On May 5th, the replacement of the turbine rotor of the UG3 of the Funil HPP was completed, which represents an important advance in the reliability and performance of Aliança Energia’s asset. The generating unit, which previously operated with restrictions due to the failure of the old rotor, underwent a structuring intervention, with the complete replacement of the equipment with a more technologically advanced model, in addition to the renovation of the turbine distributor.
The intervention increases the reliability of the asset, generates efficiency gains in energy production and increases the predictability of O&M routines. These advances directly contribute to the improvement of the company’s indicators, reinforcing its commitment to asset management and operational safety.
The project had an integrated performance of the Engineering and Projects areas of Aliança Energia, ranging from the conception of the technical solution to the hiring, manufacture and assembly of the new rotor, characterizing itself as a large and highly complex initiative. Regarding the relevance of this work for the plant’s operation, Aliança engineer Marcelo Miranda points out:
“Since the failure of the plant’s old rotor, Engineering and O&M have worked together to develop the best solution for the best possible return on the equipment. The solution of replacing the rotor instead of refurbishing the old rotor was defined, in order to minimize the downtime of the machine and obtain a rotor that could produce more energy with the same inflow. With the participation of practically all areas of the company, a world-renowned supplier was selected to supply the new rotor, and the entire manufacturing and assembly process was monitored by Aliança’s teams in order to solve the situations that occurred during manufacturing and assembly. With the completion of the process, we deliver a more modern, efficient and safe machine to the company that will bring operational safety for a long time.”
The complexity of the intervention is also emphasized by Aliança’s Operation and Maintenance Supervisor, Thiago Santos:
“The interventions carried out in UG3 lasted 296 days and involved the complete dismantling of the generating unit, with activities of high technical complexity. Among the main challenges, the lifting of loads of up to 150 tons stands out, carried out with the simultaneous operation of the two overhead cranes, in addition to the exhaustion of suction with fish rescue, diving and work in confined spaces and at height. The intervention required a high level of planning, integration between teams and strict security controls, and it was necessary, in certain periods, to adopt two work shifts to meet the schedule of activities. I also emphasize that the effort, commitment and dedication of all the teams and areas involved, Engineering, Projects, Operation and Maintenance, Planning, Health and Safety, and Environment, as well as all the others that contributed directly or indirectly, were fundamental for the completion of the work without recording accidents with people and without occurrences of environmental impacts.”
With the completion of the project, the UG3 returns to operation in superior condition, prepared to deliver consistent, efficient and reliable performance in the next operational cycles. As highlighted by Aliança’s O&M technician, Marcelo Almeida:
“After the completion of the turbine rotor replacement, the UG3 has reached a new level of reliability and performance. The recovery of operational flexibility, combined with efficiency gains, brings more security to the operation and more predictability to the day-to-day. It is an important advance for the plant and for the next operational cycles.”
