13 November 2024

Quartzelec, a leading independent electrical engineering group, has completed the overhaul of Unit 1 at the Maentwrog Hydroelectric Power Station in North Wales - the primary objective being to ensure continued reliable generation of clean, renewable energy by reducing the risk of future outages. Integrating a Partial Discharge monitoring unit to establish baseline test values, providing a critical reference point for future diagnostics, was also a key deliverable.

This project was awarded through competitive tender and involved a major service overhaul including the dismantling of the 15kV, 11.6MW, 50Hz, 600rpm GEC Alsthom generator - originally manufactured in 1991 - as well as associated turbine components. Originally awarded in April 2024, the project was completed by mid-September and included a methodical strip down, detailed inspection, testing, and refurbishment, before the unit was fully reassembled in accordance with stringent technical specifications.

The Maentwrog station is managed by Nuclear Restoration Services Ltd (NRS), a subsidiary of the Nuclear Decommissioning Authority, and underwent a similar overhaul in 2013 which was delivered by Quartzelec with additional works also having been delivered since. This year’s maintenance was designed to mirror those previous work scopes, while introducing new upgrades aimed at improving long-term operability.

The generator’s stator and rotor were transported to Quartzelec's state-of-the-art facility in Rugby for thorough cleaning, testing, and mechanical inspections. The refurbishment also included a core stud tension check and a re-varnishing of the stator windings. The turbine refurbishment was carried out on-site by Quartzelec’s appointed sub-contractor, Green Highland Renewables, ensuring all components were meticulously cleaned, inspected, and tested.

"This project wasn’t just about maintaining the equipment at Maentwrog to ensure continued reliable and safe operation, but also about futureproofing it with advanced monitoring capabilities,” stated James Barnwell, Quartzelec’s Project Lead based in Rugby. “Our LIFEVIEW® Partial Discharge monitoring system, developed and supplied through our Quartzteq operation, will play a crucial role in helping to further extend the equipment’s lifecycle and enhance overall safety. Additionally, we involved our customer’s apprentices throughout the whole process, providing them with invaluable hands-on experience and insights into best practices for NRS’s next generation of engineers.”

“Integrating a Partial Discharge (PD) monitoring system to establish baseline test values will provide us with a critical reference point for our ongoing maintenance and operational diagnostics and was a key deliverable for us,” stated Andy McAteer, NRS Site Engineer.

Mike Merritt, Maentwrog Station Team Leader also added: "The successful delivery of this project was a testament to the collaboration between all parties. The overhaul and PD implementation ensures continued operation and the long-term generation of clean energy at Maentwrog."

Quartzelec provides a comprehensive range of services for rotating electrical machinery, from complete maintenance and component replacement of legacy machines and systems to modern upgrades and advanced diagnostic tools like Partial Discharge monitoring. The company is committed to offering safety, compliance, and performance-enhancing solutions, ensuring optimal operational longevity for critical electrical infrastructure.

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