Hydraulic Lifting for Power Generation: KIET’s 8Point Synchronous System for Energy Sector Overhauls
2026-04-23
Introduction
The KIET synchronous control system at the heart of the 505-tonne generator overhaul, managing all lifting operations in a confined space.
Large rotating equipment overhauls in the energy sector demand precise, synchronized movement in tight, low-visibility spaces—where load imbalance can cause costly damage. As a direct hydraulic machinery manufacturer, KIET delivers field-tested systems that solve these constraints. In a world-first generator overhaul using a composite lifting and skidding process, KIET’s synchronous control and custom hydraulics enabled safe, predictable control of a 505-tonne unit.
The Engineering Challenge
The Class-C overhaul of Gas Turbine Generator Unit #3 at the Binhai Bay site involved a total load of 505 tonnes—an industry-benchmark difficulty. The unit’s complex base structure with unevenly distributed load points created stringent requirements for load balance during both lifting and skidding. Any deviation in posture risked equipment damage and construction delays.
Compounding the technical challenge was a confined work environment with limited operating room and poor visibility. Maintaining millimetre-level coordination across multiple lift points under such conditions demanded high-precision synchronization. The team conducted multiple rounds of solution evaluation to ensure safety and positional control throughout the operation.
KIET’s Solution — A World-First Composite Process
The composite process involved both vertical lifting and horizontal movement using a custom hydraulic skidding system.
To meet these conditions, the project adopted a composite methodology of “Synchronous Lifting + Staged Lifting + Synchronous Push-Pull.” This was the world’s first application of this process for this generator unit type and established a new technical paradigm for large equipment maintenance. The approach enabled controlled vertical movement, secure intermediate staging, and smooth horizontal repositioning.
At the core of the solution was the KIET 8-Point Variable Frequency Synchronous Hydraulic Control System. This customized system provided stable technical support throughout the project, delivering precise synchronous management of all jacking movements.
Execution combined 8 CLP-FB-1002 Series Ultra-Low Height Lock Nut Hydraulic Cylinders and 8 KET-RK-FB-10010 Hydraulic Climbing Jacks. The dual-jack arrangement delivered the required lift force and secure locking via the outer-ring threaded self-locking mechanism, mitigating risk in the confined space.
Key Equipment Deployed
Low Height Lock Nut Hydraulic Cylinder — CLP-FB-1002 Series: Eight ultra-low height cylinders from the CLP-FB-1002 series were deployed to address space constraints. Each cylinder features an outer-ring threaded self-locking mechanism to secure loads.
A close-up view of the CLP-FB-1002 Series ultra-low height cylinders providing stable, secure lifting force.
Hydraulic Climbing Jacks — KET-RK-FB-10010: Eight KET-RK-FB-10010 hydraulic climbing jacks supported the staged lifting sequence and combined with the low-profile lock-nut cylinders as a dual-jack setup.
High-polymer shim blocks provide reliable support and positional stability during the staged lifting sequence.
8-Point Synchronous Lifting System: The KIET 8-Point Variable Frequency Synchronous Hydraulic Control System governed all actions. Variable frequency control enabled high-precision synchronization across eight control points.
The KIET 8-Point Synchronous Control System delivered high-precision synchronization with zero fault-related shutdowns.
Custom Push-Pull Hydraulic Cylinders — TL-90T-650: Two TL-90T-650 Custom Push-Pull Hydraulic Cylinders handled the skidding phase in coordination with the synchronous control system.
Project Results at a Glance
Total load: 505 tonnes
Control points: 8
Fault shutdowns: Zero
Positioning accuracy: Exceeded industry standard
Completion: On schedule
World’s first composite overhaul
FAQ
1. What is a synchronous hydraulic lifting system and how does it work?
A synchronous hydraulic lifting system coordinates multiple jacks so they raise or lower a load at the same rate, protecting equipment from tilt and uneven stresses. In this project, the KIET 8-Point Variable Frequency Synchronous Hydraulic Control System managed eight points in parallel. Variable frequency control delivered precise movement synchronization and stability.
2. What hydraulic cylinder is best for confined space lifting in power plants?
Ultra-low height lock-nut cylinders provide a compact footprint and secure mechanical locking, making them well-suited to tight, low-visibility environments. In the Binhai Bay overhaul, KIET deployed eight CLP-FB-1002 Series Ultra-Low Height Lock Nut Hydraulic Cylinders. Their outer-ring threaded self-locking mechanism enabled safe holding during staged operations.
3. How do hydraulic climbing jacks support staged lifting in generator overhauls?
Hydraulic climbing jacks execute elevation changes in controlled steps, allowing teams to verify stability at each stage. In this project, eight KET-RK-FB-10010 climbing jacks worked with lock-nut cylinders in a dual-jack configuration. With 256 high-polymer shim blocks providing interim support, each stage concluded with a stable unit posture.
4. Can KIET customize hydraulic cylinders for specific push-pull requirements?
Yes. KIET manufactured and deployed two TL-90T-650 Custom Push-Pull Hydraulic Cylinders for the skidding phase of this overhaul. Integrated with the 8-point synchronous control system, they achieved smooth unit repositioning under complex constraints. This demonstrates KIET’s capability to engineer custom hydraulic solutions aligned to project-specific push-pull needs.
KIET is a direct hydraulic machinery manufacturer with custom engineering capability for complex energy projects. Discuss your next lifting, staging, and skidding challenge with our team: https://www.kiethydraulic.com/contact-us/. We can configure synchronous control and cylinders to your constraints and deliver field proven outcomes.