Reverse Engineering of Two 1 MW Double-Shaft Motors

This project involved the reverse engineering and manufacture of two 1 MW, 2-pole electric motors intended to operate as turbine start-up motors in a power generation installation.

Developed from an existing Alsthom machine supplied by the customer, the new motors were engineered to match the mechanical and electrical requirements of the original installation, allowing them to replace the existing units without changes to the surrounding system.

Reverse Engineering

The project began with the detailed examination of a damaged original motor.

The stator, rotor and mechanical construction were carefully documented before the engineering work commenced, providing the information required for the design of the replacement machines.

The resulting motors reproduce the operating characteristics required for turbine start-up while incorporating newly manufactured components throughout the active parts of the machine.

Double-Shaft Construction

Each motor was built with a double-shaft configuration, reflecting the requirements of the turbine starting system.

One shaft connects to the pony motor responsible for initiating rotation, while the opposite shaft is coupled to the turbine during the start-up sequence.

This arrangement required careful consideration of shaft geometry, rotor construction, balancing and the mechanical interfaces of the complete rotating assembly.

Manufacturing and Testing

The project comprised two identical machines.

Following manufacture and testing, the first motor entered service successfully for turbine start-up, while the second completed the installation as the companion unit of the system.

Reverse Engineering in Practice

Projects of this type combine electrical design, mechanical engineering and manufacturing into a single process.

Rather than developing a machine around a standard catalogue design, every major component is engineered around the requirements of the application, allowing existing industrial installations to continue operating with newly manufactured equipment.