HV Test Bed Installation AEMT Scottish Meeting May 16 th 2018 Ross Barraclough; Regional Director (North) AEMT – Scottish Meeting May 2018
Overview ◼ 40 Years Ago… ◼ Pre-investment Setup ◼ Previous Layout ◼ Proposed Layout ◼ Investment Justification ◼ Build Process – Challenges Met ◼ Final Result AEMT – Scottish Meeting 2 May 2018
40 Years Ago… ◼ The Falkirk Service Centre began construction on the 20 th March 1978, with the building occupied from early 1979 onwards ◼ Original facility layout developed in line with customer demands, especially from the growing North Sea O&G industry ◼ Test facilities were rudimentary and solely focused on LV test ◼ Late 1980’s saw investment in a 1,000kW full load test setup ◼ Basic functionality was embellished over the years with incremental additions as more advanced Condition Monitoring and diagnostics became available AEMT – Scottish Meeting 3 May 2018
Pre-investment Setup ◼ Test area historically divided by original walls, with much of the equipment located in the main thoroughfare through the facility ◼ Customer experience lacked professionalism and cluttered test area/control room left little opportunity for customers to easily witness tests for long periods of time ◼ Main test cell services (lube oil, chilled water, breakers, switchgear, transformers etc…) were all located in different areas, making maintenance and troubleshooting problematic ◼ Undoubtedly time for a change… AEMT – Scottish Meeting 4 May 2018
Previous Layout Control Room Customer Access AEMT – Scottish Meeting 5 May 2018
Proposed Layout Dedicated Visitor Area Service Corridor Large Control Room High Low Voltage Voltage Test Area Test Area AEMT – Scottish Meeting 6 May 2018
Proposed Layout – 3D ◼ 3D model highlighted areas of concern and allowed us to resolve it at the design stage e.g. obscured view from the customer area and layout of service corridor ◼ Excellent tool for visualising final layout and communicating with remote/non-EMS stakeholders AEMT – Scottish Meeting 7 May 2018
Investment Justification ◼ Dowding and Mills acquired by Sulzer in June 2010 ◼ Previous management team decided not to pursue investment from HQ, despite clear need for progress to be made ◼ Change of leadership at all levels over the past 2 years has led to significant collaboration, support and desire to bring the Electro Mechanical business to the same level as the Pump organisation as a best in class organisation ◼ Investment decision was unequivocal and unanimous throughout the organisation, demonstrating support for the Falkirk SC and next generation of technicians/supervisors/management AEMT – Scottish Meeting 8 May 2018
Build Process – Challenges Met ◼ Trying to operate a 24/7 Service Centre whilst the core of the facility is a building site ◼ Subcontracting the entire job to a specialist project management company – Cosmos Projects ◼ Appointing an independent QS to manage above company! ◼ The unexpected… ◼ Beam not secured to building, and simply balanced on the wall. Could have caused major injury ◼ Locating, procuring and load testing a 60Hz 2MW diesel generator AEMT – Scottish Meeting 9 May 2018
Build Process – Cont … AEMT – Scottish Meeting May 2018
Build Process – Cont … AEMT – Scottish Meeting May 2018
Final Result ◼ Horizontal load test of 2,000kW and vertical load test of 746kW ◼ Multi-tap transformer allows testing from 415V to 13.8kV ◼ Consolidated controls for all systems – generators, transformer, breakers, lube oil, dynamometer and cooling systems ◼ Automated generator control ◼ Data trending and historian capability ◼ On test condition monitoring ◼ Advanced vibration analysis ◼ Partial discharge analysis ◼ Remote monitoring of motor performance AEMT – Scottish Meeting 12 May 2018
Final Result – Cont … ◼ Service corridor allows complete access to all plant for maintenance etc… without disturbing customers or test process ◼ Customer area allows all test beds to be viewed simultaneously alongside live and historical/trended data ◼ Other areas of the workshop have seen improved 5S as a result of the investment; much of which has been driven by the technicians themselves ◼ Project completed on time and on budget! AEMT – Scottish Meeting 13 May 2018
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