Kicking off service partnership with flying colours

Customer Major wind generator OEM
Location Australia
Industry Renewables
Key Services

GENERATOR LIFE-EXTENSION

>20 years

OVERSPEED TESTING REQUIREMENTS

2236 rpm

GENERATOR RATING

3 MW

The Challenge

Finding a trusted local service partner

The generator manufacturer needed a technically capable and trusted partner to repair and refurbish its wind generator equipment. Repairing assets in Europe caused long lead times and had the potential for turbine operators to be penalized for failing to deliver energy production targets. Any candidate needed expertise in generator repairs and testing, including the ability to complete an overspeed test.

The necessary qualifications include:

  • Mechanical and electrical repairs
  • Full rewinds
  • Specialist welding
  • Electrical testing
  • At-speed balancing
 Gallery

The Solution

Enhancing generator reliability and service life

Sulzer’s local facilities and expertise in generator repairs have passed the stringent acceptance criteria set out by the OEM. This included the use of laser cladding for metal repairs instead of conventional metal spraying, ensuring a smaller heat affected zone, as well as improved durability and strength.

The Sulzer team in Sydney took a three-stage approach to balancing the rotor, enabling them to surpass the OEM’s expectations.

During the overspeed test, the variable frequency drive (VFD) controlled the rotor speed with a maximum frequency of 75 Hz, as required by the OEM.

Vibration data showed that Sulzer’s repairs had delivered a machine with better vibration results than a new machine from the factory. The target was 1.5 mm/s broadband RMS.

No-load testing procedures included remote monitoring and control for:

  • Safety stops
  • Vibration data
  • Bearing and winding temperatures
  • Speed

Sulzer has enabled the generator OEM to provide a local repair service for its products, reducing costs for customers and improving sustainability.

Explore our solutions

  • Extensive knowledge in wind turbine services and repair
    Wind turbines services
    Sulzer has extensive rotating equipment services, including the capabilities and knowledge in the overhaul, rewind, and mechanical repair of wind turbine generators. Our expertise, network, and around the clock services provide fast and flexible repairs, maintenance, and upgrades for your motors, generators and electric control panel systems.
  • Repair and overhaul services
    Repair services provide our customers with the assurance that when their piece of equipment is returned to operation they receive the maximum value from the repair process. No matter how complex the equipment, regardless of OEM, you can be confident your machine will perform as expected.

The Customer Benefit

In-country support slashes repair times

Having a local, trusted partner to repair their generators avoids the need to ship these machines to Europe, which is time-consuming and costly. The OEM can offer a much more competitive service for its customers and significantly reduce the carbon footprint of any repairs.

The refurbished generators are expected to have the same service life as a new asset, 20-25 years.

I would like to say “Thank You” to the whole Sulzer team that was engaged in this qualification. It was a long process where both Sulzer and our own teams worked together to ensure compliance with our stringent requirements. This is the first generator model repair process that has been formally qualified after successfully passing all routine testing. I appreciate your hard work, patience and commitment to meet customer requirements!

Senior Supplier Quality Engineer - Onshore Wind Turbine OEM
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