Supporting a Critical Planned Shutdown
When a customer is working to a fixed shutdown window, there is little room for delay. Every stage needs to be carefully coordinated, from the initial removal of equipment through to overhaul, testing and final reinstallation.
The team at GEM Integrated Solutions, part of Rotamec Group, recently completed a substantial programme of works involving multiple large DC and high-voltage AC motors, alongside associated fan assemblies.
With the entire project required to be completed within a two-week shutdown period, careful planning and coordination between the site and workshop teams was essential.
The Challenge
The scope involved a significant quantity of critical rotating equipment, with assets requiring both workshop and on-site attention.
The project covered four 150kW GEC DC motors, two 45kW GEC DC motors, two 110kW 3.3kV AC motors and four fan assemblies. A further two 110kW basement motors required overhaul, with these works completed on site.
With such a broad scope and a firm shutdown deadline, the project required the GEM team to coordinate site removal, transportation, workshop activity and reinstallation efficiently to keep the programme on schedule.
From Site Removal to Workshop Overhaul
The project began with the removal of the designated equipment from the customer’s site. The motors and fan assemblies were then transported to GEM’s workshop, where the scheduled overhaul works could be carried out.
Meanwhile, the two 110kW basement motors were overhauled on site, allowing the team to complete the required maintenance without unnecessarily removing these assets.
This combination of workshop and field engineering capability meant the different elements of the project could be managed as part of one coordinated programme rather than as separate activities.
Working Against the Clock
Shutdown projects demand more than technical capability. Logistics, communication and programme management are equally important, particularly when several pieces of equipment are being worked on simultaneously.
Throughout the shutdown, the GEM team worked across the various motors and fan assemblies to complete the required overhaul programme and prepare the equipment for its return to service.
Once the workshop works were complete, the equipment was transported back to site and reinstalled by the team, completing the full cycle from removal through to reinstatement.
Frequently Asked Questions
Can The Rotamec Group support planned shutdowns and maintenance outages?
Yes. The Rotamec Group can provide coordinated engineering support for planned shutdowns, including equipment removal, transportation, workshop overhaul, on-site engineering and reinstallation. This allows multiple stages of a shutdown project to be managed through one engineering group.
Do you repair and overhaul large industrial electric motors?
Yes. Our workshops provide industrial electric motor repair and overhaul services across a wide range of applications. This project included GEC DC motors rated up to 150kW and 3.3kV AC motors, demonstrating the capability to support substantial industrial rotating equipment.
Can you overhaul high-voltage motors?
Yes. This shutdown included the overhaul of 110kW 3.3kV AC motors. Requirements will vary depending on the motor and its condition, so equipment is assessed to determine the appropriate scope of repair or overhaul.
Can motor overhauls be carried out on site?
Where practical, yes. Some equipment may be more efficiently repaired or overhauled in situ. During this project, two 110kW basement motors were overhauled on site, while other equipment was removed and transported to the GEM workshop.
Do you overhaul industrial fans as well as motors?
Yes. Rotamec Group’s engineering capabilities extend beyond electric motors to associated rotating equipment, including industrial fans and fan assemblies. This can be particularly useful during shutdown projects involving several interconnected assets.
Can you remove and reinstall equipment as part of an overhaul?
Yes. Rather than providing workshop repair in isolation, Rotamec Group can support the wider project with site removal, transportation, overhaul and reinstallation, depending on the customer’s requirements.
How quickly can an industrial motor overhaul be completed?
Turnaround depends on the equipment, its condition, parts availability and the extent of repairs required. For this project, however, the complete programme of removal, overhaul and reinstallation was successfully delivered within a two-week planned shutdown window. We can work over weekends and evenings 24/7 to get the job done.
