New generator more economic than repair

Purchasing the replacement 11380kVA generator, which was delivered in only two weeks, meant that Melton did not any incur revenue losses through the power supply being interrupted.

It was fortuitous that a synchronous generator of suitable rating and performance class was readily available on the market, as this application and configuration are very rare, and such generators are usually manufactured with long lead times. Menzel Great Britain is a subsidiary of German motor manufacturer Menzel Elektromotoren who maintains a very extensive inventory and is specialized on customized adaptations on short notice and who was therefore well prepared to answer this urgent request.

The generator is powered by a steam turbine. It operates at11 kV supply voltage and weighs more than 35t. Menzel completed the various customer-specific interface modifications in the short time available. Preparing the shaft to match coupling interfaces was particularly complex, since it had to be shortened, machined for a smaller diameter, and the appropriate flange had to be weld-fitted and subjected to an ultrasound check, which ensured that the modification was sound. In order to match site requirements, Menzel also changed the cooling type of the replacement generator from IC 01 open-circuit ventilated to IC 81W air-water heat exchanger, building an adapter frame and mounting a suitable twin element heat exchanger from existing stock.

Westfield Power Station, which was commissioned in 2000, is the only biomass power plant in Scotland fueled by poultry litter. It is a key partner to the region's agricultural industry both for disposing of a high-volume waste product and as a supplier of power and fertilizer – the nutrient-rich ash produced is a precious natural alternative to artificial fertilizers. The 9.8 MW biomass steam power plant also stands out technologically as it is one of a limited few in the world utilising fluidised bed technology. The CO₂ savings compared to gas-fired power plants are considerable.

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