Pyebridge Overhaul Story
Achievements
This accomplishment underscores the success of our phased refurbishment strategy. With two gensets now completed, we look forward to initiating the overhaul of the final unit to achieve full operational capacity for the Pyebridge site.
Completion of Two Overhauls:
Both 2.7MW gensets have now been successfully overhauled and are operating at peak efficiency, providing a combined 5.4MW of power generation capacity.
Enhanced Revenue Potential:
With both gensets now optimised, the site's revenue-generating capacity has effectively doubled, reinforcing Pyebridge's role as a key asset in flexible power generation.
Operational Resilience:
The upgraded components and advanced deflagration protection have significantly increased reliability and reduced downtime risks.
Inside Pyebridge
Refurbished Genset in Action. This footage captures the fully overhauled 2.7MW genset running smoothly within its engine cell, a key milestone in Pyebridge’s operational transformation.
1. Engine Removal and Transport
The process began with the careful disconnection of each genset's components, including control systems, cooling systems, and other auxiliary connections. Once fully disconnected, the gensets were removed using heavy-duty cranes and transported to CooperÖstlund’s workshop for refurbishment.
2. Comprehensive Refurbishment
At the workshop, the gensets received new long-blocks, replacing their core operational components with upgraded, deflagration-protected technology. This ensures enhanced safety and operational efficiency. Critical parts were replaced, and remaining components were fully refurbished to meet the latest performance standards.
3. Reinstallation
Once work at workshop was completed, the overhauled long-block and components were transported back to the facility. It was then craned back into its operational position. The final process of the reinstallation was to reconnect the genset with the supporting components on site, such as the control system, cooling system, lubrication system, etc., before full recommissioning could take place.
4. Recommissioning
and Operation
The recommissioning process included cold and hot testing phases to ensure precise calibration and optimal performance under live conditions. Each genset was fine-tuned for efficiency and reliability, ultimately returning to commercial operation as though brand new.
Pyebridge Genset Process Overview
The Pyebridge 9MW flexible power generation asset has successfully completed the comprehensive overhaul of its first two gensets, marking a significant advancement in the site's performance and efficiency. The overhauls were carried out as part of a phased program to enhance operational reliability, reduce maintenance costs, and extend the life of the assets.