Fabrication of New Motor Shaft 2380 kW

This project covered the reverse engineering, fabrication, and installation of a new motor shaft and external fan as part of a comprehensive motor rehabilitation program. The work included dismantling, inspection, shaft removal using a mechanical method, new component manufacturing, winding treatment, electrical testing, rotor balancing, reassembly, and final running test to ensure the motor could return to operation with reliable mechanical and electrical performance.

Scope of Work

• Perform dismantling motor
• Perform chemical cleaning as necessary
• Perform incoming inspection (Visual, Dimensional, NDT)
• Provide summary inspection report
• Remove shaft from rotor winding with mechanical method (without heating) as per procedure
• Perform reverse engineer shaft motor
• Manufacture new shaft
• Install new shaft with mechanical method
• Manufacture new external fan
• Cleaning and re-varnishing winding stator & rotor core motor
• Heating up winding stator
• Perform electrical test: Winding Resistance Test and Polarization Index, Winding Insulation Test, Surge test winding motor (phase connected)
• Perform low speed balancing rotor
• Reassembly part motor
• Perform running test no-load and vibration test (at workshop)