Generator Refurbishment

Abu Dhabi, United Arab Emirates

Project Summary Project Value: £750,000

Service: Repair & Refurbishment
Duration: 24 Months

Background Quartzelec had the opportunity to work with a gas liquefaction company based in
Abu Dhabi. For the past four decades, the organisation has been the regional
pioneer in LNG, LPG and natural gases production. The site is 160km from the
Abu Dhabi coastline and is the core operational gas liquefaction plant, consisting
of three trains that process an average of 8 million tons of gases per year.

The LG2 generator is a Medeshia 2 pole 22MW driven by a steam turbine. The
shaft system had been subject to an over-speed event in excess of 5000 rpm
following a failure of the turbine stop valves. This resulted in a failure of the exciter
banding and the coupling bolts that join the exciter to the main rotor; resulting in
catastrophic damage to the exciter as well as excessive centrifugal loads in the
rotor components; notably the retaining rings, wedges and rotor slot profile.

The Project Quartzelec were awarded the contract to refurbish the generator following
acceptance of Quartzelec’s stress analysis that demonstrated that the main rotor
was viable for use. The contract scope included rewind of main rotor, including
new retaining rings, insulation liners and replacement of the winding packing.
Quartzelec were also contracted to supply a new exciter electrically identical to
the original but to reduce lead times by maximising the use of modern
engineering design techniques, including the use of 3D design modelling and
FEA studies. The exciter was to be packed on a new bedplate that would mount
on the original foundation points.

The bearing, rectifier, exciter and PMG were sourced externally whilst Quartzelec
designed the new exciter rotor, bedplate and covers. After assembly the exciter
was load tested to prove its electrical and mechanical performance. The rotor
was re-wound at the UAE Quartzelec workshop before being moved to Rugby for
final installation of the retaining rings and assembly of the exciter onto the rotor
before being high speed balanced and overspeed tested. The exciter and the
rotor were then packed and shipped to site where Quartzelec also managed the
site installation and final commission of the LG2 generator.

The project was the first to fully utilise the new 3D design system. It was used for
the FEA analysis to help first win the contract, also to maximise the design
optimisation to reduce lead times and to give complete confidence in the design,
including the critical site assembly on the remote island.

To discuss your support requirements, or to find out more about our total capability in Rotating
Machines, please contact: info.uk@quartzelec.com or visit www.quartzelec.com