Structural Capacity Analysis of an Existing Generator Assembly
Most hydroelectric power plants were built long before the advent of computer-aided design (CAD) software. In this context, it is common to reconstruct 3D models from hand-drawn blueprints dating back to the original construction, combined with on-site measurements and technical expertise.
A service provider commissioned Lx Sim to assess the structural capacity of major components in a generator assembly to determine whether they could withstand a prolonged increase in power—something not considered in the original design.
Challenges
- Model generator components without digital drawings, using historical plans and on-site measurements
- Determine whether original parts, designed for a specific power level, could endure a sustained power increase
- Identify technical solutions to avoid full replacement of critical components while ensuring structural integrity
Solutions
FEA Simulation
- Evaluation of mechanical response of components under prolonged power increase
- Detection of critical zones and assessment of in-service resistance
Targeted Recommendations
- Development of inspection protocols and recommendations regarding reuse or modification of certain parts based on simulation results
- Addition of structural reinforcements, particularly to the stator frame, which was identified as non-compliant with new requirements
Results
Thanks to thorough analysis and precise simulations:
- Most components were retained with only inspections or minor modifications
- The stator frame was reused through strategic reinforcement, avoiding costly replacement
- The client validated the feasibility of a power increase while preserving the integrity of existing infrastructure
This project illustrates the power of numerical simulation in modernizing equipment. By combining 3D modeling, technical expertise, and FEA analysis, it is possible to achieve performance goals without compromising safety or incurring significant costs.