New Life Inside an Old Frame

In this project, the stator of an aging motor was carefully removed from its original frame after years of operation. Instead of scrapping the entire unit, we engineered a complete redesign of the stator core.

Using precision laser-cutting techniques, we manufactured and assembled a brand-new lamination stack tailored to the original dimensions. The fresh laminations were inserted into the original housing, preserving the mechanical fit while significantly enhancing magnetic performance.

With the new core in place, the motor is now ready to undergo rewinding, bringing it one step closer to renewed operation. This hybrid approach—retaining the housing while modernizing the core—ensures extended service life, reduced costs, and full compatibility with the existing setup.

Precision Rewinding of a 1125 kVA Marine Generator

The process began with a controlled burn-off treatment. The generator was placed in our burn-off oven and subjected to 390°C for 14 hours, effectively removing the old winding without compromising the core structure.

Following this, the unit was carefully cleaned and primer-painted, setting the stage for electrical testing and new winding preparation.

The stator was then readied with precision: each slot was cleaned, treated, and prepared for the insertion of new coils, custom-designed to match the original performance specifications.

Parallel to this, the exciter stator underwent a complete overhaul, ensuring the supporting systems met the same high standards.

After the coil insertion, all windings were interconnected, and a specially designed internal cylinder was inserted. This ensures optimal varnish distribution during the Vacuum Pressure Impregnation (VPI) phase, maximizing insulation quality and durability.

The generator was then cured in our oven to harden the varnish and secure all components. Once the curing process was complete, the unit was assembled and reinstalled onboard, fully prepared for seamless marine operation.

Reverse Engineering
Precision Replication for Seamless Replacement

When legacy motors reach the end of their life cycle and direct replacements are no longer available, reverse engineering offers a reliable and efficient path forward. It’s not just about copying—it’s about recreating with precision.

Our latest project involved a medium-voltage, small-frame size 315 motor, designed with a custom base plate to achieve a 425 mm shaft height, exactly matching the client’s original setup. The motor was also fitted with an invertible terminal box, allowing flexible mounting on either side (left or right)—a small but critical feature for operational efficiency and warehouse optimization.

This is just one example of what we do:
We carefully analyze and deconstruct original motors, understand every structural and functional aspect, and then recreate them using advanced technology and a commitment to exactness. From torque and load characteristics to dimensional fit and mounting configuration, our reverse-engineered motors are designed to integrate seamlessly into existing systems.

Whether it’s restoring equipment for industrial use or replacing discontinued models, we deliver motors that match the original in function, form, and performance—while often improving reliability in the process.

When replacement isn’t available, we recreate it. Accurately. Reliably. And on time.

Reverse Engineering Project — 1,450 kW High Voltage Motor

We just completed a reverse engineering project involving a high-voltage electric motor, rated at 1,450 kW, 12 poles, 6.6 kV / 50 Hz, frame size 800.

The unit was built to support heavy industrial operations within the mining sector.

Technical Overview

• Power: 1,450 kW
• Voltage: 6.6 kV – 50 Hz
• Poles: 12
• Frame Size: 800
• High Voltage configuration
• PT100 temperature sensors in both stator windings and bearings
• Space heaters for anti-condensation protection
• Integrated flywheel and coupling assembly

Engineering Scope

This project required full reverse engineering of an existing machine, ensuring dimensional compatibility with the original installation while upgrading monitoring and protection features.

Special attention was given to:

• Thermal monitoring (windings and bearings)
• Mechanical balancing with flywheel integration
• High-voltage insulation integrity
• Structural robustness suitable for mining environments

Frame 800 machines operate at the upper end of industrial motor construction. Handling, assembly, and testing require dedicated infrastructure and precision alignment procedures.

This project remains part of our ongoing commitment to delivering large-scale, high-voltage solutions where reliability is not optional.

MV Project Delivery to Power Plant

Valiadis S.A. is proud to announce the successful completion of a medium-voltage motor replacement project for a major power plant, following our participation in an international tendering process.

Our company was awarded the contract for the design and manufacturing of four custom medium-voltage electric motors, and the project has now been completed, having passed a full load witness test with excellent results.

All motors were individually engineered to meet exact performance and dimensional requirements, replacing legacy units through a reverse engineering process. This marks the second time we have delivered motors to the same facility—the first was back in 2017. Such repeat trust from our customers is a source of pride and a strong endorsement of our quality and reliability.

Project Specifications:

• 2 pcs – 3-phase motor, 1200 kW, 1500 RPM, B3, 6 kV / 50 Hz, IP55, water-cooled – Model: TMKHV-W 500-4

• 2 pcs – 3-phase motor, 1200 kW, 1500 RPM, B3, 6 kV / 50 Hz, IP55, water-cooled – Model: TMKHV-W 450-4

This project highlights our ongoing commitment to engineering excellence, customer satisfaction, and long-term support for demanding industrial applications.

Complexul Energetic
Medium Voltage Motor Project – Romania

In July 2017, we proudly completed the delivery of four medium-voltage electric motors to Complexul Energetic Oltenia (CEO), one of Romania’s most significant contributors to national energy production.

The project was awarded to Valiadis S.A. through an international tendering process finalized in late 2016. Following extensive coordination, testing, and quality control, all items were successfully manufactured, approved, and delivered on time.

Complexul Energetic Oltenia is a strategic power provider in Romania, with over 13,300 employees and a vital role in maintaining the country’s energy security. With substantial coal reserves capable of sustaining electricity generation for decades to come, CEO plays a critical part in the Romanian National Power System.

The motors we delivered were custom-built to meet precise technical requirements and replace CEO’s aging equipment—enhancing reliability and efficiency across their operations.

Project specifications:

• 3-phase motor, 1000 kW, 1000 RPM, B3, 6000 V / 50 Hz, IP55, IC611 – Model: TMKHV 500-6

• 3-phase motor, 640 kW, 3000 RPM, B3, 6000 V / 50 Hz, IP55, IC611 – Model: TMKHV 400-2

• 3-phase motor, 500 kW, 1500 RPM, B3, 6000 V / 50 Hz, IP55, IC411 – Model: KHV 355-4

• 3-phase motor, 400 kW, 1500 RPM, B3, 6000 V / 50 Hz, IP55, IC511 – Model: KHV 560-4

This delivery reaffirms our ability to execute complex international projects with precision, responsiveness, and long-term reliability in mind.

High-Power Medium Voltage Motors Delivered as Drop-in Replacements

In November, we delivered two high-performance medium-voltage electric motors to a cement plant, following a request for fully interchangeable spare units. To meet the requirements, both motors were developed through complete reverse engineering, ensuring that every detail—mechanical and electrical—matched the client’s original specifications.

Delivered units:

• 2400 kW, 6 poles, 4.16 kV, 50 Hz, IC616, Frame size 560

  • Inverter duty motor

• 900 kW, 6 poles, 4.16 kV, 50 Hz, IC611, Frame size 500

  • Slip ring motor

Both motors are now on-site as operational-ready spares, providing immediate backup capability for critical cement plant operations.

This project reflects our ability to deliver custom, high-power motor solutions designed to integrate seamlessly into existing infrastructure—especially in industries where downtime is not an option.

Power Plant
Medium Voltage Reverse Engineered Motors Delivered and Running

In June, we successfully completed the delivery of two medium-voltage electric motors to a power plant, following an international tender in which Valiadis S.A. was selected as the best bidder.

The motors—designed to replace existing equipment—were supplied as spare units and required full reverse engineering to match the mechanical and performance specifications of the originals. After delivery, both motors were installed and are now operating with excellent results.

Delivered units:

• 630 kW, 8 poles, Frame size 560, 6.3 kV

• 280 kW, 8 poles, Frame size 450, 6.3 kV

This project is yet another example of our expertise in supplying customized medium-voltage solutions—especially when exact replication is required to ensure seamless integration with legacy infrastructure.

High-Performance Motors for Full Load Testing – Valencia, Spain

We are proud to announce the successful delivery of a significant project involving a full range of inverter duty motors, installed at a specialized testing station in Valencia, Spain. The facility belongs to Power Electronics, a major global manufacturer of inverters, and is dedicated to conducting medium-voltage full load tests on their inverter systems.

The motors we provided are specifically designed for inverter operation, delivering reliable performance, tight control under varying speeds, and the robust construction needed for continuous-duty testing environments.

Motors delivered for the project:

Medium Voltage Inverter Duty Motors:

• 500 kW – 1500 RPM – 690 V – Frame 400

• 1000 kW – 1500 RPM – 690 V – Frame 500

• 1500 kW – 1500 RPM – 690 V – Frame 560 (×2 pcs)

• 500 kW – 1500 RPM – 6.6 kV – Frame 450

• 1000 kW – 1500 RPM – 6.6 kV – Frame 500

• 2500 kW – 1500 RPM – 6.6 kV – Frame 710

In addition, a batch of low-voltage motors was installed at the same station, serving the same purpose: to support comprehensive, real-world inverter testing under varying loads and speeds.

This project reflects our ability to deliver custom-engineered, inverter-compatible motor solutions for critical applications and high-demand environments.