim Re-Tightening, and Analysis of Axial Forces Due to Stator/Rotor Axial Misalignment;

  • 2017 – 2018 - Engineering and Manufacturing Specification for Spare Stator Winding Bars for SHL Blowering 80.0 MVA, 12.5 kV, 16 Pole/375 r/min Hydro Generator;

  • 2017 – 2019 – Principal Australian Based Consultant for Snowy Hydro for the Procurement of New Guthega Hydro Generator – 45 MVA, 11 kV, 428.6 rpm/14 Pole.  The Consulting Work Involved Review and Development of the Tender Document, Audit of the Manufacturing Facility in India, Detailed Design Reviews, Both Mechanical and Electrical and Overseeing HV Stator Winding Type Testing in India;

  • 2018 – 2019 –Australian Based Consultant for Snowy 2 Hydro Pumped Storage Scheme Motor-Generators.  The Work Included Review and Development of the Tender Documents for Motor-Generators, and Design Review of Tender Submissions, Both Electrical and Mechanical;

  • 2018 – 2019 – Complete Design and Installation of Circuit Rings for Osborne PS in Adelaide 160 MVA Turbo Generator.  The Aim of the Project was HV/LV Leads Inversion to Eliminate High Partial Discharge Activity Caused by Degraded Outer Corona Protection System.  The Project Included the Design for the Complete Workshop Simulation of Generator End Winding to Ensure Correct Fit and Reduce Risks of On-Site Installation Problems.  The Installation was Trouble-Free and Successful.  The Generator is Now Operating with Greatly Reduced Levels of Partial Discharges and has Estimated Life Extension of About 10 Years.

GMECS​

GENERATOR & MOTOR ENGINEERING

CONSULTING SERVICES 

 

Tel: +61 477 024 179