Case studies

Hydro Generator Overhaul & Vibration Investigation

Our Customer’s Challenge

An energy provider based in Ireland faced a significant challenge with high vibration levels on the 21,000kW Hydro Generator, impacting its reliability and long-term performance. The issue required a comprehensive solution to identify the root cause and implement corrective measures. With a tight operational schedule, the client called upon Quartzelec to carry out a full generator overhaul, including rotor removal, detailed inspections, and advanced engineering analysis. The critical challenge lay in addressing the out-of-tolerance rotor shaft run-out whilst ensuring minimal downtime and maintaining the unit’s operational integrity for future use.

The Quartzelec Solution

Quartzelec performed a complete overhaul of the Hydro Generator, where the generator rotor was removed for a detailed laser scan of the shaft and coupling faces, enabling precise identification of the out-of-tolerance shaft run-out which was contributing to the high vibration levels. Thorough inspections, electrical testing, cleaning, repairs, rebuilding, realignment and in-depth engineering analysis was completed and all heavy lifts were managed on-site within the Turbine Hall, ensuring the work adhered to strict timelines.

The five-month project resulted in significantly reduced vibration levels, restoring the generator to reliable operation until its next scheduled outage.

Key Benefits

Significant Vibration Reduction: Post-overhaul vibration levels were substantially improved, ensuring smoother and more reliable generator performance
Enhanced Equipment Longevity: Addressing the root cause of the vibration issue reduces stress on components, extending the lifespan of the hydro-generator
Minimal Downtime: The entire overhaul was completed within five months, aligning with the client’s operational requirements, minimising disruption
Tailored Engineering Expertise: Quartzelec’s advanced diagnostics, precise rebuild procedures, and on-site capabilities provided a custom solution, restoring confidence in the generator’s long-term performance

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