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, with extensive experience in the public and private power generation industry. This power generation division is amongst the best skilled aftermarket service providers in Africa.

M&C Power Generation is housed in a 14000 m² facility in Benoni (South Africa). The facility includes 80 ton overhead crane capacity and two pressurised clean-condition rewind facilities. The M&C power generation division provides aftermarket services for power generators – and motor-generators – up to 373 MVA, and larger on site. We also manufacture and repair various types of stator and rotor coils, and act as independent third party advisors to any of the abovementioned services in supervisory or quality control roles.

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 of generator stator or rotor
  • Modifications of generators - including but not limited to:
  • Rotor and stator insulation system upgrades
  • Rotor and stator cooling system improvements
  • Rotor winding modifications and enhancements
  • Rotor shaft repairs and modifications
  • Rotor and stator wedge replacements
  • Rotor coil retaining ring upgrades to 18Cr-18Mn/P900
  • Rotor slip ring replacements
  • 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
  • Full range of testing and condition monitoring
  • On-site and off-site balancing
  • Fault finding and root cause analysis

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
  • Upgrades 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 reports
  • Run-up and run-down signatures
  • Testing and condition monitoring
  • On-site and off-site balancing

On-site rotor services:

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

On-site stator services:

  • Assessment of insulation systems
  • Polarization index
  • High voltage testing
  • Partial discharge analysis
  • Core testing: El-Cid, Power Flux, etc.
  • Assessment of windings
  • Wedge tightness, bar bumping and fretting tests

Engineering improvements:

M&C’s ultimate goal is to provide customers with a range of engineering design improvements to improve the long term reliability and dependability of their 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 our customers.

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 equipment

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, and continues throughout the dismantling process
  • Detailed 3D CAD models are created of critical parts
  • Detailed digital photographs are recorded
  • Exact sizes are measured
  • Advanced testing and analyses is 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 modes
  • Frequent feedback with progress of assessment and repair
  • Detailed recommendations for the repair, with details of engineering improvements
  • Proposed changes and possible influences on the reliability of the equipment
  • Third party inspections or verifications as required
  • Repairs are conducted with detailed digitised QC documents
  • All critical areas are documented and tested