Ferry generator failure prompts fleet inspection and repair
Friday, 5th May 2017
In order to keep the ferry operational when a generator fails a team of engineers must go on board to make an assessment of the damage. Sulzer was called on board by a customer where the shaft generator had failed.
Marine design standards ensure that even in the event of a catastrophic failure, back-up systems are in place to keep a vessel operational.
Some of the most important assets on a marine vessel are the generators, providing power for onboard services, including propulsion in some cases. With such a vital role, it is essential that stand-by assets are included in the design so that, in the event of a failure, normal operation can continue while the cause is investigated and repaired.
Ferries have a set timetable and any deviation from it can cause significant inconvenience to passengers and freight alike. It is therefore necessary to complete most repair work while the vessel continues to operate.
The challenge
An accurate assessment via a thorough inspection of the damage was required, however, due to the restrictive access, specialist lifting services were called upon to remove the rotor for dismantling. On dismantle the following challenges were uncovered:
- Damage to the windings
- Bolt failure which caused extensive damage to the core laminations
- Disintegration of aluminum clamps on poles
- Damaged white metal bearings
The solution
As the damage uncovered was more severe than first thought extreme action to complete the repair was required, including:
- A complicated but full removal of the 10-tonne generator to the local Sulzer service facilities – within a 17-hour window whilst the ferry was in port
- A full set of coils manufactured at Sulzer’s in-house coil manufacturing shop
- Complete rotor overhaul, with new clamps and bolts
- Removal of damaged laminations
- and installation of a new stator core
- Sourcing of upgraded retaining bolts
- Full generator repairs
The benefits to your operations
Root cause analysis determined that the rotor clamp bolts had fatigued. Recommendations to inspect the entire fleet have been made to safe-guard the customer and to minimize the risk of a similar failure.
Working with Sulzer makes a difference:
- On-board teams
- Reliable and expert services
- Upgraded component sourcing
- In-house coil manufacturing
- Lloyds and Bureau Veritas registered
Find you best service solution on Sulzer’s website
