Sulzer Ltd

The legislation around the efficiency of electric motors is continuing to tighten, and therefore the volume of Variable Speed Drives (VSDs) in service increases. Often specified by the motor manufacturer as part of the original installation - or retrofitted to improve efficiency - the drive contains both hardware and software that is designed to work with a motor in a specific application. So, what happens if the drive ceases to operate?

In the steel industry, down-time can be a very costly experience; therefore minimising the completion time for major overhauls and repair projects is a prime objective. For one steel manufacturing site in Brazil, a large, integrally-geared compressor needed two impellers replacing and the Original Equipment Manufacturer (OEM) had quoted 18 months as the expected project duration. The steel company then turned to Sulzer for an alternative solution which was delivered in just six months and with a 35% saving in overall costs compared to the OEM.

Longstanding engineering partner of Sulzer, TechnipFMC, has won the Hydraulic Institute Award for Innovation and Technology for its innovative products and solutions. The company specialising in oil and gas projects, technologies, systems and services was recognised during a ceremony at the Institute’s Centennial Celebration Gala in Florida, USA.

Evolving on a massive scale over the last 20 years, electronic control components have come a long way, however, many systems are much older than that and are now classified as obsolete. In the event of a failure within such a control system, spares or replacement products may not be available anymore, so what are the options?

Chosen to provide the UK market with maintenance and repair services for ABB medium and high voltage motors and generators, Sulzer has signed an agreement which provides ABB customers with direct access to the specialist skills and extensive facilities of Sulzer’s service centres in Birmingham and Falkirk.

At this year’s All-Energy 2017 exhibition, there will be the chance to visit Sulzer, a provider of services and solutions to the renewable energy sector, taking place in Glasgow from the 10th- 11th May. Taking place at the Scottish Exhibition and Conference Centre, the exhibition will provide a forum for the energy community to discuss the latest innovations occurring in the industry. Visitors will be able to liaise with Sulzer experts to discuss solutions at Stand K20 throughout the show.

Requiring a combination of in-house engineering skills and a partnership with a well-resourced, specialist repair provider, keeping lost production time to a minimum is a challenge. This became evident for one steel mill when a bearing failure caused a production line to stop and an urgent repair was required. Calling on Sulzer engineers, the plant initiated a round-the-clock repair procedure that minimised downtime and delivered a cost effective and long-lasting solution.

Used in a range of applications and usually performing a central role in a manufacturing process, industrial compressors, are required to deliver a reliable service. All operators carry out preventative maintenance routines to protect against unexpected failures, but if the worst does happen the repair needs to completed quickly and efficiently.

It is all down to marine design standards that ensure, even in the event of a catastrophic failure, back-up systems are in place to keep a vessel operational. For one European ferry operator, this has enabled them to continue operating safely, despite the failure of an on-board shaft generator. 

A growing source of renewable energy, landfill gas, and in particular the owners of waste storage sites are governed by strict regulations for the construction, operation and emissions generated at these facilities. An operator was searching for a solution to its engine generator emissions problems. The installed engine control schemes were manual but the landfill gas composition varied from day to day.

A number of suppliers have been awarded long service awards from Drayton Manor Theme Park, including Sulzer’s Birmingham Service Centre, which offers extensive repair services and fast turnarounds for all of the electric motors in the theme park. As part of the park’s 65th anniversary celebration, Sulzer received a silver platter in recognition of the high quality service and enduring relationship that has been built over many years.

An increasing strain is being put on the global power generation industry to keep up with demand while also having to comply with more stringent environmental legislation. A growing world population requires more power, while fuel prices continue to be volatile, natural gas has recently become a more attractive option.

The status of ‘Approved Service & Repair Centre’ for ATB Laurence Scott (ATB LS), the centre of excellence for the design and manufacture of mid and high voltage induction motors has, been awarded to Sulzer. With such a large installed machinery base, the manufacturer is keen to ensure that it can maintain a high level of maintenance service.

The Thinktank Science Museum in Birmingham is set to see industry experts convene on 6th and 7th December 2016, for the latest conference of the Power Generation Gas Turbine User Group. Visitors to the conference will be able to see a number of notable speakers making presentations on a wide range of topics across the two days, including Sulzer, an independent maintenance provider to gas turbine operators.

Mining operations run continuously and any time for maintenance needs to be minimised. One of the major procedures is the overhaul of mine haul truck wheel sets, and for customers that operate the Komatsu 930E, the time to complete this task has been reduced by Sulzer’s exchange programme. Modern mining equipment has to operate round the clock in order to be productive.

Repairing high-voltage steam turbine generators requires expertise at the best of times, but when the hybrid ‘hairpin’ coil design is far from the conventional diamond coil, it is essential that those entrusted with the repair have the knowledge and capability to complete the project accurately.

Orlando, Florida, will be hosting the POWER-GEN International 2016 show in December and Sulzer will be welcoming people from more than 100 countries to see its complete range of products and services on offer.

Losing low pressure steam and production time, due to a high voltage generator failure in an oil refinery, can have a significant impact on production. An Israeli oil refinery that recently experienced one such generator failure has turned to Sulzer for help.

Further enhanced with the ability to refurbish small steam turbines in Piedmont, South Carolina, is Sulzer and its repair facilities. This additional service complements the existing range of repairs for electric motors, pumps, compressors and generators. In addition to mechanical repairs and welding services, the service centre has an experienced field services team that delivers on-site repairs around the clock.

These days businesses need to be efficient and reliable, no matter what the size - from gas platform to a dairy farm, it’s a necessity for them all. Selecting maintenance partners and specialist electro-mechanical repair contractors is an important process; one that can reduce downtime and improve reliability and operational efficiency.