Overhaul 30MVA generator

A 30MVA (10.5 kV) generator is essential for cogeneration at a prominent food manufacturer. During recent online condition measurements of were discovered signs of degradation in the windings. This, combined with significant contamination of the generator, necessitated intervention.

Online monitoring

Partial discharges

Regular or online monitoring of partial discharges (partial discharges) in the windings of generators is critical to preventing a range of long-term problems and costs. Regular monitoring of partial discharges and proactive action at the first signs of problems can therefore provide significant benefits in both the short and long term.

By regularly monitoring partial discharges in generators, the aging process of the windings can be closely monitored. This preventive monitoring also leads to significant cost savings by avoiding costly emergency repairs or complete rewinding. Moreover, timely detection and intervention increases overall generator reliability and safety, while minimizing the risk of production downtime and maintaining efficient energy consumption.

Reverse engineering

3D scanning

Particular attention was paid to the generator cooling fans. Using advanced 3D scanning technologies, exact replicas of the cooling fans were created, making it possible to produce brand new spare parts.

Pictured is a 3D print of the entire assembly. The unprecedented accuracy makes reproducing spare parts much easier.

Assembly and commissioning

After a complete overhaul and extensive testing, our assembly team expertly reinstalled and commissioned the generator, checking every detail to ensure optimal performance.

Our service team excels in challenging situations, even in tight locations. With expertise in logistics and the use of the various horizontal and vertical transport options, we move fragile machines skillfully and efficiently. This is how we minimize the impact on your production.

Visualizing partial discharges

Accurate localization

Using an acoustic camera to visualize partial discharges offers several advantages:

Precise localization: The acoustic camera can very precisely locate the source of partial discharges, enabling faster and targeted interventions.

Real-time monitoring: With real-time visualization, operators can get instant feedback on plant condition and quickly identify any problems.

Safety: Acoustic cameras provide a non-invasive method of inspecting equipment, avoiding direct contact with hazardous or high-voltage components.

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Efficiency: The ability to detect partial discharges quickly and accurately saves time and reduces the need for lengthy and costly downtime for maintenance.

Comprehensive analysis: Many acoustic cameras offer advanced analysis features, allowing users to identify patterns, compare measurements and perform in-depth evaluations.

Preventive maintenance: Regular monitoring with an acoustic camera can detect early signs of wear or damage before they grow into larger problems.

Cost savings: Detecting problems early can prevent costly repairs or replacements in the long run.

In short: Using an acoustic camera to visualize partial discharges increases the accuracy, safety, and efficiency of the maintenance and inspection process.

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