45MW gas-fired generator repair delivers improved reliability

Among the largest private electricity power generators in Thailand recently skilled a loss of generating capability in one of its 6 gas-fired generators which supplies the actual heavily industrialised area wherever it is located. With an important need for a swift as well as reliable repair, the local Sulzer agent was contacted, expecting to to getting the 45MW power generator back up and running as quickly as possible.

Thailand ranks among the biggest per-capita power consumers within south-east Asia and has a good installed generating capacity associated with around 32GW. Demand through local steel, textiles and also rubber industries has led to power demand increasing in a annual rate of just as much as 3. 5%. With the nearby electricity supply under continuous pressure, it was essential that this generating facility was came back to full capacity in the earliest opportunity.

Once the preliminary request had been made, a great engineer from the UK had been immediately dispatched to the engine power to start the investigation function. The initial findings and suggestions were compiled into a statement which was handed to the customer so that they could make an informed choice on the most appropriate course of action.

The very first and most obvious observation has been that the generator was not situated in a conventional generator hall but rather it was found in a more separated, covered area. This resulted in an initial issue with removing the particular rotor for repair because a large fence and other hurdles would need to be negotiated to permit the rotor to be checked out and repaired.

In this case typically the preliminary investigation showed there was a fault with the stator core and two of often the stator windings would need to get replaced. The report also created recommendations for the complete inspection from the rotor and made provision for a few more routine maintenance methods while the stator was being fixed.

Once the repair scope along with schedule was agreed, the actual Sulzer engineers were given the 16 day window by which to complete the repair in addition to return the generator in order to service. While the local support agent maintained the conversation with the client and prepared the local aspects of the task, a team in Liverpool, UK, where the replacement shelves would be manufactured coordinated the particular materials and personnel needed.

Neil Fuller, Tendering and Projects Manager at Sulzer’s Service Centre in Luton, commented: “We provide tech support team that enable our regional service agents to deliver the quality service that our clients anticipate. By working closely using the customer and keeping all of them fully apprised of the job, we are able to ensure the deadlines are met, even if we come across unexpected issues.

“In many we will provide a project office manager for repairs such as this, however the client is always given a variety of options when it comes to completing typically the repair. Depending on the urgency, we are able to support a 24/7 restoration schedule and with our own coils manufacturing and testing service in Birmingham, we can assure the new components are manufactured as well as tested prior to being moved to site where the group needs them. ”

When the generator was handed over towards the Sulzer team they required a 220-tonne mobile motorised hoist to lift the 12-tonne rotor over the nearby obstructions so that it could be transported to some workshop for a full ‘rings-off’ inspection. Based on the age of often the generator a number of remedial functions were carried out on the one that had been previously agreed, prior to it was tested and prepared with regard to re-assembly.

In the meantime, the damage for the stator core was restored and the two new shelves were installed before additional testing was completed to make sure a reliable repair. Before long it had been time to bring the crane returning to the site to allow the one to be reinstalled.

Neil proceeds: “As with many projects such as this, we found some extra issues with the generator since the project progressed, but our own continuous communication with the consumer allowed these to be fixed easily without causing any more delay. This business is all about providing quality within an agreed timescale and that requires a level of believe in from the client which in turn is founded on the experience and expertise of these completing the repair. ”

As part of a wider servicing programme, the Sulzer crew suggested that the remaining 5 generators should receive an age-appropriate inspection so that any earlier warning signs could be picked up and also actioned.

As a result of the effective inspection, recommendation and fix works carried out to restore the actual 45 MW generator into a fully operational state, just before departing for their return trip, part of the repair team had been invited to visit one of the client’s other sites in order to complete a few remedial works and precautionary maintenance checks on a number of other generators.

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