Dedicated to improving manufacturing efficiency

New synchronous generator more economic than repair

Menzel Elektromotoren was able to supply a synchronous generator from stock and adapt it for the customer at short notice

Menzel Great Britain Ltd has supplied a synchronous generator with a power rating of 11380 kVA to Westfield Power Station in Scotland. The plant operated by the Independent Power Producer (IPP) Melton Renewable Energy UK Ltd had suffered a failure of the existing generator. Purchasing the replacement generator, which was delivered in only two weeks, was significantly more cost-effective than a lengthy repair, as the IPP may incur revenue losses when the power supply is interrupted.

It was fortuitous that a synchronous generator of suitable rating and performance class was readily available on the market, as this application and configuration are very rare, and such generators are usually manufactured with long lead times. Menzel Great Britain is a subsidiary of German motor manufacturer Menzel Elektromotoren who maintains a very extensive inventory and is specialized on customized adaptations on short notice and who was therefore well prepared to answer this urgent request.  


The generator is powered by a steam turbine. It operates at 11 kV supply voltage and weighs more than 35 tons. Menzel completed the various customer-specific interface modifications in the short time available. Preparing the shaft to match coupling interfaces was particularly complex, since it had to be shortened, machined for a smaller diameter, and the appropriate flange had to be weld-fitted and subjected to an ultrasound check, which ensured that the modification was sound.

In order to match site requirements, Menzel also changed the cooling type of the replacement generator from IC 01 open-circuit ventilated to IC 81W air-water heat exchanger, building an adapter frame and mounting a suitable twin element heat exchanger from existing stock. Westfield Power Station, which was commissioned in 2000, is the only biomass power plant in Scotland fueled by poultry litter. It is a key partner to the region's agricultural industry both for disposing of a high-volume waste product and as a supplier of power and fertilizer – the nutrient-rich ash produced is a precious natural alternative to artificial fertilizers.

The 9.8 MW biomass steam power plant also stands out technologically as it is one of a limited few in the world utilizing fluidized bed technology. The CO2 savings compared to gas-fired power plants are considerable. Three-phase synchronous and asynchronous generators for highest efficiencies:

Related Articles

Production of forklift model ends after more than 25 years

Last year, after more than 25 years in production, Hyster manufactured the last in a long line of XL 24v three wheel electric trucks. The…

Energy crisis: it's time to focus on the power stations we don't have to build

British companies, factories and hospitals are bidding to be paid by the national power provider to reduce demand at short notice if the…

New trucks offer high efficiency, performance and comfort

Jungheinrich has launched new additions to its ranges of IC-engine and electric-powered counterbalanced trucks. Both electric and engine…

Energy report confirms that virtual events reduce carbon emissions by more than 99%

This is the conclusion drawn from a recent paper ‘Making industrial exhibitions green’, based on existing life-cycle…

SME partnership promotes motor customisation

CP Automation teams up with Spanish motor expert VASCAT Supply and repair specialist CP Automation and motor manufacturer VASCAT are…

New white paper explores role of next generation fuses in protecting battery systems and preventing EV fires

Sensata Technologies, one of the world’s leading suppliers of sensor solutions, industrial controls, power management, and electrical…