011 607 1700 support@mandc.co.za

Generators, alternators and turbines

Generators, alternators and turbines

The M&C power generation team has a history of providing quality aftermarket services in the power generation sector both locally and internationally and has extensive experience in the public and private power generation industry. The power generation division is amongst the best skilled aftermarket service providers in Africa.

M&C Power Generation is housed in a 12000 m² facility in Benoni. This facility includes a 80 ton overhead crane capacity and a pressurised clean condition rewind bay. The M&C power generation division provides aftermarket services for power generators up to 373 MVA and larger on site. We also manufacture and repair various types of stator and rotor coils and act as an independent third party advisor to any of the above mentioned services in the role of supervisory or quality control.

Electrical power generation services:

  • Minor and major repairs on any design or type of generator stator or rotor
  • General overhauls of any design or type generator stator or rotor
  • Modifications of generators including but not limited to;
    –  Upgrading rotor and stator insulation systems
    –  Improving rotor and stator cooling systems
    –  Modifying rotor windings
    –  Modifying rotor shafts
    –  Replacement of rotor and stator wedges
    –  Upgrading rotor coil retaining rings
    –  Replacement of rotor slip rings
  • Complete rewinding of generator rotors and stators
  • Minor and major repairs on any design or type of exciter stator or rotor
  • Complete rewinding of exciter rotors and stators
  • Testing and condition monitoring
  • On-site balancing

Mechanical power generation services:

  • General overhauls of any design or type of turbine
  • Diaphragm refurbishment
  • Pressure parts refurbishment and replacement spares
  • Reverse engineering and manufacturing of components
  • Bearing refurbishment
  • Fault finding and root cause analysis
  • Upgrading and maintenance of oil systems
  • Scope of work compilation
  • Comprehensive project planning
  • Quality control and document compilation
  • Complete re-blading and balancing of turbine rotors
  • Metallurgical investigations and reporting
  • Run-up and run-down signatures
  • Testing and monitoring
  • On-site balancing

On-site rotor services:

  • Assessment of insulation systems
  • Insulation resistance
  • RSG testing
  • Stray flux testing
  • Thermal stability testing
  • High voltage testing
  • Volt drop testing
  • Assessment of coil retaining rings
  • On-site machining
  • Degaussing and magnetisation surveys

On-site stator services:

  • Assessment of insulation systems
  • Polarization index
  • High voltage
  • Partial discharge
  • El Cid, Power Flux, etc. Testing
  • Assessment of windings
  • Wedge tightness test, bar bumping and fretting

Engineering improvements:
The ultimate goal is to provide customers with the option to implement engineering design improvements to improve the long term reliability and dependability of the equipment. In order for this to be effective a partnership is required. All engineering improvements are the result of close co-operation between M&C and the customer.

Repairs are thoroughly investigated in order to:

  • Identify the root cause of failure (if possible)
  • Identify weaknesses in the design
  • Propose engineering solutions to improve the generator

1. Failure analysis:
Detailed failure analysis is required before engineering improvements can be proposed:

  • This detailed process starts with the first visual inspection of the machine which continues throughout the dismantling process
  • Detailed 3D CAD drawings are made of critical parts
  • Detailed digital photographs are recorded
  • Exact sizes are measured
  • Advanced testing and analyses are performed by experts in their fields
  • Detailed and documented electrical tests are conducted
  • Every component is checked – not just the obvious failed components
  • 3D laser mapping and modelling
  • Finite element analysis
  • Resonance studies
2. Engineering design reporting:
Detailed reports are compiled and issued including:

  • Detailed failure analysis and thorough explanations of the implications of failure aspects
  • Frequent feedback with progress of assessment and repair
  • Detailed recommendations for the repair with details of engineering improvements
  • Proposed changes and possible influences on reliability of the generator
  • Third party inspection or verifications contracted as required
  • Repairs are concluded with detailed final QC documents
  • All critical areas are documented and tested