Electro Mechanical Services - Houghton International

Specialist & Bespoke Repairs

Houghton International Electro Mechanical Services Specialist & Bespoke Repairs2

Project overview17 tonne, 4.6MW 3500HP DC thruster motor on an offshore oil rig had been severely damaged due to flooding. As a result, a complete repair and refurbishment to the stator, armature, bearings and brush gear was required. Project entailed• Complete strip down and fault diagnosis.• Manufacture of new field and interpole bricks.• Full rewind of interpole and field coils. Interpoles required copper wound on edge.• Manufacture compensating bars and rewind.• Complete rewind of armature. Manufacture of all coils. Armature included dampening winding, equaliser winding and main winding. All connections TIG welded.• Complete overhaul of brushgear. Supply of new holders and brushes.• Complete mechanical overhaul. Supply of new bearings.• All components shot blasted and painted with high specification marine paint.• Horizontal load test and vertical light run test to prove winding and mechanical works.

CASE STUDY:

A leading international offshore services provider

Houghton International Electro Mechanical Services Specialist & Bespoke Repairs 3

WELCOME

Through our commitment to total quality we plan to continue to lead the UK’s electro mechanical services repair market in terms of innovation and customer service through investment in plant, equipment and people.

Our dedicated Electro Mechanical Services facility comprises state of the art technology to provide a comprehensive range of in-house and on-site services to support our customers in the power generation, renewables, industrial, water, oil & gas, marine and rail transport sectors.

In 2012 we invested in new facilities and plant including a 20 tonne crane, a silicone VPI plant to complement our epoxy capability, along with TIG welding and undercutting equipment to enable us to provide the extensive range of operations required for a high quality armature rewind.

We pride ourselves on our attention to detail, providing a high quality service and delivering on time. We keep our customers updated through on-going dialogue and reporting. This helps us to provide a focused, customer needs driven, fast response service.

Our quality assurance model is accredited to ISO 9001:2008 and as safety is the highest priority for our business, in 2012 we were awarded OHSAS ISO18001 for health and safety. This achievement underlines our commitment to staff welfare.

We value our independence and work alongside our customers to solve their problems and provide a flexible commercial framework that adds significant value to their businesses. That’s why our customers keep coming back to us.

Please contact us to learn how we can add value in your business.

Michael MittenChief Executive Officer

Houghton International Rail Leading Traction Motor and MA Set Repairs 3


everyone matters


OUR EXPERTISE OUR PEOPLEOUR QUALITY

OUR EXPERTISEWe have committed to significant investment to ensure our workshop has the latest facilities and equipment to provide a comprehensive range of services, both in-house and on-site. This is highlighted by the installation of a 20 tonne crane allowing us to accommodate major projects.

We minimise customer downtime by operating a 24hr, 7 days a week emergency repair service that is operational 365 days a year. We understand time is money for our customers and we work alongside them to solve their problems, efficiently and effectively.

Our staff are multi-skilled engineers with extensive experience who can carry out mechanical and electrical repairs on a broad range of equipment including AC and DC motors, pumps, gearboxes and generators, both in-house and on our customer’s premises.

First and foremost, we value our customers and always strive to exceed their expectations.

OUR PEOPLEWe recognise that people are our most important asset. We have a highly skilled team that successfully combines youth with experience. We employ for attitude and train for skill. We aim to be the employer of choice for talented people and invest in them to ensure that they have the opportunities to develop. In return we expect loyalty, a total focus on our customers’ needs, delivery to deadlines and commitment to our total quality process. We are totally committed to our apprentice programme. 14% of employees are apprentices undergoing a four year structured programme and upon successful completion there will be further opportunities for personal development in addition to career progression within the company. At Houghton International ‘everyone matters’.

OUR QUALITYHoughton International operate in sectors where quality procedures and the safety of equipment are critical.

As such we have developed a rigorous quality policy with processes and procedures to ensure that everything we do is of the highest standard. These policies and procedures are reviewed across all areas of the business on an on-going basis which reflects our culture of continuous improvement. Quality assurance checks are conducted at each stage of the manufacturing process. Our quality management system is accredited to BS EN ISO 9001:2008, electrical tests to B.S.60034 – 15:2009. We can also test to customers specific criteria if required.Our occupational health and safety management system is accredited to OHSAS 18001; 2007.

As part of our commitment to total quality assurance and the development of our supply chain we have established strong relationships with suppliers.

IN-HOUSE SERVICES

• AC/DC motor, generator rewinds and repairs • 24 hour emergency repair service • Automated commutator undercutting • Bespoke engineering and tool making • Dynamic balancing • Pumps - service and overhaul • Repairs to ATEX Ex equipment • Test equipment • Transformer repairs • Vacuum Pressure Impregnation (VPI) facility • Welding - TIG, MIG and Stick

ON-SITE SERVICES

• Breakdown fault finding and electrical installation • Condition monitoring • Laser alignment • Motor management • Shock pulse monitoring /bearing analysis • Test, disconnect and removal of rotating machinery • Thermal imaging • Vibration analysis

NEW AND RECONDITIONED MOTORS

• Stockist and repair of WEG electric motors • Service agent and spare parts stockist for MeccAlte alternators and generators

OUR SERVICES



AC / DC MOTOR, GENERATOR REWINDS AND REPAIRS Houghton International are at the forefront of the AC and DC motor and generator rewind/repair industry, serving a broad range of sectors including power generation, renewables, industrial, water, oil & gas, marine and rail transport.

24 HOUR EMERGENCY REPAIR SERVICE We provide a 24 hour emergency repair service underpinned by our preventative maintenance services which include condition monitoring, motor management, vibration analysis, laser alignment, shock pulse monitoring / bearing analysis and thermal imaging.

AUTOMATED COMMUTATOR UNDERCUTTING We have an extensive undercutting capacity including a fully automatic Rimac undercutting machine.

Automatic undercutting offers advantages over manual undercutting processes in both terms of time saving and improved accuracy, thus enabling us to provide a cost effective service for our customers.

BESPOKE ENGINEERING AND TOOL MAKING This specialist division compliments our electro mechanical expertise by enabling us to manage highly complex repairs to large, one-off machinery as well as driving process and quality improvements across our entire business.

Our team’s collaborative culture is focused on understanding our customer’s objectives to achieve and engineer custom solutions that are world class.

DYNAMIC BALANCING Dynamic balancing is an essential component of both diagnostic and verification testing.

Our balancing capacity includes a new Schenk HM40BU balancing machine and we are able to conduct dynamic balancing to up to 5 tonnes.

PUMPS - SERVICE AND OVERHAUL We have extensive experience servicing and overhauling pumps of all types including submersible. We carry out in-situ condition monitoring and full re-winds of equipment to be used in volatile environments.

REPAIRS TO ATEX Ex EQUIPMENT Houghton International is an AEMT approved overhauler of Ex-rated pumps and motors.

Staff are certified through AEMT to BS EN 60079-19:2007 & IEC 60079-19:2006 where both theoretical and practical competency are rigorously assessed with respect to Ex d, Ex de, Ex e and Ex N type pumps and motors.

As such our customers can be assured that their ATEX Ex-rated equipment will be returned to them fully compliant with:

• ATEX regulations • A harmonised construction standard • The UK Health and Safety at Work Act • Offshore regulations, where applicable

TEST EQUIPMENTSignificant investment has been made in sourcing the latest test equipment to allow for a more comprehensive range of electrical and mechanical tests to be offered to our customers. This includes an AWA12KV surge Baker test complete with AT-101ZTX bar to bar tester.

Our customers can be assured that not only are we using the most advanced test equipment available, but the scope of our BSI EN ISO 9001:2008 quality management system approval includes the regular internal and external audit of our calibration system.

Not only has significant investment been made in our in-house testing facilities but we have also invested in our on-site test facilities. Our engineers are equipped to undertake an extensive range of tests which far exceed the traditional Megger test to diagnose a motor’s condition.In addition to our comprehensive range of condition monitoring test equipment, we can test for the following while the motor is still in-situ;

• Surge on windings • DC dielectric strength • Insulation resistance / Megger test • Polarisation index • 1,2/50 pulse

IN-HOUSE SERVICES


TRANSFORMER REPAIRSWe are able to manufacture and supply transformers from <1kVA to >600kVA, in addition to providing full overhaul of existing units.

All coils used in either the manufacture or repair of these units are produced in-house and we conduct all mechanical repairs required. This allows us to take complete ownership of the job which serves to maintain the highest standards of quality control.

VACUUM PRESSURE IMPREGNATION (VPI) FACILITYHoughton International offer an in-house Vacuum Pressure Impregnation (VPI) facility for both epoxy and silicone resins.Motors, generators and coils up to 2.13 metres (7ft) in diameter are processed under vacuum and pressure with solventless epoxy or silicone resin to provide void-free electrical windings.

We are able to provide VPI for AC and DC stators, armatures and field coils. Large frame motors from 460 volts through 13,800 volts should receive VPI treatment to ensure the longest attainable service life.

WELDING We provide a comprehensive range of welding services.

TIG WeldingTIG (Tungsten Inert Gas) welding is a process where high quality and precision is required. TIG welding can be used for carbon steel, stainless steel, aluminum and other alloys, ferrous and non-ferrous. TIG welding is also referred to as gas tungsten arc welding (GTAW).

We have extensive experience in TIG welding to meet the needs for light to medium steel manufacturing, fabrication projects and production welding. We specialise in TIG welding for armatures and commutators.

MIG WeldingMIG welding is a semi-automatic or automatic arc welding process preferred for its versatility and speed. MIG welding can be used for the following materials: carbon steel, stainless steel, aluminum, and other alloys, ferrous and non-ferrous. MIG welding is also known as metal active gas (MAG) welding or gas metal arc welding (GMAW).

We have extensive experience in MIG welding for light to medium steel manufacturing, fabrication projects and production welding.

Stick WeldingStick welding’s primary benefit is the versatility of the process and simplicity of its equipment and operation.

Stick welding is used predominantly to weld iron and steels (including stainless steel). However aluminium, nickel and copper alloys can also be welded using this method. Stick welding is more formally referred to as shielded metal arc welding (SMAW) or manual metal arc (MMA) welding.

Houghton International Rail Leading Traction Motor and MA Set Repairs 9


BREAKDOWN FAULT FINDING & ELECTRICAL INSTALLATIONHoughton International undertake comprehensive fault-finding and analysis for every repair we complete as part of our quality management system.

Our skilled team of engineers work with our customers at their premises in order to fully understand the underlying problems and symptoms associated with failure.

We understand that repairing a motor without asking why it has failed risks the problem recurring. We don’t just repair a motor or a generator for our customers, we detect the original source of the failure. By doing this, we can make recommendations to prevent the same problem occurring again in the future.

CONDITION MONITORINGPreventative maintenance is achieved following the implementation of one of our condition monitoring systems, and involves the identification of potential problems before they have the opportunity to become critical.

As a result of an on-going condition monitoring programme, maintenance may be scheduled and actions taken to avoid the consequences of in-service failure before the failure actually occurs. This saves our customers money and maximises plant and machinery availability and productivity.

LASER ALIGNMENTMotor misalignment can cause a variety of issues including bearing defects, mechanical failure, electrical failure and excessive vibration.

We offer Optalign laser alignment for any scenario, be it motors connected to gearboxes or pumps or generators to an engine. Laser alignment minimises any angular or offset alignment problems. The equipment and our skilled engineers can obtain results of 100% alignment, with detailed reports showing final readings.

MOTOR MANAGEMENTHoughton International offer a comprehensive motor management system, a planned maintenance regime.Preventative maintenance reduces costs and avoids downtime by preventing failure.

Our customers benefit from having an individual project manager to discuss all aspects of their motors and maintenance regime, alongside the reassurance of dealing with a BSI approved company.

We manage our customer’s motors and can visit on-site to identify each motor while it is live.

ON-SITE SERVICES


SHOCK PULSE MONITORING / BEARING ANALYSISWith our shock pulse monitoring /bearing analysis equipment we are able to advise our customers of a potential bearing failure prior to it actually happening. This can prevent the occurrence of further damage to the motor and potential costly downtime.

Using a traffic light system we can advise if the bearings are running satisfactorily (green), require monitoring (yellow) or require urgent attention (red). As with vibration analysis, one of the main benefits of planned preventative maintenance and testing is that our customers are able to reduce downtime and the costs incurred as a result of unplanned maintenance.

TEST, DISCONNECT & REMOVAL OF ROTATING MACHINERYAs demonstrated through our OHSAS 18001:2007 occupational health and safety management system, safety is an absolute priority at Houghton International. As such our engineers carry out site-risk assessments and are able to provide method statements for all works carried out on-site. Our skilled staff ensure that all appropriate precautions are taken prior to testing, disconnecting or removing rotating machinery.

THERMAL IMAGING At Houghton International, thermal or infrared imaging is used as a method of condition monitoring for rotating machinery and fixed circuitry. A thermal imaging survey allows for the identification of poor connections, overloaded circuits, failing components or imbalanced loads. These faults, if left unidentified will result in increased plant downtime, loss of production and/or risk from fire.

Additionally, we can conduct thermal imaging as part of full-load verification testing of motors to ensure that no bearings or connections are running at a temperature above specified parameters.

VIBRATION ANALYSIS Through our vibration analysis service, our customers are able to prevent the occurrence of motor damage, unit downtime and a potential motor rewind.

Vibration analysis is a non-intrusive fast response preventative maintenance solution. The service is designed to locate a potential problem during a scheduled maintenance regime and rectify it before it causes further damage to the machinery.


“A&P North East operate drydocks at Hebburn on Tyneside and at Teesport on the Tees.

The facility at Teesport has two drydocks which are served with a common pump room with two pumps, generally operated as one duty and one standby. The pumps are driven by Metro Vickers AC Motors, 500HP, 2750 Volts, Stator 800 Volts.

In late 2012 the motor on No1 Pump failed and quotations were sought for an overhaul and rewind.

Houghton International provided a competitively priced offer and following an audit of their works and discussions with both the management and operators who were to undertake the task, the order was placed with them.

Throughout the process of overhaul and rewind A&P staff visited the Houghton International workshops and regular progress updates with photographs were provided by email. The repairs and rewind were carried out in a meticulous manner by the operatives who treated the motor as if it was their personal property.

The motor was returned to site early and installed with the assistance of the A&P dockside cranes. Alignment and recommissioning was carried out by A&P and Houghton International working together.

A subsequent visit was arranged following the motor having been “run in” to check the operation and alignment.

Throughout the overhaul and rewind Houghton International have been a very professional company to deal with and have taken the care I would expect and is required on a motor of this size and age.

The motor and pump set is now performing as good as when new, almost 100 years ago.”

John Leckie, Asset Manager, A&P North East

CASE STUDY:

A&P Group 500HP dock pump overhaul and rewind


STOCKIST AND REPAIR OF WEG ELECTRIC MOTORSHoughton International is an approved WEG stockist. We stock WEG motors in all sizes and ratings, the majority of which are available for next day delivery.

Our specialist engineers are also able to conduct repairs where required.

SERVICE AGENT AND SPARE PARTS STOCKIST FOR MeccAlte ALTERNATORS AND GENERATORSHoughton International is an approved service agent and authorised spare parts stockist for all MeccAlte products within the UK market.

NEW AND RECONDITIONED MOTORS


WHAT OUR CUSTOMERS SAYROLLS-ROYCE“The diligence, innovation and timeliness applied to the conduct of this contract has assisted Rolls-Royce enormously in what is an exceptionally challenging development motor programme and your teams

contribution cannot be underestimated.”

Nicky Moore, Senior Procurement Engineer

NORTHUMBRIAN WATER“I have been dealing with Houghton International for a number of years, particularly with the motor rewind/repair dept. Over the years I’ve never been let down in the any of the jobs they have under taken on my behalf.

They always collect the parts extremely quickly and the workmanship is always excellent with a quick turnaround time. Most importantly they are a firm that I know I can rely on.

I look forward to many more years working together.”

Kevin Tucker, Maintenance Team Leader

DH MARINE (SHETLAND)“Our organisation had need to use the services of Houghton International in September 2011 when we transported a bow thrust motor and an AC motor from the islands to your depot. From our initial enquiry to receiving back the equipment all inspected, repaired and re-wound, we received an excellent service. There was an urgency to receive back the bow thrust motor and you kindly met our deadline by working 24/7, this was very much appreciated by the customer – you kept us informed all the way.

Our organisation would have no hesitation in using your company again if we had a need, we know that we

would continue to receive an efficient service – well done to the team.”

Gaye Somerville, Office Manager

NEWCASTLE CITY COUNCIL“We have been dealing with Houghton International for over 9 years. During this time we have developed a good working relationship with the staff, who we find extremely helpful.

We receive a good service for all work that is undertaken and we benefit from their warranty service. The charges for undertaking the work have always been reasonable when compared to their competitors.

Any request for an Engineer to work on site is dealt with swiftly and we find the onsite Engineers are extremely knowledgeable and always happy to assist us.

Specific examples of work that Houghton International have undertaken include: repairing large pumps and motors serving air handling units at the City Pool and repairing numerous amounts of smaller motors, pumps and fans at various locations across Newcastle upon Tyne .All work is completed to a consistent,

high level of quality. I would highly recommend Houghton International for any type of electrical work.”

Trevor Walton, Contract Manager, Mechanical Services



WELLSTREAM INTERNATIONAL“I have been dealing with Houghton International for many years for a variety of repairs and rewinds.

I have the confidence that I can ring them asking for a motor to be picked up from our works and within a few hours a highly skilled member of their team will be working on the motor at their site, to identify and solve the problem, and wherever possible have the motor back to me ASAP. Simultaneously, they will be keeping me well informed of the cost of the repair and the progress of the job.

I have a good relationship with them, can always rely on them in a crisis and would highly recommend them.”

Gordon Scott

THE NEWCASTLE UPON TYNE HOSPITALS, NHS FOUNDATION TRUST“The Newcastle Hospitals have relied on the services provided by Houghton International for many years now especially with the motor rewind/repair dept. That said when we have found ourselves stuck with a problem, on such example of a bespoke and obsolete solenoid, their team were able to provide us with a solution both being time efficient and cost effective that was over the expectations that we had for the company at the time.

The services that the Trust has received had not been compromised despite what I guess to be difficult times in the marketplace and we hope to continue relying on their expertise and service for many more years.”

Nick Hood, Hospital Engineer,The Freeman Hospital

UNION ELECTRIC STEEL UK“We have been dealing with Houghton International for many years for a variety of jobs including large AC and DC motor rewinds ,slip ring motor repairs and crane motor repairs.

The Engineers are extremely knowledgeable, happy to assist us and are willing to go the extra mile to solve our problems. The work is always completed to the highest possible standard and delivered on time.

During this time we have developed a good working relationship with the staff and I find the customer service is second to none. I am extremely satisfied with the overall level of service provided & would highly recommend Houghton International.”

Ronnie Dodds

BHK (UK) “I have been dealing with Houghton International for quite a while now with the motor rewind/repair dept. To be honest I haven’t been let down once in all the transactions that I have under taken with them.

The response time to picking up the motors is brilliant and the workmanship is again brilliant. I cannot fault them. Most importantly for me they are a firm that I know I can rely on to do a first class job.

I look forward to many more years working together.”

Graeme Cox, Maintenance Supervisor


CONTACT

Due to our policy of continuous improvement Houghton International Electrical Services Ltd reserve the right to modify product specifications without notice.

© Houghton International Electrical Services Ltd 2013.

HiBRID™, HiFLEX™, HiRES™, HiTRANS™, HiTRAX™ and HiVAX™ are trademarks of Houghton International Electrical Services Ltd.

Houghton InternationalRiverside CourtFisher StreetNewcastle upon TyneNE6 4LTUnited Kingdom

T: +44 (0)191 234 3000 E: [email protected] W: www.houghton-international.com

Electro Mechanical Services - Houghton International

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