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East Haven, CT 06512
Schulz Electric Refurbishes Critical Circulating Water Pump Motor in Only Four Days
The Primary Challenge
Schulz Electric was contacted by a nuclear power plant in the New England
region that serves a community of over 2 million homes. After five years of service,
a 1500 HP, 4 kV, 24-pole circulating water pump motor (measuring approximately
7’ wide, 8’ tall, and weighing several tons) needed refurbishing while the plant was
still online. To add to their concern, the power plant is located close to the ocean.
The aging motor was not only approaching the end of its serviceable life, but was
highly susceptible to moisture intrusion and the salt-laden air, which can build
up in air passages within the motor. These environmental conditions can lead to
elevated operating temperatures and corrosion developing on the rotor, stator, and
shaft components. These factors combined, placed the plant at an increased risk
of downtime that could have potentially led to a significant loss of revenue if they
were forced into a shutdown event.
Classified as a “Balance of Plant” motor, continued operation
of equipment of this type is deemed as vital to ensure continuous power output to the grid. Power plants cannot run without these critical motors, and downtime cost estimates can
be upwards of $1 million per day. These costs prompted the
customer to request the refurbishment to be completed within
a five-day time frame, well short of the six to eight weeks it
usually takes for a refurbishment project of this scope.
The customer came to Schulz Electric with this challenge
because of their reputation for excellence in expedited repair
and their advantageous proximity to the plant. With industry leading technical expertise and a facility large enough to
handle the challenge, Schulz accelerated the electric motor
refurbishment and was able to complete the project, ahead
of schedule, in only FOUR DAYS from the time the motor
shipped to when it arrived back at the plant.
Photo of the circulating water pump motor at the
Schulz Electric facility.
A thorough analysis of the motor was conducted immediately upon receiving it by a team of six core technical
experts, a quality assurance technician, and a threeperson technical and administrative review team.
The scope of the refurbishment project included:
A battery of electrical and mechanical tests to
determine the health of the motor
Inspections to find discrepancies
Performing CO2 dry ice cleaning (in place of a walnut
shell or silicon bead process) for greater efficiency and
mitigating the risk of foreign materials while removing
salt, corrosion, and other contaminants
Placing the motor in a 24/7 work schedule queue
Replacing and upgrading components and restoring
the motor to a like-new condition
In-shop balancing, final quality checks, and no-load
Schulz Electric’s nuclear group specializes in nuclear motor repair. We offer a variety of nuclear services including environmentally qualified form and random wound insulation, contaminated electric motor repair with RCP electric motor overhaul and rewind, safety-related repairs, electric motor testing capabilities, high quality, cost effective solutions for MOV dilemmas, all from our nuclear motor repair facility and in-house decontamination facility.
"This refurbishment was one of the fastest Schulz ever
completed,” said Whit Ward, a field support engineer
for Schulz Electric. “Not only were we able to aid in mitigating risk by finishing it in only four days, but our team
delivered improved motor performance through the
better balancing we were able to achieve."
While a detailed refurbishing project is not typically done
for speed, Schulz Electric was able to be flexible and
create a result with no compromise to quality in the
process. The project’s success was a key milestone
for Schulz, as it led to more business and becoming a
trusted advisor to the plant for their future electric motor
About Schulz Electric Nuclear Group
Leading Experts for Safety-Related Electric Motor Repair
Schulz Electric is one of the leading electric motor repair facilities in the New England region that specializes in services for the Nuclear Industry. Our portfolio of capabilities includes all of the following:
Superior design in environmentally qualified (EQ) electric motor insulation systems
Safety-related electric motor repair
EQ harsh environment expertise
Contaminated electric motor repair
Electric motor storage and maintenance services
EDG services and expertise
Electric motor dedication
MOV motor repair
In-house motor decontamination facility
Full motor rewind and repair capabilities
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