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ELECTRICAL MACHINES DROP IN REPLACEMENTS & UPGRADES Identical or upgraded machines for high voltage applications
Parsons Peebles specialise in drop in replacement and upgraded electrical machines for difficult applications – your challenge is our comfort zone
ELECTRICAL MACHINES DROP IN REPLACEMENTS & UPGRADES A BESPOKE SOLUTION When an operator needs to replace a motor or generator that has reached the end of its useful life, Parsons Peebles will provide a direct “drop-in” replacement unit regardless of the unit’s original manufacture. In addition to ensuring the replacement unit is interchangeable, we can often incorporate upgrades into the design. We ensure mechanical interchangeability, including: » Matching terminal points » Matching existing footprint » Match torque/speed requirements
THE PARSONS PEEBLES ADVANTAGE We offer a complete service from tender, site audit, engineering, manufacture, certification and installation to minimise the hassles of replacement or upgrade. This is conducted to the high OEM standards of a motor manufacturer with over 100 years experience in the industry.
Replacement machines can be to existing or upgraded specifications depending on specific project requirements. These upgrades can include: » Improved power from same space envelope » Reduced noise levels » Reduced starting current In addition to completely new motors or generators we can also upgrade an existing machine, utilising as many of the existing machine components as is practical and ensuring reliable operation. We truly offer a bespoke offering tailored to the unique requirements of your operation and existing equipment.
Parsons Peebles Offering
Customer Benefit
Full solution from site survey through to commissioning
Reduced time and cost through utilisation of single vendor
Replace / upgrade motors or generators regardless of
original equipment manufacturer Ability to upgrade or enhance the motor or generator e.g.
increased power, reduced starting current Match baseplate and bolting down arrangement Replicate ancillaries interface and connections Replicate motor performance characteristics Contain or even reduce machine space envelope
One stop shop for all replacements / upgrade requirements Adds system flexibility if required and addresses
duty changes Reduced time and cost for installation as no skid
reconfiguration or other site/system modifications required Reduces project costs & complexity Ensures complete skid compatibility
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DROP IN REPLACEMENT If your existing motor or generator needs replaced then many manufacturers will push their standard or mildly modified catalogue offering. This can lead to the requirement to change terminal points, motor footprint or even your electrical system. Let Parsons Peebles offer you a tailor made drop in replacement – it will often cost less in terms of total project cost too.
A Range of Drop In Solutions
Reducing your Spend
Parsons Peebles can supply drop in replacements made to measure. These can range from simple identical machines if the replacement is for a Parsons Peebles machine to upgraded replacements for third party machines.
With an eye on reducing operational expenditure for our customers we have come up with clever dual use spare drop-in solutions. These can be single motors that are easily reconfigured to act as replacements for two pieces of driven equipment. In this way you effectively achieve two emergency spares for a significantly lower outlay.
Drop in machine types include: » Direct drop in replacements » Upgraded drop in replacements » Dual use drop in replacements No matter the type of replacement, operational requirements of the machine or industry involved we will provide a speedy and cost effective solution.
In additional where possible we will refurbish your old machine so it can be used as an emergency spare. Parsons Peebles can even store this for you in our custom fitted storage facility.
IMPERIAL MACHINES – NO PROBLEM In situations where drop in or upgraded machines are considered these are frequently for old motors or generators that were manufactured to imperial rather than metric dimensions. This isn’t an issue for Parsons Peebles. No matter the make or age of the machine we are well practised in fabricating adaptor components or our preferred route of a fully bespoke machine to original imperial dimensions. Either way you’ll be supplied with a machine that just “plugs and plays”. 3
SCENARIOS WHERE AN UPGRADED OR DROP IN REPLACEMENT MACHINE IS THE CLEVER CHOICE The Most Cost Effective Choice For motors or generators Parsons Peebles will assess your site and develop an engineered solution to solve your particular requirements. Taking into account your budget, lead-time requirement, service and site conditions we will offer a new machine or where possible upgraded machine solution. The following scenarios illustrate typical applications where we have fulfilled our clients needs.
Typical Drop in Replacement Scenarios These are typical situations that lend themselves to a full drop in replacement machine: » An existing machine has reached end of useful life and needs a full replacement » A machine failure has occurred and it is not economical to repair » Creation of a special drop-in replacement spare that can cover two duties, thus reducing the expense of spares holding (see case study on page 6)
Typical Upgrade Scenarios Upgraded machines are frequently offered in the following situations: » Time constraints or budget does not allow a full replacement machine solution » The existing machine enclosure or other key machine elements can be retained whilst a rotor or stator upgrade to achieve increased, speed or output is achievable » Existing site problems mean an upgrade is required to engineer out reliability issues, e.g. change to cooling method due to incorrect initial specification or change in site conditions
Care Taken to Ensure Reliability Parsons Peebles will always design the replaced or upgraded machine taking into account full mechanical and electrical considerations as we would with any new motor or generator. This design process includes: » Ensuring starting current is compatible with electrical system » Ensuring starting torque is sufficient for driven load » Covering all thermal and cooling requirements » Ensuring all instrumentation is optimised for reliable operation » Full compliance with all relevant certification requirements
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ENSURING A GREAT FIT Providing a new machine that just slots in requires engineering expertise and experience. Parsons Peebles have successfully provided solutions for numerous clients to remove the issue of complex site modifications.
Plug and Play All terminal points are made to match existing interfaces so that you have a 100% interchangeable motor. These include: » 1:1 mechanically interchangeable design – no structural modifications of the foundation or bolting, jacking » Identical cable entries and terminal boxes – no complex realignment or new cabling requirements » Shaft centre line maintained – no complex realignment requirements and existing half-couplings can be used » Oil and cooling pipework – terminal points are retained, with flexible hoses used where appropriate
Typical machine interfaces: 1 3
2 4
1 Main terminal box designed for plug & play. Terminal configuration & position, gland plate position – all to match existing 2 Shaft centre line matched to existing. Holding down bolts, jacking, dowelling fully compatible. Oil pipes flexible 3 Cooler pipe connections in same position 4 Auxiliary terminal boxes in same position
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CASE STUDY Advanced Dual Use Upgrade Solution SITUATION Parsons Peebles were requested to evaluate the potential to obtain increased output power from an existing pump drive motor. Thereafter Parsons Peebles were requested to evaluate the feasibility of supplying a new-build strategic spare which could be used at two different locations on the same installation.
CHALLENGE » While the units are similar they were for completely different applications, one a Pump Drive the other a Compressor Drive with other discrete differences in the configuration of the machines » The new machine to be utilised as a spare for the existing machines to permit its removal for maintenance overhaul at a shore based workshop whilst maintaining Pumping and Compression capability for production » To evaluate the existing Crude Oil Export Pump Motor design for a higher output power in the existing machine or a revised design in the same footprint
INDUSTRY Offshore Oil & Gas CUSTOMER/LOCATION Conoco / North Sea, UK MACHINE TYPE Dual crude oil export pump and compressor motor
SOLUTION & OPERATIONAL IMPROVEMENTS » Design evaluation shows the requested higher power can be accommodated » While the two existing machines have differently configured shaft extensions one tapered with oil pressure assembly and one parallel – the solution will be to provide one parallel extension with new couplings for each application required » The main supply cabling is on the same side of the two machines but at different entry angles differing by 90 degrees – to be accommodated by common neck and 90 degrees change facility » The main bearings on the two machines are the same diameter but differently cooled – one with circulating oil the other with a water cooling arrangement – a hybrid bearing will resolve » Both machines are water cooled but have their supply and return headers on opposite sides of the machine – pipework management to resolve (example shown on right) » The instrumentation terminal box cabling connections are on different sides of the two machines – cable and box management will resolve
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MACHINE UPGRADES Wherever possible Parsons Peebles will look to maximise your investment by upgrading or modifying your existing motor or generator rather than offering a full replacement. Our ability to engineer a bespoke solution for your application can frequently save money, time and risk. Upgrades made Easy Our extensive experience in upgrading machines allows Parsons Peebles to offer increased power, reduced starting current or other modifications without the requirement of a completely new machine in many cases. We can frequently use the existing motor frame and through modifications to the stator and/or rotor meet the new drive requirement. Naturally just like our full drop-in machines our upgrades are 100% mechanically interchangeable and electrically compatible.
Full Spectrum of Upgrades Provided Our upgrade experience covers the complete range of possible upgrade situations: » Power upgrades » Change of machine running speed » Dual use upgrade solutions » Reduction in starting current or noise » Cooling system modifications » Certification upgrade » Modifications to enclosure or bearing types
MODIFICATION OF MACHINE PARAMETERS Our engineering team have the design flexibility to modify parameters of a motor and generator within the same space envelope. This could cover decreasing full load current, increasing power output, modifying noise levels, modifying motor cooling methodology or a combination of requirements. The following example illustrates a typical scenario.
6.0
3.0
5.0
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4.0
2.0
3.0
1.5
2.0
1.0
1.0
0.5
0.0
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20
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60
80
100
% Synchronous Speed
Our replacement or upgrade would be designed such that the new machine would have start-up characteristics similar to the existing machine. This would typically require the starting current as a percentage of full load current to come down (ie if existing had a starting current of 5xFLC then the uprated machine with a starting current of 3xFLC could potentially draw less power than existing on start up). 7
Key
Parsons Peebles low starting current machine
Original Machine
Current
Current
Torque
Torque
Example of the decrease in starting current achievable should this be a design requirement of the upgrade
0.0
Torque x FLT
An offshore operator requires to increase sea water injection due to new wells coming on line. The most cost effective option is often to uprate the pump internals whilst keeping the existing interfaces. More than likely this operational requirement would result in the existing motor not being rated highly enough for the new pump duty.
Current x FLC
Sea Water Injection Pump Drive Motor
Typical speed / torque comparison Regular AC induction motor vs Parsons Peebles low starting current motor
CASE STUDY Rapid Machine Upgrade at the UK’s Largest Power Station SITUATION In a coal fired power station induced draft fans are an integral part of the boiler operating system, drawing out gas and providing the essential flow of air through the boiler. The change from coal to full biomass firing generated the requirement for higher fan performance, above the original operating specification for the ID fan motors.
CHALLENGE An increased motor output was required, without modifying its dimensions to ensure shaft alignment. A quick and cost effective solution was required, motors of this size have long manufacturing lead times and with a limited window of opportunity, an innovative but effective solution was needed.
INDUSTRY Power CUSTOMER/LOCATION Drax Power / Selby, UK MACHINE TYPE Induced drat fan motor
SOLUTION The induced draft fan motor was returned from site to Parsons Peebles main Rosyth facility. After initial inspections a series of Continuously Varied frequency output load capability tests were undertaken. The tests were performed at the original design rated current of 153, 195 and 215 amps. This allowed for the motor to be re-rated. The results obtained showed that the motor could be re-rated to match the same performance enhancements of the fans. The rated output was increased by 42% to 3,375 kW.
OPERATIONAL IMPROVEMENTS The load testing carried out by Parsons Peebles has allowed the modifications to the fans to take place to increase the output, and improve the performance of the unit, with the confidence that the motor is running within its increased capable limits.
CUSTOMERS FINANCIAL BENEFIT The financial benefits of uprating the existing machine meant the end user avoided the cost of replacing the motor with a new increased power machine. This potentially saved the client in excess of £200,000 in new equipment cost as well as removing the need for any maintenance downtime on the site. Lead time for a new machine would have been approximately 36 weeks.
“ Parsons Peebles were able to offer a viable solution, both minimising downtime, and allowing us to avoid a costly exercise of replacing motors. The help and advice of Parsons Peebles enabled us to return the unit to service on time, and with ... confidence.“ - Drax Power Station
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A COMPLETE ENGINEERED SOLUTION Parsons Peebles can take the hassle out of your drop in replacement or machine upgrade requirements. Our complete service from site audit through to installation & commissioning ensures a rapid and cost effective solution to your challenge. A One Stop Shop
An Accredited Partner
As a full solutions provider we can save our customers time and money by carrying out the complete drop-in or upgrade process. From initial site visit and consultation we can quickly propose an engineered solution and then proceed to design, manufacture, test and subsequent installation and commissioning. In the case of drop-ins we can also look at your redundant machine and where possible refurbish this as a site spare.
We are a trusted partner with experience in oil & gas, power and industrial applications and have worked with all the major oil companies and utilities. This is backed up by our full set of accreditations: » ISO 9001 – Quality Management System » ISO 14001 – Environmental Management System » BASEEFA – ATEX QA Notification / IECEx Quality Assessment » Achilles FPAL - Offshore Oil & Gas » Utilities Vendor Database, Achilles (UVDB) – Verified » Association of Electrical & Mechanical Trades (AEMT) » Hazardous area machine manufacture & repair » Certified Repair Personnel
At every stage of the process you have a skilled team who are used to working to the strict time constraints associated with maintenance outages or to reduce exposure to the problem machine experiencing failure.
Parsons Peebles offer full replacement or upgrade services for our own and all major high voltage brands
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User Identifies issue with current machine
Initial design parameters gathered and likely site assessment
Does the unit require an upgrade?
No
Establish new operational parameters e.g. LSC, Power, Weight etc.
Manufacturing of upgraded or drop in machine
Customer award of project
Full in-house design verification and performance testing
Yes
No
Yes
Secondary site survey (if required)
Is unit a Parsons Peebles design?
Establish existing OEM product details
Design and cost / quote process
Delivery and installation on site
Ongoing service contract / condition monitoring
Typical flow chart showing the process for a drop in or replacement machine
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Parsons Peebles offer a truly “one-stop shop� solution. From initial site survey through to full installation and beyond
SITUATION
CASE STUDY Full Replacement Service at Constrained Offshore Site
The original Borsig compressor drive motor (supplied in 1979) had been inspected and cracks were found in the rotor frame. As this machine was production critical it was decided that it was not cost effective to remove and repair due to the estimated time out of operation.
INDUSTRY Offshore Oil & Gas
CHALLENGE
CUSTOMER/LOCATION Talisman / Fulmar Platform, North Sea, UK
Build and install a new drop in replacement motor to reduce expensive and unexpected platform shutdown. The new motor was made to industry standards and supplied to the client in time for their planned annual shutdown to minimise the imapct on production. Additionally development of a detailed changeout procedure to allow for the location , weight and size of the machine in question.
MACHINE TYPE Compressor drive
SOLUTION » Replacement machine was specified to have minimum interface changes with original » Detailed offshore survey was carried out to enable risk assessments and develop scope for changeout » New machine was assembled, tested then dismantled to allow for transport and installation in stages » Plan was developed in conjunction with various disciplines in customers organisation to ensure smooth and speedy turnaround » Project was successfully executed within a tight time frame (4 weeks)
OPERATIONAL IMPROVEMENTS » Machine upgrade from Exe to Exp to comply with current legislation » Downtime minimised due to detailed planning and speedy execution.
CUSTOMERS FINANCIAL BENEFIT Parsons Peebles provided a ‘one stop shop’ for this turnkey offshore project. From supply of a bespoke replacement machine through scope development and execution of change out. This negated the need for any costly ‘tier 1’ contractor involvement and limited the requirement for management of change processes. This saved the customer in the region of £500k excluding any costs for lost production.
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THE PARSONS PEEBLES MACHINE ADVANTAGE All Parsons Peebles electrical machines offer unique advantages that ensure they operate reliably in service for industry leading time between overhauls. Unsurpassed Quality and Life in service Our machines are made to last and have a typical design life of 40 years. Many of our machines are still running far beyond this even when operating in hostile applications and environments.
Keyed Bar Rotor Design The Parsons Peebles system of rotor cage construction uses a keyed bar rotor design. This eliminates the risks of bar fractures typically associated with ageing machines, frequent starting and high inertia loads. Since the concept was introduced in 1946 the system has been used as a standard feature in motors for the most arduous and demanding applications in the world. We are not aware of a single rotor bar that has failed using this system. » Proven security of the rotor cage system in the most demanding of applications » Improved rotor cage reliability reduces service costs and downtime » Suitable for very high starting frequency and high inertia loads » New keyed-bar rotors can be supplied for existing motors, even non-Parsons Peebles machines
Typical Range of Machines Covered INDUCTION MOTORS & GENERATORS – MEDIUM AND HIGH VOLTAGE » 500kW up to 20MW » 3.3kV up to 13.8kV - 50Hz and 60Hz » 2-pole to 40-pole SLIPRING MOTORS AND GENERATORS » 500kW to 20MW » 3.3kV up to 13.8kV - 50Hz and 60Hz » 4-pole to 40-pole SYNCHRONOUS – SALIENT POLE – MOTORS AND GENERATORS » 4-pole to 40-pole - up to 50MW » Motors for - compressor, pump or fan drives etc » Generators for - gas turbine, diesel, steam turbine and hydro applications » Rotary Frequency Convertors - 50Hz to 60Hz - up to 20MVA
FOR COMPLETE PEACE OF MIND – GO FULL LOAD TEST We always recommend a full load test for new drop-in replacement or upgraded machines. Parsons Peebles are well positioned with one of the most advanced test facilities in Europe to fulfil this need. Our test facility is suitable for both 50 Hz and 60 Hz operation and we test both Parsons Peebles and other manufacturers machines with equal rigour. Critical drives and applications, motors and generators up to 50MW can be operated at full rated load and temperature in order to prove their satisfactory operation across the entire load range. This eliminates any guesswork on the motors condition and gives a true picture as to the machines capability to operate satisfactorily in service. 13
TOTAL NEW EQUIPMENT AND AFTERMARKET SOLUTIONS Service Agility with OEM Capability As well as drop-in and replacement motor and generator services Parsons Peebles have a extensive range of aftermarket solutions. We combine the best elements of OEM design expertise with the flexibility and field experience of a full line service provider.
Our maintenance solutions are designed to directly align to our customers maintenance strategies, from simple repairs through to sophisticated asset management solutions.
We are able to offer parts, workshop services and site services covering all key requirements for high voltage machines and regularly service our own and other equipment globally with our highly skilled team.
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To learn more, please contact your Parsons Peebles representative or visit www.parsons-peebles.com Parsons Peebles, Wood Road, Rosyth Royal Dockyard, Dunfermline, Fife, KY11 2EA, Scotland, UK e: info@parsons-peebles.com | t: +44 (0) 1383 421 150
We reserve the right to make technical changes or modify the contents of this document without prior notice. The document and its text, images, diagrams, data and information it contains must not be copied or reproduced in whole or in part, in any form or by any means, without the prior written consent of Parsons Peebles. PP_DropIn_Rev 001_A4 Š 2015 Parsons Peebles