A customer in the British Virgin Islands contacted BRUSH Aftermarket after a failure of one of its Salient Pole alternator units following 25 years of trouble free operation.
During a thunderstorm the roof of the power station leaked and allowed water to enter the open ventilated top of the alternator while it was operating on full load. A third party protection relay failed to operate correctly, the result was a fire in the end winding. On reviewing the photographs supplied BRUSH thought the alternator looked recoverable, however the customer feared the worst.
A BRUSH winding engineer visited the site and conducted a full appraisal of the alternator, the rotor was removed and the rotor and stator were tested to determine if the alternator was indeed recoverable. The results of the tests were favourable and the decision was taken to rewind the stator and refurbish the rotor.
A coordinated recovery program was undertaken by the BRUSH Aftermarket UK office, the rotor was refurbished at the BRUSH Aftermarket facility in Ridderkerk, The Netherlands and the stator re-wound on site by engineers from the UK and The Netherlands.
The stator was moved to a clean location on site & the old windings removed, the core was re-tested and the new windings inserted, tested and coated with resin. When the resin has cured the windings were coated with a red oxide anti-tracking air drying varnish. The rotor was completely refurbished including re-winding the poles, using the existing copper coils.
Upon delivery to site, engineers from BRUSH Aftermarket re-assembled, installed and re-commissioned the alternator, successfully returning the machine back to full commercial operation.
The refurbishment of the Salient Pole Alternator reinforces BRUSH Aftermarket’s ability to successfully carry out repairs and refurbishments on generators of any age or type.