How do you replace a 120-tonne machine component at our customer Société Électrique de l’Our (SEO) when space underground is extremely limited and the existing transport solution no longer meets current requirements?
The answer lies in a solution that is specifically engineered around the conditions at the Vianden pumped-storage power plant: one that is technically sound, safe, and backed by the necessary documentation.To meet this challenge, we collaborated closely with SEO’s project team to design and manufacture a new transport and turning device for removing heavy rotors. This project brought together our expertise in engineering, calculations and manufacturing.
A power plant with a vital role
The Vianden pumped-storage power plant, commissioned in 1964, is one of the most significant facilities of its kind in Europe. The plant can provide power and respond rapidly to fluctuations in the electricity grid within approximately ten to fifteen seconds.This flexibility is becoming increasingly important in a power generation system where sources such as wind and solar are inherently variable. In order to maintain this capability in the long term, the machinery operating deep inside the plant must remain both reliable and efficient.
When moving a rotor becomes a logistical challenge
Since 2017, SEO has been gradually replacing the rotors of a particular type of machine. Each rotor weighs around 120 tonnes. Removing a component of this size is technically demanding, but the real challenge begins when it needs to be transported.Space underground is extremely limited. Due to its dimensions, the rotor cannot simply be lifted and placed directly onto the heavy transport vehicle. First, it has to be set down using the existing crane systems, and then it has to be turned before it can be positioned correctly for transport.
The maximum overall height must also be maintained to ensure the load can pass through existing access routes and tunnels.
Until now, equipment dating back to the 1980s had been used for this operation. However, after several decades of service, a new solution was required to meet today’s technical and safety standards.
Our task: engineering a solution for exceptional conditions
Together with SEO’s project team, we analysed the requirements and conditions on site. Based on these findings, we developed a customised solution for this specific application.The device had to be able to support the considerable load safely, perform the required turning operation, and function within the highly restricted available space. At the same time, we had to consider the height limitations for subsequent heavy transport.
The project enabled us to combine several areas of expertise within KARL HUGO, from technical planning and engineering to calculations and manufacturing. The result is not an off-the-shelf product, but rather a bespoke device that has been specifically engineered for the conditions at the Vianden pumped-storage power plant.
It has also been designed with future applications in mind. While the current rotors weigh around 120 tonnes, the new device is designed to handle loads of up to 150 tonnes.
Beyond manufacturing: CE-compliant custom engineering
When designing equipment to handle loads of this magnitude, safety is paramount. A device must do more than just perform its intended function. Its design and dimensions must be technically verifiable and supported by the relevant calculations and documentation.This is why our involvement in this project extended beyond engineering and manufacturing. We also carried out the required structural calculations and documentation for a CE-compliant solution.
At KARL HUGO, we combine engineering, calculations, manufacturing and technical documentation within one coordinated process. The result is not just a custom-manufactured component, but a complete engineering solution with documented design parameters and safety requirements.
This expertise is particularly valuable for special-purpose engineering, custom tooling, complex lifting and transport applications, and developing purpose-built equipment for industrial environments.
Designed for 120 tonnes. Engineered for the next challenge.
This project marks the completion of the replacement programme for the four rotors of this machine type by SEO. However, the next project is already on the horizon: another machine of a different type is scheduled for dismantling and overhaul in 2027.The transport solution for this operation is still being evaluated. However, by designing the new device to handle loads of up to 150 tonnes, we have created additional options for future applications.
This project exemplifies our approach to custom engineering challenges at KARL HUGO. We take the time to understand the on-site requirements and conditions and combine our engineering and manufacturing expertise to develop safe, practical solutions that fit the purpose.
This is because, where standard solutions reach their limits, our custom engineering begins.
