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CASE STUDY

BRUSH Generators at Extreme Altitudes

BRUSH was asked to provide generators for a location in Chile specially adapted for the high altitude in the Atacama Desert



BRUSH generators provide assured power and are essential where reliability is paramount.

Profile

Product

2 Pole Air Cooled Generators

Location

Chile

Geothermal power production is a form of renewable energy generation that harnesses thermal energy from underground sources.

Boreholes are drilled into the geothermal source and water is injected at pressure to be heated. The water returns in the form of steam, which is used to drive geothermal steam turbines. The driver in turn, rotates a generator which produces electrical power.

The thermal energy must be of a certain temperature to be suitable for power generation, and the location of the energy sources meeting this requirement are often in environmentally challenging locations.

The Challenge

BRUSH was asked to provide generators for a location in Chile specially adapted for extreme conditions. The location of the site was at high altitude in the Atacama Desert at 4,500m. At these altitudes the air is much thinner and had high levels of hydrogen sulphide (H2S) and sulphur dioxide (SO2) gases. We called on our long experience in designing engineered solutions for generator applications to meet this challenge.

The Solution

Ensuring the equipment used to produce the power could endure harsh elements was imperative, so we supplied two specially modified, 27.6MW, four-pole, 1,500r/min generators with a rated voltage of 9,500V and a power output of 32.5MVA. Each of the dual-shaft generators were powered by two 15MW turbines and designed to withstand the challenges presented by extracting geothermal energy in 4,500m conditions.

At high altitudes the air is much thinner which can increase the potential for damaging partial discharge activity in the stator winding.

Our design team developed a solution that de-rated the generation voltage to reduce the risk of stator damage, while maintaining the specified power output. This means that the generators will be kept online by optimising the stress on the electrical insulation system

We evaluated solutions for generator cooling due to the thinner air, this was complicated by both the ambient temperatures at extremes lows of -31°C, and the presence of toxic H2S and SO2 gases.

To counter these threats, we designed a pressurisation system that provided clean air to the inner part of the generators and that featured a special filtration system to neutralise the H2S and SO2 gases. Specialized heating was installed to keep the generator warm during times when the system was idle.

This application location also presented human challenges. Service personnel could only be present at such extreme altitudes for short periods of time without suffering from altitude sickness. This meant installation, and later maintenance, had to be carefully planned and scheduled with the operator. Strict guidelines were put in place to ensure the safety and health of the team.

The Result

We completed the design and build within the agreed delivery lead time, and power output specification. In doing so, we contributed to the first power plant built at this altitude worldwide, increasing the number of locations that can be considered for geothermal energy production.

When you have a challenging power generation application contact BRUSH to discuss our solutions.

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PROJECT AWARD

BYE-Guangzhou Metro BT

Hawker Siddeley Switchgear (now BRUSH Switchgear) has, in partnership with BYE, been awarded the opportunity to supply a total of 443 NDC Circuit Breakers across lines 21, 14 and Knowledge City line

Profile

Product

2 Pole Air Cooled Generators

Customer

BYE

Location

Guangzhou, China

Installation

2016-2018

Guangzhou Metro is the metro system of the city of Guangzhou in Guangdong Province of China. It was the fourth metro system to be built in mainland China, after those of Beijing, Tianjin and Shanghai.

Having delivered 2.054 billion rides in 2013, Guangzhou Metro is the sixth busiest metro system in the world, after the metro systems of Tokyo, Seoul, Moscow, Beijing, and Shanghai and operates 164 stations.

The city, in the south of one of the world’s most populous countries, was initially planned to have a two-line metro system, which uses some of the latest light-rail technology, and was a model for a completely integrated project.

The number of lines was, however, increased later. The metro now operates eight lines, with an additional six lines underway.

The Challenge

Guangzhou Metro is now undergoing an expansion project increasing the metro by 16 lines with a length of 432.6km by 2025 in order to connect their rising areas. It is estimated that the total investment will reach 297.6 billion yuan.

Key Benefits

Quick turnaround
Solve site delivery restrictions
Express turnaround times

The Solution

Hawker Siddeley Switchgear (now BRUSH Switchgear) has, in partnership with BYE, been awarded the opportunity to supply a total of 443 NDC Circuit Breakers across lines 21, 14 and Knowledge City line. Totalling 166,526,302 yuan.

182 NDC Circuit Breakers will be supplied to Line 14 Phase 1. Line 14 runs from the North to the South of the city with 54.4km of track.

201 NDC Circuit Breakers will be supplied to Line 21. Line 21 is 61.5km which covers areas that are underground and through mountains. Finally 60 NDC Circuit Breakers will be supplied to the Knowledge City Line which is 21.9km.

The Result

An ongoing partnership for BYE’s future projects and a more secure metro line at the heart of China’s traction distribution system.

Providing Guangzhou Metro a safe, reliable, low maintenance solution.

Resources

Project Case Studies
BYE-Guangzhou Metro BT
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CASE STUDY

BRUSH Solves Urgent Customer Problem in Record Time

Exceptional service to restore DNO network resilience

Profile

Product

2 Pole Air Cooled Generators

Customer

Scottish & Southern Electricity Networks

Location

Bradford upon Avon, Bath, UK

Installation

2019

A leading UK Distribution Network Operator (DNO) notified BRUSH that due to a failure on one of their distribution sites, an urgent requirement was the installation of their strategic spare 15/30MVA, 33/11KV Power transformer.

The Challenge

Brush visited the site on the next working day to assess the requirements and it was evident that the compact spare unit would require converting to separate coolers . The transformer had been held in storage at BRUSH (since 2013) as a strategic spare. The client notified BRUSH that the failed unit must be replaced and the new unit energised within four weeks to avoid any risk to their network. A further challenge for BRUSH was to overcome the width restrictions on route to the site within the already reduced timescales.

The Solution

The stored transformer was originally built as a compact unit, meaning all the ancillary details were tank mounted. The DNO specified a separate cooler bank assembly to match the failed unit, and the transformer required reconfiguring prior to any in-factory testing. The transformer was immediately removed from the BRUSH on site storage facility and taken into the factory for work to commence. The transformer was successfully converted from a compact design to a separate cooler bank.

Following the mechanical build of the transformer within the BRUSH factory, a second Factory Acceptance Test (FAT) was carried out to ensure the unit was functioning correctly prior to despatch to site. Additionally, the transformer was subject to full oil processing and a complete re-spray.

Key Benefits

Quick turnaround
Solve site delivery restrictions
Express turnaround times

“As you know we were all very impressed and appreciative of the sterling efforts from all your goodselves at BRUSH in helping us achieve a prompt and safe replacement of C1MT at Bradford on Avon back in September / October 2019”

Scottish & Southern Electricity Networks

Following a site visit, it was agreed between the client, BRUSH and the heavy haulage contractor that due to width restrictions on route to site the transformer would have to be transported at a maximum width of 2.75 metres, requiring the unit to be stripped to the minimum width. To achieve this, the HV, LV and neutral cable boxes, disconnecting chamber, tapchanger, auxiliary transformer and cooler control cubicle were removed.

The Result

BRUSH Transformers Service Team successfully delivered the Transformer to site ahead of schedule and worked for ten consecutive days to re-build the Transformer. The Mechanical installation included the previously removed HV, LV & Neutral cable boxes, Disconnecting chamber, Auxiliary Transformer, Tapchanger in addition to the full cooler bank assembly.

Other duties included all Wiring, Oil handling and Cold Commissioning. BRUSH also carried out a full ratio on the Tap changer due to disconnection for transport. Upon completion, the Transformer was handed over to the DNO a week ahead of schedule. The Transformer was successfully energised in October 2019 and BRUSH Transformers Service Team received high praise from the client for the handling of the project, resulting in another BRUSH Transformer becoming part of the network ahead of schedule.

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CASE STUDY

BRUSH Commissioned for Major 2-Pole Generator Update

As the world’s largest independent manufacturer of generators above 20MVA, we were proud to be commissioned by current operators of the power station to carry out a major overhaul of their BDAX 9-450PRH generator.

Profile

Product

2 Pole Air Cooled Generators

Installation

TBC

BRUSH And An Established UK Power Station Share A Long History.

We originally manufactured two GT units and one ST unit in the early 1990s. These generators are still in operation today as peaking units to support the UK grid.

As the world’s largest independent manufacturer of generators above 20MVA, we were proud to be commissioned by current operators of the power station to carry out a major overhaul of their BDAX 9-450PRH generator.

Given our proven track record and unrivalled experience in the production and servicing of 2-pole generators – that perform such a vital function in power stations around the world by converting the mechanical energy created by the turbine into electricity – we were the obvious choice.

The Solution

The scale and scope of the project was huge, but we have the capacity and expertise to meet even the most challenging of deadlines.

Our service engineers began by dismantling the generator on site before removing the rotor and taking it back to our factory. The endcaps were removed and after a thorough inspection and clean, the rotor was carefully reassembled before being balanced in our specialist overspeed pit facility.

Key Benefits

Quick turnaround
Solve site delivery restrictions
Express turnaround times

Meanwhile, our team inspected and cleaned the generator’s stator before putting it through a series of rigorous tests.

Once all of this was complete, we returned the rotor to site, where we reassembled and commissioned the generator before handing it back to the owner.

The Result

In a world where time is money, we completed the whole project in just 10 weeks, thanks to the efficiency of our service and the expertise and dedication of our team.

Successfully back up and running, the generator now helps provide power to approximately 500,000 homes, thanks in no small part to BRUSH.

CASE STUDY

BRUSH Conducts Mid-Journey Generator Repairs for Major Cruise Ship

While passengers are enjoying a trip of a lifetime, a staggering array of complex and powerful machinery is working below deck on cruise ships.



BRUSH generators provide assured power and are essential where reliability is paramount.

Profile

Product

2 Pole Air Cooled Generators

Customer

Cruise Operator

Location

Offshore

While passengers are enjoying a trip of a lifetime, a staggering array of complex and powerful machinery is working below deck on cruise ships. While the ship’s engineers are well-trained to solve most issues with ease and ensure easy travel from port to port, sometimes equipment urgently requires expert attention. In this case, the vessel contacted BRUSH experts who are available to provide technical support 24/7.

The Background

One of our customers, an operator of a world-renowned cruise line, noted that there were increasingly high temperature readings on a critical bearing, they quickly contacted us through our Service 24™ program.

The Solution

Our customer carried out basic testing and deduced that the bearing likely needed to be replaced. Fortunately, they had stocked critical spares including a spare bearing on-board, but they had not stocked the essential bearing accessories such as jacking oil pipes and non-return valves.

Key Benefits

Quick turnaround
Solve site delivery restrictions
Express turnaround times

As time was of the essence, we quickly organized a plan to deliver the necessary parts to the vessel. The parts were gathered, and since the hoses were on the critical path, to keep the turnaround time a fast as possible, we had them manufactured at extremely short notice. These parts covered both the gas turbine driven generators on the vessel.


One of our engineers was able to travel to the ship within a few days with the spare parts, providing an extremely fast plant-to-craft delivery.

The Result

On inspection, the bearing was found to be worn from adverse operating conditions, after being in service without issue for 15 years. While aboard, our engineer was able to identify several other minor issues and advised the customer on the best course of action to get the problems fixed.

BRUSH generators provide assured power and are essential where reliability is paramount. The job was completed successfully, and our engineer returned home leaving a satisfied customer to set sail.

News

Innovative Vacuum Tap Changer Technology To Future-Proof UK Distribution Networks

The 33kV power transformer is an integral part of the UK’s electrical distribution networks

We are pleased to announce publication of our latest BRUSH Engineered Solutions White Paper on “How tapping into 33kV transformer assets decarbonises UK distribution networks.”

The current backbone of the UK’s electricity transmission and distribution systems was built at a time when generation was dominated by large, centralised structures. Similar to the Victorian railway system not being able to adequately support modern high-speed rail, the growth of renewables and the electrification of transport mean that large parts of existing infrastructure are no longer fit for purpose.

The 33kV power transformer is an integral part of the UK’s electrical distribution networks. With an extended lifespan, it lends itself perfectly to not only demonstrate the challenges of future-proofing networks under the premise of ‘lower cost zero-carbon’, but also showcases how simple infrastructure decisions can help facilitate the transition.

For example, a power transformer in an existing network might no longer meet technical requirements due to capacity constraints or limitations in view of operational flexibility. To address such changes in technical requirements two fundamental, short term strategies are available: (1) asset replacement or (2) asset retrofit.

Where the useful life of existing assets can be extended with modern equipment that can be easily retro-fitted, networks are future proofed whilst minimising costs and lowering the carbon footprint.

The Vacutap® VBO® On Load Tap Changer (OLTC) for 33kV power transformers (VBO) uses vacuum technology with an innovative drive system. Developed by MR in collaboration with BRUSH it is maintenance free for up to 300,000 operations, and allows 100% reverse power flow.

Chris Abbot, BRUSH Group CEO comments: “We are proud to have been instrumental in bringing this new technology to the UK market. With easy bolt-on installation of the VBO to existing 33kV power transformers, required capital investment is reduced when compared to asset replacement, in particular when taking the significant tap changer maintenance savings of up to £250,000 per unit into account. What’s more the remaining lifespan of the transformer will be utilised, if not extended, and associated carbon footprints reduced accordingly.”

Resources

Whitepaper
BRUSH Engineered Solutions Tapping into 33kV transformer assets – Vacutap VBO
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Latest BRUSH Power Distribution News

NEWS

BRUSH Group Committing To Net Zero By 2050

Committed to support industrial decarbonisation and sustainable development, we have pledged to increase the focus on the impact our activities have upon the environment by setting ambitious objectives to achieve our target of Net Zero greenhouse gas emissions by 2050. We are backing the industry climate commitment to NetZero by 2050 and are signatories of BEAMA’s NetZerobyDesign.

On signing this historic pledge BRUSH CEO Chris Abbot comments: “As BRUSH commences its journey under the new ownership of One Equity Partnership (OEP), this provides a great opportunity for BRUSH to enhance our focus on the impact our activities have upon the environment by setting ambitious objectives to achieve our target of net zero greenhouse gas emissions by 2050 in line with the Paris Climate Agreement.

As part of our journey, we will implement a Sustainability Policy in 2021 and implement a supporting strategy in 2022 which will be applicable to all BRUSH businesses.  As part of the evolving BRUSH sustainability strategy, we will continue to identify and adapt relevant group business level targets to ensure we meet this ambitious goal.  “

Latest BRUSH News

NEWS

One Equity Partners Acquires BRUSH Group

We are thrilled to announce that on the 18th June 2021 One Equity Partners (“OEP“), a leading middle market private equity firm based in the US, acquired the BRUSH Group. 

This is a very exciting opportunity for the next phase of our Company’s development. BRUSH will not only be well positioned to grow through further investment but also to support the increasing challenges of our world-class customers in the Power Generation & Power Distribution Sectors. 

“With a rich history dating back to the 1880s, BRUSH has a proven track record for market leadership, product innovation, and trusted customer service. OEP is excited to partner with BRUSH’s industry leading management team, led by CEO Chris Abbott, for the next chapter in the BRUSH story,” said Ori Birnboim, Managing Director, OEP. 

“OEP has a strong track record of building market-leading industrial companies through organic and inorganic investment initiatives that drive operational performance, add product capabilities and expand geographic reach,” comments Chris Abbott. “We are pleased to be partnering with OEP as we continue to further develop and grow.”

BRUSH Group Acquires Aprenda Ltd

As part of our journey and strategy for growth, we are also very excited to announce that, with OEP’s support BRUSH Group has recently completed the acquisition of Aprenda Ltd., based in Cambridgeshire. Aprenda is a well-respected design services and independent connections provider to the UK power distribution industry. 

“We’re thrilled to have completed the acquisition of Aprenda with the support of OEP. Together, we look forward to starting a new and exciting chapter of growth for BRUSH,” said Chris Abbot.

Latest BRUSH News

NEWS

Virtual Factory Acceptance Testing, V-FAT

Supporting critical electrical energy management solutions worldwide, the COVID-19 pandemic and resulting lockdowns in many countries posed a significant challenge for BRUSH Group’s global customers.

To help maintain critical delivery schedules, we worked alongside our customers to develop and deploy a new, remote witness testing routine, using video conferencing and live camera streams instead of on-site attendance.

Ensuring that our products could undergo witnessed tests to maintain delivery schedules despite factory visits being impossible the teams in our Czech generator manufacturing and UK switchgear plant designed and implemented tailor made remote test witnessing programs.

By live streaming of the main parameters and responding to customer requests via live chat all parties are kept informed at all times.

Customer feedback regarding the virtual testing routine has been very positive and based on associated customer benefits in saved time and travel expenses, BRUSH is now offering customers remote witness testing programs as an alternative to the traditional on-site process.

Brochure

Brochure
Virtual Factory Acceptance Testing (V-FAT) Brochure
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Latest BRUSH News

NEWS

Brush Group Website Covid-19 Notice

The COVID-19 Pandemic Continues To Challenge The Lives And Work Of All Around The World And BRUSH Continues To Diligently Observe Government Directives And Advice With Regard To Managing The Spread Of The COVID-19 Outbreak.

We wish to reassure our customers that BRUSH Switchgear, BRUSH Transformers & HGI in the UK, BRUSH Generators in the Czech Republic, BRUSH NL in the Netherlands and BRUSH Americas in the USA all remain fully operational with our dedicated Field Service Engineers available to support our customers critical operations.
 

We support customers within the Power Generation and Infrastructure sectors with many of our activities falling under the “Critical” classification and are actively working with our supply chain to minimise risks of disruption.
 

BRUSH continues to monitor the situation closely and will react appropriately where required to help ensure that we continue to provide the superior service and support that hallmarks BRUSH as a trusted electrical equipment & service partner for our customers around the world.

Latest BRUSH News