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Generator Replacement in a TCG 2020 V12 Gas Cogeneration Unit Fueled by Agricultural Biogas
Based on the received order, which included the supply and installation of a brand-new alternator and a flexible coupling element, Eneria’s specialized service team proceeded with the comprehensive operation of replacing a key component of a TCG 2020 V12 gas cogeneration unit, operating on biogas derived from agricultural production.
The first stage of work involved preparing for the disassembly of the existing alternator (Photo No. 1). Due to the significant weight of the unit, precisely 4000 kg, and its placement inside the aggregate’s containerized enclosure, it was necessary to deploy specialized lifting equipment. A crane with appropriate lifting capacity and reach was used, enabling the safe disconnection and lifting of the old alternator from its bed on the aggregate frame.
Photo No. 1: Initial stage of the overhaul process.
After disassembling the old alternator, the coupling elements were removed. The flexible element connecting the alternator to the engine was unbolted from the coupling hub, to which it was attached using standard bolted connections. The next step was to disassemble the coupling hub mounted on the shaft of the old alternator. Due to the tight fit, a multi-ton hydraulic puller was used for this task, which, with significant force, allowed the hub to be slid off the shaft (Photo No. 2).
Photo No. 2: Hub disassembly stage.
The next, more complex stage of work was the assembly of the coupling hub onto the shaft of the supplied, brand-new alternator (prepared for assembly with the hub and flexible element). Correct torque transfer from the engine to the alternator requires precise fitting, characterized by dimensional interference (the hub bore diameter is intentionally smaller than the shaft diameter). To enable assembly without the risk of damaging the new alternator’s bearings, a thermal expansion technique was used for the hub. Using an induction heater, the hub was heated to a precisely specified temperature, in accordance with the recommendations in the factory service documentation (Photo 3). Controlled heating caused the hub material to expand, allowing it to be slipped onto the alternator shaft without excessive force. After cooling, the hub achieved the required tight connection with the shaft.
Photo No. 3: Induction heater facilitating hub removal.
After mounting the hub, the new flexible coupling element was bolted to it (the assembled alternator with the coupling is shown in Photo No. 4). Then, the prepared alternator assembly was remounted onto the frame of the gas cogeneration unit, using the same specialized lifting equipment used for disassembly.
Photo No. 4: Alternator with coupling.
After the mechanical installation of the alternator, Eneria’s engineers carried out the necessary electrical connections in the alternator’s junction box (Photo No. 5) and connected the excitation system components (Photo No. 6).
Photo No. 5: Wiring connections in the new alternator.
Photo No. 6: Connection of the new alternator’s excitation system.
A crucial step after mechanical and electrical installation was the aggregate’s alignment measurement and adjustment procedure. In practice, this process involves precisely positioning the alternator relative to the internal combustion engine of the generator set to ensure shaft collinearity. Correct alignment is critical for minimizing vibrations, bearing and coupling element wear, and for ensuring long-term, trouble-free operation of the entire system. Due to the complexity of this issue, a detailed description of the alignment procedure will be presented in a separate material.
The alternator supplied and installed by Eneria, after the necessary connections were made and it was commissioned in the gas cogeneration unit powered by agricultural biogas, successfully completed the synchronization process with the national power grid. It is currently operating at full rated power (100%), and the electricity it generates, derived from a renewable energy source, is used, among other things, to power the infrastructure that enables you to read this description. Online.
Author: Piotr ROMAŃSKI
CAT GAS Industrial Engines Service Expert
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