Full rehabilitation of a critical 2500 kW motor (seawater pump) · Morón Complex

• Scope of Service: Repair and major maintenance of a 2500 kW motor for a seawater pump system.

1. Executive Summary

Key Impact: Complete restoration of a 2500 kW (approx. 3350 HP) motor dedicated to seawater service. The project included an exhaustive workshop maintenance protocol under ISO 9001 standards and EASA practice, ensuring reliability in pumping critical cooling water for the plant.

2. Technical Challenge (The Problem)

• Equipment Complexity: This is a large motor (2500 kW) operating in severe environmental conditions. The equipment required an in-depth intervention to correct the natural wear of its components and validate its electrical integrity.
• Precision Requirements: The client demanded strict compliance with tolerances and high-precision dynamic balancing (ISO 1940-G-2.5) to prevent destructive vibration.

3. Comprehensive Solution (Engineering by SIDELCA)

The service was carried out over 30 calendar days, following a technically detailed work specification:

• Disassembly and Diagnostics Phase:
• Uncoupling, removal of radiators, fan blades and hubs.
• Initial insulation and polarization index testing.
• Resistive balance testing and surge comparison.
• Stator Treatment:
• Washing with dielectric fluid using a steam machine and specialized rinsing.
• Full oven drying at controlled temperature with monitoring of drying curves.
• Varnishing and internal/external painting with an epoxy finish.
• Precision Mechanics and Rotor:
• Dimensional inspection of shafts, bearing housings and seals.
• Dynamic balancing of the rotor with fan and coupling installed.
• Installation of specific bearings: drive end (DE) 6040-MC3 and non-drive end (NDE) 29334E.
• Final Quality Control:
• No-load operating test to validate parameters.
• Application of primer and final finish to covers and cooling system.

4. Results and Value Metrics

• Optimized Investment: The project was completed at a total cost of USD 75,000.00, a fraction of the cost of a new 2500 kW motor.
• Quality Assurance: Executed under ISO 9001 and FONDONORMA certifications and with EASA (The Electro-Mechanical Authority) endorsement.
• Operational Continuity: Technical assistance during start-up ensured that Pequiven's seawater system recovered its nominal design capacity.

5. Project Technical Data