TDC Parsons Peebles is currently manufacturing a large wound stator for a legacy machine originally built in 1996 at the Edinburgh Pilton facility. This was one of the largest four-pole generators produced at the time, intended for a paper mill in New Zealand.

The machine train comprises a nominal 40MW, 450kPa back pressure turbine with 1250kPa pass-out, an Allen 40.7MW parallel shaft gearbox, and a Parsons Peebles 39,600kW, 1500rpm, 11kV synchronous generator.

Following the initial call regarding the stator failure in service, TDC Parsons Peebles quickly began reviewing its extensive archives and locating all original design documentation. This enabled the pre-procurement of critical long-lead items to ensure the quickest possible turnaround. With an estimated 42,000kg of electrical steel required and 33,000 lamination segments needed to build the core, our supply chain was key to sourcing and delivering on time. The core dimensions are 2,020mm outer diameter, 1,270mm inner diameter, with an overall length of 2,500mm.

In-house, our engineering team has also modernised the stator coils to enhance the original design, while strictly maintaining the generator’s original output at the customer’s request. Once all designs and drawings were checked and verified, our dedicated project management and procurement team were on hand to begin the next phase prior to manufacture.

The core is currently undergoing full welding following consolidation and will proceed to winding, followed by impregnation and testing, before being loaded into a bespoke transportation frame to ensure safe delivery to site.