Life extension overhaul of a critical naval vessel propulsion motor, delivering 15+ years of additional service life with improved power output.
Review the project background, diagnosis, intervention steps, standards, and results summarized below.
Project Background
A key propulsion motor on a naval vessel exhibited insulation degradation and performance issues ahead of a major deployment cycle. Replacement lead times were long and costly, so the client required a comprehensive overhaul within a tight dockyard window.
Assessment & Diagnosis
Carried out detailed inspection and electrical testing to confirm insulation ageing and partial discharge activity.
Assessed mechanical condition of rotor, bearings and housing for wear and alignment issues.
Reviewed classification society requirements and naval specifications for repair acceptance.
Coordinated with dockyard teams to define safe work procedures and access constraints.
Execution & Intervention
Executed complete stator and rotor refurbishment with upgraded insulation system suitable for marine duty.
Replaced bearings, seals and critical fasteners using marine-grade materials.
Performed dynamic balancing and alignment checks to ensure vibration limits within naval standards.
Conducted full suite of electrical and mechanical tests, including load trials where applicable.
Prepared detailed repair and test dossier for classification society and naval approval.
Quality & Standards
Work performed under ISO 9001:2015 certified quality system.
Repair and testing aligned with relevant IEC/IEEE standards and classification society rules.
HSE practices aligned with ISO 45001 and dockyard safety protocols.
Measurable Results
Extended propulsion motor service life by an estimated 15 years.
Improved power output by approximately 8% versus pre-overhaul condition, confirmed during harbour and sea trials.
Electrical tests (IR/PI, surge, hipot) and vibration measurements met or exceeded naval and classification society acceptance limits.
Achieved full classification society and naval approval on first submission.
Completed work within the planned docking schedule, avoiding deployment delays.
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