Rapid IECEx-compliant repair of a critical Ex-rated process motor for an oil refinery, completed within 48 hours to avoid multi-million dollar production losses.
Review the project background, diagnosis, intervention steps, standards, and results summarized below.
Project Background
A critical Ex d process pump motor in a hazardous area failed unexpectedly during peak refinery throughput. The failure halted a major process line, with potential production losses exceeding several million USD per day if not restored quickly and in full compliance with hazardous area requirements.
Assessment & Diagnosis
Rapid mobilisation of RKELC field team within hours of notification.
On-site inspection confirmed winding failure with evidence of thermal stress and contamination.
Mechanical inspection identified bearing wear and contamination due to operating conditions.
Verification of Ex markings, temperature class and protection concept to ensure repair would maintain IECEx compliance.
Execution & Intervention
Safely de-energised and isolated the motor in coordination with refinery operations and HSE teams.
Transported the motor to RKELC workshop under controlled conditions, preserving Ex integrity.
Performed complete rewinding using IECEx-approved materials and processes for the specified temperature class.
Replaced bearings and seals with corrosion-resistant, refinery-grade components.
Conducted routine and type tests including surge test, hipot, IR/PI, vibration and no-load tests.
Issued full repair documentation and Ex repair report to support hazardous area compliance.
Quality & Standards
Repair executed in line with IECEx guidance for repair and overhaul of Ex equipment.
Electrical tests aligned with IEEE and IEC 60034 requirements for rotating machines.
Quality and documentation under ISO 9001:2015; safety processes aligned with ISO 45001.
Measurable Results
48-hour turnaround from removal to reinstallation and commissioning.
Avoided potential losses estimated at more than USD 5 million in production impact.
Post-repair tests confirmed restored insulation strength, with IR/PI values back within OEM-recommended ranges and vibration levels reduced to within ISO class limits.
Extended motor life by an estimated 10 years with upgraded insulation and bearings, validated by improved temperature and vibration trends under full load.
Maintained hazardous area certification and compliance for the Ex-rated motor.
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