When there is trouble in the field or below decks, even if it’s 3am, Friday rush hour or the last 5 minutes of a close Bowl game, Ward Leonard is on-call to immediately come to your facility and handle any motor, generator and pump problem.
We know failures or catastrophic events can happen at any time, and our tireless team of passport-carrying On-Site Field Service technicians is highly trained and experienced in all types of work at upstream, midstream and downstream facilities—whether it’s onshore or off.
On-site troubleshooting capabilities include:
- AC / DC motors, generators & pumps
- Motor starters & controls
- Variable frequency drives
- Sync Systems
- Generator Panels
- Engine Shut down Systems
- SCR Systems
- Automatic Transfer Switches
Removal, Installation & Commissioning
Whether it’s an install for a new-build, a removal for maintenance, or commissioning of a new motor, generator or pump, our decades of experience will ensure consistent productivity.
We will evaluate the condition of the mounting skid, the coupling, the electrical system, and anything related to the system that could compromise the performance of the packaged unit, and then recommend a plan of repair.
Your electric motor, generator, or pump will then be brought into one of our conveniently located state-of-the-art facilities to be repaired to better than new condition using exacting standards like EASA, NEMA, IEEE, ISO, IEC, ANSI-ASMEB73.1, API 610, DIN 24256, and UL-NFPA20. Units will be run tested with five-points of vibration measurements captured in a controlled environment.
Once the repair is complete, we will install the unit and laser align it to eliminate soft foot and horizontal, vertical, axial, and face misalignment.
Our field service technicians will take five-points of baseline vibration measurements as well as all electrical data and bearing and stator temperatures, then compare readings to the in shop measurements taken to ensure acceptable operation and long life of the unit.
Alignment to Engines and Driven Equipment
Alignment is a critical part of any successful preventative maintenance program, as misalignment is responsible for up to 50% of all damage to rotating electrical equipment.
Tight machine tolerances and precision bearings require proper alignment to minimize vibration and premature failure. Excessive vibration from misalignment is carried through to components like bearings and couplings that reduce their lifespan and reliability.
Coupling failure, bearing failure, and catastrophic machine failure due to rotating components contacting non-rotating components can be minimized through proper alignment.
Our laser alignment tools produce reports that can be compared to readings obtained at scheduled maintenance intervals to identify excessive movement in coupled machines.
Vibration analysis is the science of monitoring vibration patterns of motors, pumps and generators, and then predicting their maintenance needs.
Vibration in any mechanical device is wasted energy and creates unwanted noise, premature wear, and causes for early failure. Professional monitoring of the vibrations can point you in the direction to repair the issues and correct the vibrations, as vibration causes many undesirable results; from stress fractures to premature wearing of mechanical fits (bearing housing fits), to loosening of fasteners.
Our factory-trained and certified vibration analysts can help pinpoint the cause through trending vibration patterns. We can then correct the problem, whether it is a worn bearing fit, a needed laser alignment, or a field or shop balance of the rotating assembly. Our field balance units work on any motor or generator that has exposed end rings on the rotor and our in-house balancer can balance rotating assemblies up to weights of 25,000 pounds.
Unbalanced rotating machinery is a major cause of machine failure or malfunction, as a lack of balancing puts unnecessary stress on the bearings, shaft, and bearing supports.
Ward Leonard will perform field balancing anywhere you need us to — at your facility, on your vessel, or offshore location — on motors and generators that are deemed out of balance through vibration analysis trending.
Our factory trained and experienced field service technicians, paired with our state-of-the-art field balance equipment, can handle all of your field balancing needs — and minimize your downtime while allowing for operation immediately after the balance is complete.
Reducing vibration can reduce the stresses to equipment, and therefore reduce the chances of premature mechanical failure and extending the mechanical life of your rotating equipment. Some motors or generators are not candidates for field balancing due to sealed endbells or limited access to rotor end caps.
When you develop your maintenance program to avert costly failures on your offshore locations, vessels, and facilities, it is critical that you include thermal imaging as a monitoring technique to extend the life of your electric motors, generators, and electrical systems.
Thermal imaging is a non-invasive diagnostic method that is performed while your equipment is running under normal operating conditions.
Ward Leonard factory trained field service technicians utilize state-of-the-art thermal imaging technology to detect temperature rises on bearings, as well as temperature rises on electrical connections to identify loose terminal or soldered connections. Once completed, we provide you with recommended repair scenarios to correct the issues.
Ward Leonard provides predictive maintenance (PdMA) testing that can help improve reliability, ensure the best return on asset value, decrease costly downtime and decrease catastrophic failures.
The lifespan of a motor or generator can be optimized using the trending data and information obtained from a quality piece of test equipment and a highly trained technician. Ward Leonard can trend the condition of AC induction, synchronous, wound rotor, and DC motors and their associated circuits.
We track and trend 6 major fault zones, and all are monitored, measured, and recorded for trending and analysis purposes:
- Power Quality
- Power Circuits
- Stator Windings
- Air gaps
Bearing & Coupling Changes
If your bearing is in poor condition and needs to be replaced, Ward Leonard carries a large inventory of bearings in stock and all of the bearings used on your job are acquired from authorized distributors.
Babbitt bearings are reconditioned and reinstalled in a timely manner for quick turnaround and minimum downtime. All bearing housing fits are measured and compared to EASA standards.
In addition to bearings, our technicians can also do coupling installations, inspections and replacements, and verify the thrust on motors and generators. By removing the end bells in the field or vessel, we can inspect or change any roller, ball or split roller bearing.
Are your generators in need of a cleaning but you don’t have available downtime? To keep you in compliance, our team of field service technicians can perform a clean in place and a full field inspection and evaluation will be done prior to cleaning.
We can remove the majority of the grease and debris from your industrial generator with our low-pressure, high temperature portable steam cleaners and non-caustic soap. This can be set up in any non-classified area, with hoses routed to your classified area to perform the clean in place. After the generator cleaning, we will run your unit in dry out mode to remove the remainder of the moisture.
Our proprietary dry-out kits are equipped with jumpers for the stator leads, a current transformer to monitor stator amperage, all connecting cabling, amp meters for the stator and exciter field, and volt meters for both as well. We create amperage with no voltage so that there is no potential for the wet stator to blow.
After this process, we will perform bearing inspections, labyrinth seal inspections / replacement, and lubrication surveys. The final testing will include insulation resistance, static testing, and operational testing. We will provide you with condition reports once all inspections and cleanings are complete!
Before starting an electric motor or generator that has been shut down after a storm, a planned shutdown, or a low insulation to ground reading, the unit should have the insulation resistance to ground verified (megg readings).
Ward Leonard has engineered a proprietary dry out kit that is effective in bringing your generators back to a useable insulation to ground reading. It consists of volt and amp meters to monitor stator amperage and exciter field voltage and amperage, jumpers for the stator leads, a current transformer to feed the amp meter, leads for DC voltage feed to the generator, and the connecting cabling to the generator.
The dry out kit is packaged in a Pelican case that is small enough to be a carry-on for an airplane trip, and durable enough for a boat or helicopter ride. It is available for rent with one of our highly trained service technicians, or for sale for immediate and continuous use.
Storm damage Assessment of Electrical Systems
Whatever type disaster you endure, we have the right people and test equipment to quickly determine the correct course of action to save you from further damage.
Having an intelligent concrete plan of action in place for after disastrous events is crucial to maintain productivity and performance.
After serious events, Ward Leonard can go immediately once the danger subsides to:
- Meg your motors, generators, cables & electrical systems
- PdMA your motors
- Perform dry-outs generators
- Determine the extent of damage
- Put together a plan of action to get you back up & operational
Ward Leonard will also perform root cause analysis of failed rotating equipment to prevent future failures and to maintain equipment reliability. A true root cause analysis RCA requires a study of the entire system that encompasses the failed equipment. It is not just about pinpointing the failure; it is about determining if another component in the system contributed to the failure.
Load Testing In Place
Load testing is a critical step in the maintenance regimen of a generator. It not only proves the generator’s operation, but also tests the integrity of the engine and its supporting systems.
From 240 VAC to 13,800 VAC, we have transformers to pair with our load banks to perform full kW tests on most generator sets. A load bank resistive load is a unity power factor test; this is an approved method for all emergency backup generators NFPA 110 and an industry norm.
Ward Leonard will help keep you in compliance (NFPA 110) with our trained and experienced service technicians — with up to 2500kW load banks on hand to put your mind at ease, and verify your generator set’s operation.
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