Thai 45MW Gas-Fired
Generator Repair Delivers
Improved Reliability
apprised of the project, we are able to
ensure the deadlines are met, even if we
encounter unexpected issues.
A 220-tonne mobile
crane was used to lift the
12-tonne rotor
"In many cases we will provide a project
manager for repairs such as this, but the
client is always given a range of options
when it comes to completing the repair.
Depending on the urgency, we can
support a 24/7 repair schedule and with
our own coil manufacturing and testing
facility in Birmingham, we can guarantee
the new components are manufactured
and tested prior to being transported to
site where the team needs them."
One of the largest private electricity
generators in Thailand recently
experienced a loss of generating capacity
in one of its six gas-fired generators which
supplies the heavily industrialised area
where it is located. With an urgent need
for a swift and reliable repair, the local
Sulzer agent was contacted, with a view to
getting the 45 MW generator back up and
running as soon as possible.
Thailand ranks among the largest percapita power consumers in Southeast Asia
and has an installed generating capacity
of around 32 GW. Demand from local steel,
textiles and rubber industries has resulted
in power demand increasing at an annual
rate of as much as 3.5%. With the local
electricity supply under constant pressure,
it was essential that the generating facility
was returned to full capacity at the earliest
opportunity.
Once the initial request had been made,
an experienced engineer from the UK was
immediately dispatched to the power
plant to start the investigation work.
The initial findings and
We provide technical
support that enable our
local service agents to deliver
the high quality service that
our clients expect. By working
closely with the customer and
keeping them fully apprised of
the project, we are able to ensure
the deadlines are met, even if we
encounter unexpected issues.
Neil Fuller, Tendering & Projects Manager at
Sulzer's Service Centre in Birmingham
recommendations were compiled into a
report which was handed to the client so
that they could make an informed decision
on the most appropriate course of action.
The first and most obvious observation
was that the generator was not located in
a conventional generator hall but instead
it was found in a more isolated, covered
area. This led to an initial issue with
removing the rotor for repair since a large
fence and other obstacles would need
to be negotiated to allow the rotor to be
inspected and repaired.
In this case the preliminary investigation
showed that there was a fault with the
stator core and two of the stator windings
would need to be replaced. The report also
made recommendations for the complete
inspection of the rotor and made provision
for some more routine maintenance
procedures while the stator was being
repaired.
Once the repair scope and schedule was
agreed, the Sulzer engineers were given a
16 day window in which to complete the
repair and return the generator to service.
While the local service agent maintained
the communication with the client
and organised the local aspects of the
project, a team in Birmingham where the
replacement coils would be manufactured
coordinated the materials and personnel
required.
Neil Fuller, Tendering & Projects Manager
at Sulzer's Service Centre in Birmingham
commented, "We provide technical
support that enable our local service
agents to deliver the high quality service
that our clients expect. By working closely
with the customer and keeping them fully
Once the generator was handed over to
the Sulzer team they needed a 220-tonne
mobile crane to lift the 12-tonne rotor
over the nearby obstacles so that it could
be transported to a workshop for a full
'rings-off' inspection. Based on the age
of the generator a number of remedial
works were carried out on the rotor that
had been previously agreed, before it was
tested and prepared for re-assembly.
In the meantime, the damage to the stator
core was repaired and the two new coils
were installed before further testing was
completed to ensure a reliable repair.
Before long it was time to bring the crane
back to the site to allow the rotor to be
reinstalled.
Neil continues: "As with many projects like
this, we found some additional issues with
the generator as the project progressed,
but our continuous communication with
the client allowed these to be solved easily
without causing any further delay. This
business is all about delivering quality
within an agreed timescale and that
requires a level of trust from the client
which in turn is based on the experience
and expertise of those completing the
repair."
Sulzer can support a 24/7
repair schedule and has its
own coil manufacturing
and testing facility