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Induction Heating Used for Removal of Hydroelectric Generator Rotor

· Leave a comment · Colin Brown
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Induction Heating for Rotor Expansion Lift
A customer involved in the rebuilding of a hydroelectric power generation station came to Red-D-Arc with a unique challenge: Use induction heat to help separate a massive rotor from its center shaft assembly. A traditional approach is to use a combination of open flame along with dry ice which would have taken several weeks to set up and also ran the risk of being ineffective due to the scale and complexity of the project.

Sil Nonis, an induction heating specialist at Red-D-Arc, suggested using 6 induction heating units activated in sequence to provide thermal growth in a uniform pattern; releasing the interference from the center shaft before lifting the rotor. The 6 Miller ProHeat 35 Induction Heating Systems powered two half circle assemblies, positioned at the bottom of the locking ring which was 5′ in diameter as well as two half circle assemblies positioned on a top locking ring which was 4′ in diameter. Massive rotor arms also had 4 pads attached to them, positioned in sequence.

Setup took approximately 2 days and removal of the rotor was completed in a single day. The same process will be used to reinstall the rotor after it has been rebuilt. Over the next few years two additional rotor assemblies will be removed, rebuilt and reinstalled using the same process.

Extending the Legs of a Large Seabound Work Platform

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A Red-D-Arc customer shared some interesting photos which document the process of extending the legs of a large seabound work platform and also feature several Red-D-Arc rotators. The platform is used for cleanup activities on the seabed and in order to work at greater depths; the legs of the work platform needed to be extended. The massive cylindrical legs were placed on Red-D-Arc rotators and rotated while the cutting and welding processes were carried out. Once the extensions were completed the legs were then returned to the platform.

Growing Line Systems Used for Wind Farm in Adriatic Sea

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Growing Line Systems

Red-D-Arc contributed several Growing Line Systems to be used in the production of wind tower foundations for a wind farm in the Adriatic Sea. In addition to the Growing Line Systems, Submerged Arc Welders were supplied along with camera systems that are equipped with a monitor and touch screen for optimal control of functions. Red-D-Arc equipment was used because the foundations must be long and strong to withstand the depth of the Adriatic Sea.

To learn more about Red-D-Arc Growing Lines and Fit Up Stations watch our video: reddarc.uk/videos

Submerged Arc Systems for Wind Farm Manufacturing

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Red-D-Arc delivered three submerged arc systems to a construction company from Willebroek (Belgium) which has acquired a record contract for the construction of foundation structures to be used in an offshore wind farm close to the German-Dutch border. The Red-D-Arc column and booms are 7 m x 7 m and are equipped with a double wire system powered by the ESAB 1250 for welding 4 mm cored wire. In addition, each of the column and booms included a seam tracking system and flux recovery unit. Thanks to the advanced electronics and touch screen interface controls the turnkey systems each require only a single operator.

Red-D-Arc Generators to Power Niagara Wind Project

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Red-D-Arc will be supplying the Niagara Wind Farm Project with 77 rental power generators to service the construction of new wind turbines. Once completed, the Niagara Region Wind Farm will be one of the largest in North America and will supply residents of Ontario Canada with an additional 230 Mega Watts of wind energy. Red-D-Arc developed a custom power distribution panel to meet the specific onsite needs of the builder. This is another example of how Red-D-Arc employees create solutions that help our clients reach their goals. Red-D-Arc is recognized internationally as a leading provider of welding and weld automation rental equipment and we continue to expand our fleet of rental power generators, light towers and other welding-related specialty equipment.

wind turbines

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