Challenge: Upgrading Motors
Without Removing Grouted Baseplates
A large oil and gas producer in the Grande Prairie area needed to replace outdated motors on their mainline pumps with new, upgraded units. However, removing the existing baseplates was not an option, as they were grouted in place. The client required a custom-designed solution to install larger, higher-horsepower motors while maintaining structural integrity and compatibility with the existing baseplates.
Westpower’s Custom In-Situ Re-Rate Solution
To meet the client’s requirements, Westpower developed a tailored in-situ motor and baseplate re-rate solution. Our field service team executed the following key steps to ensure precise and durable installation for all 6 1200 HP motors:
- Structural Modification: Removed old pedestals and welded new pedestals to support the larger motors.
- Precision Machining: Performed in-situ machining to achieve flatness and levelness to API 686 tolerances.
- Component Upgrades: Supplied and installed new couplings balanced to API 671 method 2.
- Laser Alignment: Ensured precise motor alignment.
- Grout Gap Inspection & Epoxy Injection: Filled gaps to reinforce structural integrity and prevent long-term wear.
- Protective Coating: Repainted the assembly for professional finish and corrosion protection.
Westpower’s engineering team handled the complete design and engineering, fabrication, installation, and post-upgrade validation, ensuring compliance with API standards. Due to the size and 1,200 HP rating of these motors, on-site machining was performed to achieve the required tolerances for levelness and stability.
Project Execution & Results
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- Scope: In-situ re-rate of six (6) 1,200 HP motors
- Completion Time: 10-day turnaround
- Expert Team: Welders, machinists, and millwrights worked collaboratively to execute the project efficiently.
- Outcome: Successfully installed and aligned upgraded motors without baseplate removal, ensuring improved pump performance and operational reliability.
