Our hydro generator capabilities

Whether you’re planning an upgrade, addressing a performance issue, or responding to an unexpected outage, fast and knowledgeable support is critical. Hydro generator insulation systems typically require rewinding after 40–50 years. Refurbishment offers the opportunity to redesign stator coils for improved insulation and efficiency. Using advanced modeling software, we optimize performance with new coils and cores.

From compact units to large-scale hydro generators, Sulzer provides complete rewind solutions and re-engineers replacement parts to extend service life and boost performance.

Field service

Specialist on-site support for hydro generators

Experienced field teams working on hydro generators, with a strong understanding of the specific challenges of large, ageing machines and complex site conditions during planned outages, including inspection, outage support, rotor and stator repairs, uprates, and life-extension work on aging assets.

Your benefit: Extended asset life and more reliable operation through expert on-site support, repairs, and uprates for ageing hydro generators.

Engineering

Hydro-focused diagnostics and life extension

Advanced engineering expertise supporting aging hydro fleets, addressing insulation degradation, mechanical wear, and performance challenges to guide effective life extension, including root cause analysis, condition assessment, uprates, and tailored strategies to extend generator life.

Your benefit: Extended generator life and improved reliability through targeted diagnostics, uprates, and life-extension strategies.

Coil manufacturing

Hydro generator coil and bar replacement

In-house design and manufacture of stator coils and bars for large hydro generators, typically replacing original windings after decades of operation, to restore performance and enable long-term life extension, including stator bars, coil replacement, insulation upgrades, and life extension solutions.

Your benefit: Restored performance and extended generator life through high-quality coil and bar replacement with upgraded insulation systems.

Speak to our experts

Watch how Sulzer restored power at Dinas Station
Hydropower generators are built for long-term reliability, but aging equipment can fail unexpectedly. When Statkraft faced a generator failure at Dinas Power Station, Sulzer’s expert teams delivered a fast, safe, and efficient repair—minimizing downtime and restoring performance. Watch the video to see how Sulzer made the difference.

White paper

How Sulzer extended the life of a legacy UK hydropower plant

 

As the energy transition accelerates, maintaining existing renewable assets is just as important as building new ones. Many UK hydropower stations have delivered reliable, low carbon electricity for decades, but now require expert refurbishment to continue performing at their best.

 

This white paper highlights how Sulzer successfully overhauled a hydro generator at a Welsh power station, restoring performance and extending its service life for years to come.

Download whitepaper

Download relevant hydro generator services content

Brochure

High voltage coil manufacturing for hydro power generation

ENGLISH pdf
Languages:
EN

White paper

Regenerated after 58 years of service

ENGLISH pdf
Languages:
EN

Frequently asked questions

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