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Railcorp
ATMR were awarded the tender to overhaul 31 x 33kV and 66kV Rectifier Transformers for Railcorp in Sydney CBD NSW. The region covered goes out west to Lithgow and north to Newcastle.
The majority of transformers weigh 40 tonnes each and most are over 40 years old. These transformers supply power to the NSW Metropolitan Rail System and our refurbishments will ensure that they continue to provide power for the next 20+ years.
The scope - to drain, strip, dismantle and remove the existing transformer from site and transport to our Villawood facility, where we refurbished each transformer (oiling, testing, draining, stripping etc) and then transported the transformer to it's new location. Once at the new location, the existing transformer was drained, stripped and dismantled, removed and replaced with the newly refurbished unit.
CS Energy Ltd
Techncial Advisor for generator first inspection
at Kogan Creek power station
Customer: CS Energy Ltd
Location: Kogan Creek Power Station, Qld
Scope: ATMR's Principal Engineer, Stephen Lucas, was on site for a period of 8 weeks as a Technical Advisor for Generator First Inspection.
- Siemens Steam Turbine Generator with a coal fired boiler
- The Unit is 904000KVA or 750MW or 1,000,000 Horsepower Generator
- 21000 Volts or 21KV
- 24000 A or 24KA
- The Project is the units' first Major inspection after commissioning in 2007 where the generator and turbine are dismantled for detailed inspections and maintenance activity.
BMA
Flakwoods Auxilliary Fan
Customer: BMA
Location: Moranbah, Qld
Scope:
- Upgrade fan capacity from 18m³ to 22m³ to MDG3 compliance
- Code D overhaul 110kw Exd starter enclosure and report
- Installed new motor and inline bearing assembly and laser aligned
- Grit blast and crack test all frame components and carry out subsequent repairs
- Installed all new I.S. RTDs, vibration & methane sensors, barriers, Trolex programmable controller, alarms (siren & beacon), RTU and UPS units
- Install all new cabling and FRAS
- Installed all new PLC controls, main contactor &circuit breaker
- Performed commissioning tests and report
- Full load test run 4 hours
- Painted to customer specification
- Fully updated wiring schematics & verification dossier
- Shrink wrapped and delivered to site
Anglo Coal
Enclosure Repairs
Customer: Anglo Coal
Location: Moranbah, Qld
Scope:
- Code D overhaul Exd starter enclosure and report
- Code D overhaul Exd motors and report
- Manufacture certified base mounting skids
- Overhaul pump units
- Install all new hydraulic hoses to MDG41 compliance
- Install new cabling and FRAS
- Modify electrical wiring to customer requirements including new I.S. barriers, main transformer, main circuit breaker, power supplies, dump valve and pressure switches
- Performed commissioning tests and report
- Full load test run 4 hours
- Painted to customer specification
- Fully updated wiring schematics & verification dossier
- Shrink wrapped and delivered to site
Eraring Energy
ATMR has an extensive knowledge of gearboxes and advanced gear technology. ATMR was engaged to repair the Valmet wind turbine gearboxes for Eraring Energy in Blayney NSW.
ATMR saw deterioration of bearing(s) in one wheel only, while the other bearings remained in relatively very good condition. It theorised that this was due to uneven load sharing (caused by very small geometric imperfections of the planet carrier and its resistance to deflect (and accommodate such imperfections) due to its high rigidity).
After consultations with Eraring, ATMR chose to:
- Replace the original bearing by cylindrical roller bearing NJ2324.C3 (again two inside each planet wheel). These bearings have higher load rating than the original 22324ED.C3.
- Repair the planet bores and bearing journals (pins) by electro chroming and precision grinding to new specification (both will now provide heavy interference fits to minimize relative movement).
- Install inner ring spacer inside each planet wheel to guarantee certain end play and to prevent axial preloads.
- Complicated threading of all components is achieved by correct sequence of assembly and finally by heating the planet carrier pre-assembly to around +150° centigrade and inserting the pins at -196° centigrade. Temperature normalization achieves final interference fits.
Eloise
Two Wilson Schneider pumps duplex pumps complete with drive train were sent to ATMR for overhaul.
Eloise chose ATMR due to our wide scope of capabilities - completing all the mechanical, electrical, fabrication, fitting, reclaiming, machining, grinding, blasting, painting, component replacement, design and testing.
ATMR's scope on the pumps primarily consisted of overhauling the wet ends consisting of the valve bodies, pistons and rods, reclaiming of the bores and valve chambers. Internally the pump, gearbox and cam mechanisms were overhauled and minor components replaced. All ancillary items such as junction boxes, oil feed pumps, filters, heat exchangers, electrical wiring, pressure switches, solenoid valves, external pipe work and all other services to the pump were also replaced.
The drive chain consisted of a high voltage motor, a fluid coupling, gearbox and inching drive. All these items were also fully serviced completely in house.
The units were assembled and a no-load test was conducted on the entire assembly to ensure correct operation and that all services to the equipment was working properly.
Sydney M5 Tunnel
The Villawood motors facility completed a refurbishment project involving the overhaul of 140 jet fans which supply all the ventilation to the Sydney M5 Tunnel.
Each fan is approximately six metres long. This project took over 18 months to complete as the tunnel is affected by peak traffic load during the day.
As part of the project, ATMR also overhauled 6 x 400kw ventilation exhaust supply fans. All logistics were carried on nightshift to accommodate the closures in the tunnel.
Ring Motor
- Customer: Oz Minerals
- 1.6kv, 3231amps, 8100kva, 300 tonnes.
- World Class Expertise.
- Recommended by Siemens.
- Supervised the decommissioning in Norway.
- Technical advisor for logistics of transport to Sydney.
- Overhauled motor at Sydney Villawood site.
- Supervised the installation at mine site.
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