INDUSTRY SOLUTIONS

Hydroelectric plants and small hydro stations operate large synchronous hydro generators whose design and parameters depend directly on the turbine type, rotation speed and unit rating. The reliability of the stator, rotor, excitation system and bearing assemblies determines the stability of the whole unit.

Elektropromremont carries out complete repair and restoration of hydro generators and their individual assemblies directly at the installation site. We rewind generators and stators. Where required we fully replace the stator winding, repair or replace the active iron, restore slot insulation and the winding fixing system. We manufacture new stator coils and bars, including complex bar windings with conductor transposition.

A dedicated area is the repair of the hydro generator rotor and its salient poles. We inspect the poles, repair and manufacture pole coils, restore or manufacture pole shoes, and repair contact joints, the damper system, insulation and other rotor components.

We restore thrust bearings, guide bearings and other bearing assemblies of hydro generators. We re-babbitt sleeve bearings, machine working surfaces, repair and manufacture new segments, sealing and oil-deflector elements and other parts to drawings or to sample.

Because of their size and the complexity of dismantling, a large share of the work is done directly at the hydro unit. Field crews carry out diagnostics and fault assessment, dismantling and installation of assemblies, generator repair, restoration of the stator, rotor, bearing assemblies and mechanical parts, alignment and a full set of post-repair tests.

Nuclear power plants operate a broad fleet of high-voltage motors driving primary and auxiliary mechanisms — reactor coolant, feed, condensate and other pump sets, ventilation systems and process equipment. For such machines the insulation reliability, winding manufacturing quality and the mechanical condition of the rotor and bearing assemblies are critical.

Elektropromremont carries out complete repair of electric motors for nuclear power facilities and manufactures and supplies spare parts for electrical machines. The company holds technical specifications for the manufacturing of spare parts for electrical machines approved by NNEGC Energoatom.

We perform the full cycle: diagnostics and fault assessment, overhaul and rewinding of motors, stator and rotor rewinding, manufacturing of new winding sections, coils and bars, repair of the active iron, squirrel-cage and wound rotors, restoration of shafts and seats, end shields, housing parts and bearing assemblies. We carry out rotor balancing, machining, impregnation and heat treatment of windings, assembly and a full set of post-repair electrical tests.

A dedicated area is the manufacturing of spare parts for nuclear plant motors: stator winding sections and bars, rotor winding elements, shafts, bearing assemblies, sealing and oil-deflector rings, housing and other parts to the customer’s technical documentation.

Wind turbines use electrical machines of very different designs — from wound-rotor asynchronous generators to modern permanent-magnet synchronous generators with direct drive. The specific generator design depends on the manufacturer, rating and turbine generation. Modern installations use both geared configurations with DFIG generators and gearless systems with synchronous generators.

Elektropromremont carries out diagnostics, repair and restoration of wind turbine generators and auxiliary motors. Depending on the machine design we perform fault assessment, stator rewinding, rotor repair and rewinding, manufacturing and replacement of winding sections and coils, active iron repair, restoration of shafts and seats, bearing assembly repair, machining, rotor balancing and electrical testing after repair.

A dedicated area is the restoration of individual generator assemblies and parts, which makes repair a viable alternative to replacing an expensive unit. For wind power this is standard service practice: manufacturers likewise provide for generator repair and restoration both at specialised workshops and directly on the turbine.

Steel plants operate one of the most demanding fleets of industrial electrical machines. Drives run in high temperatures, dust, vibration, shock loads, frequent starts, reversals and heavy overloads. Large machines are used in rolling, blast furnace, steelmaking and oxygen compressor operations, at pump and ventilation stations, on cranes and on conveying equipment.

Elektropromremont carries out complete repair and rewinding of motors at metallurgical plants — large DC machines, synchronous and high-voltage asynchronous motors, crane-metallurgical and special electrical machines.

We perform diagnostics and full fault assessment, stator rewinding, rotor and armature rewinding, repair and manufacturing of winding sections, repair of commutators, slip rings and brush gear, restoration of the active iron, shafts and seats. We repair sleeve bearings and bearing pedestals, carry out machining, balancing of rotors and armatures, impregnation and heat treatment of windings, assembly and a full set of post-repair tests.

A dedicated area is the repair of large DC machines driving rolling mill main drives. We repair heavy armatures, restore and manufacture commutators, rewind armatures, repair main and interpoles and manufacture spare parts. For oversized machines, diagnostics and selected repair operations can be performed directly at the customer’s site.

Ore mining and processing plants, quarries, crushing and beneficiation facilities operate large electrical machines in conditions of heavy dust, vibration, shock loads and long continuous duty. The drives run mining excavators, crushers, ore mills, conveyors, pump stations, fans and other process equipment.

Elektropromremont carries out complete repair and rewinding of motors at ore mining and processing plants — synchronous and high-voltage asynchronous machines, DC motors and generators, and special electrical machines on open-pit equipment.

We perform diagnostics and fault assessment, stator rewinding, wound rotor and armature rewinding, manufacturing of new winding sections and coils, repair of commutators, slip rings and brush gear, squirrel-cage rotors, restoration of the active iron, shafts and seats. We repair bearing assemblies, carry out machining, balancing of rotors and armatures, impregnation and heat treatment of windings, assembly and a full set of post-repair tests.

A dedicated area is the repair of electrical machines on mining excavators. We restore the DC motors of hoist, crowd, swing and travel drives, as well as the generators of motor-generator sets. We repair and rewind armatures, restore and manufacture commutators, repair pole coils, shafts, bearing assemblies and other parts.

For beneficiation plants we repair large synchronous motors of ore and ball mills, as well as high-voltage motors of crushers, screens, conveyors, pumps and ventilation equipment.

Coal mines and preparation plants operate a broad fleet of electrical machines driving mine hoists, conveyors, main ventilation fans, drainage pumps, crushers, screens and other process equipment. A large share of the drives work in heavy dust, humidity and significant mechanical loads and, for underground equipment, must meet explosion-proof requirements.

Elektropromremont carries out complete repair and rewinding of motors at coal mines and preparation plants. We work with high-voltage asynchronous machines, wound-rotor and squirrel-cage motors, and explosion-proof and special mining designs.

We perform diagnostics and fault assessment, stator rewinding, wound rotor repair and rewinding, manufacturing of new winding sections and coils, repair of slip rings and brush gear, squirrel-cage rotors, restoration of the active iron, shafts and seats. We repair end shields and housings, bearing assemblies, carry out machining, rotor balancing, impregnation and heat treatment of windings, assembly and a full set of post-repair tests.

A dedicated area is the repair of mine hoist motors and large main ventilation drives. For oversized equipment we carry out diagnostics, dismantling and installation, selected repair work on site, vibration diagnostics and alignment of the motor with its driven machine.

Cement production places high continuous loads on the drives of the main process equipment. The most critical are the drives of raw and cement mills, crushers, kilns, induced-draft fans, process fans, compressors and conveying systems, which use large synchronous and high-voltage asynchronous motors.

Elektropromremont carries out complete repair and rewinding of motors at cement plants. We perform diagnostics and fault assessment, stator rewinding, rotor repair and rewinding, manufacturing of new winding sections and coils, repair of the active iron, squirrel-cage and wound rotors, restoration of shafts and seats, repair of end shields and bearing assemblies.

We have experience repairing the synchronous motors of cement and raw mill main drives with full stator winding replacement and rotor winding repair. We repair slip rings and brush gear, sleeve bearings and bearing pedestals, carry out machining, rotor balancing, impregnation and heat treatment of windings, assembly and a full set of post-repair tests.

For oversized machines we provide on-site diagnostics and repair at the installation location, dismantling and installation, vibration diagnostics, bearing assembly repair, laser alignment of the motor with its driven machine and commissioning of the unit.

Quarries, aggregate and stone-crushing plants, and producers of sand, granite, limestone and other mineral raw materials use heavy-duty drives in conditions of high dust, vibration, shock loads and long duty cycles. The main electromechanical equipment is concentrated in the drives of crushers, screens, mills, conveyors, excavators, pumps and dust extraction systems.

Elektropromremont carries out overhaul and rewinding of motors at building materials enterprises. We perform diagnostics and fault assessment, stator rewinding, rotor repair and rewinding, manufacturing of new winding sections and coils, repair of squirrel-cage and wound rotors, restoration of the active iron, shafts and seats, end shields and bearing assemblies.

We carry out machining, slip ring repair, impregnation and heat treatment of windings, dynamic balancing of rotors, assembly and a full set of post-repair tests. We work both with general-purpose motors and with high-voltage asynchronous and synchronous machines driving the main process equipment.

For oversized equipment we perform selected work directly at the customer’s site — diagnostics, dismantling and installation, bearing assembly repair, vibration diagnostics and laser alignment of the motor with its driven machine.

Chemical plants operate a significant number of large electrical machines driving compressors, turbo compressors, pumps, boosters, fans and other process equipment. Many productions run continuously, in aggressive environments and with elevated reliability requirements for the drive.

Elektropromremont carries out complete repair and rewinding of motors at chemical plants — large synchronous, high-voltage asynchronous and special electrical machines of both domestic and imported manufacture.

We perform diagnostics and fault assessment, stator rewinding, rotor repair and rewinding, manufacturing of new winding sections, coils and bars, repair of the active iron, slip rings and brush gear, restoration of shafts and seats. We repair bearing assemblies and sleeve bearings, carry out machining, rotor balancing, impregnation and heat treatment of windings, assembly and a full set of post-repair tests.

A dedicated area is the repair of oversized compressor motors, for which transport to the workshop may be difficult or impractical. We carry out diagnostics and selected repair operations directly at the customer’s site, dismantling and installation, vibration diagnostics, bearing assembly repair and laser alignment of the motor with its driven machine.

Refineries run a large amount of continuously operating rotating equipment — process pumps, compressors, blowers, fans and auxiliary units. The drives serve atmospheric and vacuum distillation, reforming, hydrotreating, catalytic cracking and coking units, as well as water supply, cooling systems and tank farms. Pumps and compressors are among the principal groups of rotating equipment at a refinery.

Elektropromremont carries out diagnostics, overhaul and rewinding of motors, stator and rotor rewinding, manufacturing of winding sections and bars, repair of the active iron, shafts and seats, restoration of bearing assemblies and sleeve bearings, rotor balancing, machining, impregnation and heat treatment of windings, assembly and post-repair testing of electrical machines.

We work with synchronous and asynchronous motors, high-voltage machines, explosion-proof and special designs, and imported equipment. The oil, gas and chemical industries apply specific motor requirements, in particular API 541, API 547 and the applicable requirements for hazardous-area equipment.

Oversized electrical machines can be repaired either at our workshop or directly at the installation site, including fault assessment, dismantling and installation, alignment, diagnostics and acceptance testing.

Companies producing, processing and transporting oil and natural gas operate a wide range of electrical machines: from the drives of drilling rigs and pump units to large high-voltage motors at compressor stations and mainline pump sets.

Elektropromremont carries out motor repair and rewinding, stator and rotor rewinding, manufacturing and replacement of winding sections and bars, repair of the active iron, shafts and bearing assemblies, rotor balancing, mechanical restoration, assembly and post-repair testing. Oversized equipment can be repaired either at our workshop or directly at the customer’s site.

A dedicated area is the repair of high-voltage machines driving compressors, boosters and mainline pumps, which run continuously and carry elevated reliability requirements.

The electrical machines of traction rolling stock run under constantly changing load, frequent starts, overloads and significant mechanical and vibration stress. The quality of traction motor, traction generator and auxiliary machine repair therefore directly affects locomotive reliability and the service life of its traction equipment.

Elektropromremont carries out overhaul of railway traction motors and restoration of their main assemblies. We perform fault assessment, armature repair and rewinding, field winding rewinding, repair and manufacturing of main and interpole coils, commutator repair, restoration of shafts and seats, bearing assemblies, armature balancing, machining and testing of the machines after repair.

We can not only repair a complete machine but also manufacture and restore individual parts — commutators, shafts, pole coils, windings and other elements. We repair DC and AC machines for electric locomotives, diesel locomotives and other special railway rolling stock.

Elektropromremont repairs and manufactures traction electrical machines for trams, trolleybuses and metro cars. We work both with classic DC traction motors and with other electrical machines of rolling stock.

We perform the full traction motor repair cycle: diagnostics and fault assessment, motor rewinding, armature rewinding, repair and manufacturing of main and interpole windings, commutator repair, restoration of shafts and seats, repair of end shields and housings, armature balancing, assembly and post-repair testing.

A dedicated area is the manufacturing of traction motors and spare parts for them. We manufacture new complete armatures, commutators, armature winding sections, main and interpole coils, shafts, brush holders, housing and other parts to the customer’s drawings, technical documentation or sample.

Seaports and transhipment terminals use a large number of drives working with frequent starts, braking, reversals and variable load. The most demanding requirements apply to crane motors of the hoisting, crane travel and trolley mechanisms, as well as to the drives of conveying and transhipment equipment.

Elektropromremont carries out overhaul and rewinding of crane motors, wound-rotor and squirrel-cage asynchronous motors, and the electrical machines of auxiliary port equipment. We perform fault assessment, stator rewinding, wound rotor rewinding and repair, slip ring restoration, repair of shafts and seats, bearing assemblies and housing parts, rotor balancing, machining and testing of the motor after repair.

We also repair high-power motors for port pumping, ventilation, conveying and transhipment installations. Where required we manufacture new coils and winding sections and restore or manufacture individual parts of the machines.

Uninterrupted water supply and wastewater service depends directly on the reliability of the pump drives. Water intakes, first- and second-lift pumping stations, booster stations, sewage pumping stations and treatment works operate vertical and horizontal pump sets with synchronous and asynchronous motors, including high-voltage and oversized machines. Water supply pumping, wastewater transfer, water treatment and treatment works form the main groups of electromechanical equipment at a water utility.

Elektropromremont carries out diagnostics, overhaul and rewinding of water utility motors, stator and rotor rewinding, manufacturing of new winding sections and bars, repair of the active iron, restoration of shafts and seats, repair of bearing assemblies and sleeve bearings, end shields and housings, rotor balancing, machining, impregnation and heat treatment of windings, assembly and post-repair testing.

We work both with large vertical and horizontal motors of the main pump sets and with a wide fleet of medium and small asynchronous motors on auxiliary mechanisms. Oversized machines can be repaired at our workshop, or selected operations can be carried out directly at the installation site.

Pumping and water transfer stations move large volumes of water over long distances, supply regions with limited local water resources, fill trunk canals and reservoirs, and run irrigation and land reclamation systems. Such facilities are built around large vertical and horizontal pump sets whose drives operate continuously under constant load and are critical to the entire system.

Elektropromremont carries out overhaul and rewinding of motors at pumping and transfer stations — from diagnostics and fault assessment to full restoration of the electrical and mechanical parts. We perform stator rewinding, rotor repair and rewinding, manufacturing of winding sections and bars, repair of the active iron, shafts, bearing assemblies and sleeve bearings, restoration of seats, rotor balancing, machining and high-voltage testing.

For oversized equipment we can carry out selected operations directly at the pumping station: dismantling and installation, diagnostics, repair of individual assemblies, laser alignment of the motor with the pump, vibration monitoring and commissioning of the unit after repair.

Machine building plants use a wide range of electrical machines — from the motors of the main process equipment to the drives of machine tools, presses, crane facilities, compressor, pump and ventilation installations. A separate group is formed by test rigs and special process equipment, which use machines of various designs and duty cycles.

Elektropromremont carries out overhaul and rewinding of motors at machine building plants — asynchronous and synchronous machines, DC motors, crane and special motors. We perform diagnostics and fault assessment, stator rewinding, wound rotor and armature rewinding, manufacturing of winding sections and coils, repair of commutators and slip rings, restoration of the active iron, shafts, seats, end shields and bearing assemblies.

We also carry out mechanical restoration of the machines, impregnation and heat treatment of windings, dynamic balancing of rotors and armatures, assembly and a full set of post-repair tests. Where required we manufacture new shafts, commutators, coils, winding sections, bearing elements and other parts to drawings or to sample.

We work both with the large machines of the main production mechanisms and with small and medium-power motors with round-wire random windings, widely used on machine tools and auxiliary equipment.

Pulp and paper mills, board and paper factories and packaging producers use a large number of drives that run continuously and keep the process uninterrupted. The drives of paper and board machines, refining equipment, pumps, fans, vacuum systems, conveyors and auxiliary mechanisms are particularly important.

Elektropromremont carries out overhaul and rewinding of motors at pulp and paper enterprises — from diagnostics and fault assessment to full restoration of the electrical and mechanical parts. We perform stator rewinding, rotor repair and rewinding, DC motor and armature repair, manufacturing of coils and winding sections, commutator repair, restoration of shafts and seats, bearing assemblies, balancing of rotors and armatures, machining and testing after repair.

A dedicated area is the repair of variable-speed drives of paper and board machines, where plants of different generations may use either DC motors or modern asynchronous motors with frequency control. We work with electrical machines of domestic and imported manufacture and, where required, manufacture and restore individual parts.

Food industry enterprises use a large number of drives of various ratings — from the drives of the main process lines to pumps, compressors, fans, conveyors and refrigeration equipment. We work with equipment at meat processing plants, beverage and juice producers, and dairy, confectionery and other food producers, where process continuity and fast recovery of critical equipment matter most.

Elektropromremont carries out overhaul and rewinding of motors at food industry enterprises, both domestic and imported. We perform diagnostics and fault assessment, stator rewinding, rotor repair and rewinding, manufacturing of new winding sections and coils, restoration of shafts and seats, bearing assembly repair, machining, rotor balancing and testing of the motor after repair.

We also work with imported motors on process and automated production lines, where replacing a machine can be costly or involve long lead times. We repair ABB, Siemens, WEG and other manufacturers’ motors and restore individual mechanical and electrical assemblies.

Sugar plants run an extensive system of drives — from in-house generation turbogenerators and large process equipment drives to a great number of asynchronous motors on pumps, fans, conveyors and auxiliary mechanisms. The seasonal nature of production makes equipment reliability and the ability to complete a full overhaul between campaigns especially important.

Elektropromremont carries out overhaul of generators and motors at sugar plants. We perform diagnostics and fault assessment, stator repair and rewinding, rotor repair and rewinding, manufacturing of new winding sections and coils, active iron repair, restoration of shafts and seats, bearing assemblies, rotor balancing, machining and testing of the machines after repair.

A dedicated area is the repair of the turbogenerators of the plants’ own power supply systems, as well as the drives of the main process equipment — the beet processing section, diffusion units, pumps, centrifuges, fans, conveyors and other equipment. Where required we manufacture and restore individual assemblies and parts.

Agribusiness enterprises and grain elevator complexes use a large number of drives in grain intake, cleaning, drying, conveying, storage and processing systems. The motors drive bucket elevators, belt and chain conveyors, screw conveyors, grain cleaning equipment, fans, grain dryers, crushers, dust extraction units and other process mechanisms.

Elektropromremont carries out overhaul and rewinding of motors at grain elevators and agribusiness enterprises. We perform diagnostics and fault assessment, stator rewinding, rotor repair and rewinding, manufacturing of new windings, restoration of the active iron, shafts and seats, repair of end shields and bearing assemblies, rotor balancing, machining, impregnation and heat treatment of windings, assembly and post-repair testing.

We pay particular attention to motors operating in heavy dust and under continuous process load. We work with general-purpose, enclosed, dust-protected and special motor designs depending on the operating conditions and the hazard category of the process area.

We repair both small asynchronous motors on conveyors and auxiliary mechanisms and large machines on grain drying complexes, ventilation and dust extraction systems, crushers, mills and compound feed production.