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Sulzer Helps National Grid to Provide Reliable Power to the People

By helping to secure maximum availability for the critical gas booster station infrastructure, Sulzer has helped National Grid provide reliable power to millions.

January 31, 2023. By News Bureau

With global energy markets under pressure, utility companies are working hard to ensure that millions have reliable access to power. Consequently, when National Grid faced maintenance issues with two motors installed at critical gas booster station sites in England, they approached Sulzer.

Delivering turnkey redesigns and rewinds for the complex 16 MW units – Sulzer has helped National Grid to secure gas supply to homes and businesses nationwide.

Gas booster stations are critical strategic components in the UK’s gas supply network. At these facilities, motor driven compressors are used to ensure the distribution of gas to where it is needed. Consequently, any reliability issues at these sites can adversely affect gas supplies if not resolved promptly.

Initially, National Grid identified an issue with two large 16 MW motors, one installed at a compressor site near Wormington in Gloucestershire and the other located close to Churchover near Rugby.

The problem arose when resistance temperature detectors (RTDs) embedded inside the motor windings began to fail, compromising the ability of operators to gain accurate temperature readings and condition monitoring data. As the motors were Ex rated, this also threatened the compliance of the installations.

The rare six-phase synchronous motors used at the sites weigh up to 51 tonnes each and can operate at a nominal speed of 5’200 rpm and an overspeed of 6’435 rpm.

Controlled by variable speed drives (VSDs) and featuring complex rotors 6.5 meters in length, the bespoke motors are designed to ensure increased demand for gas can be met by speeding up the compressor to push more through the network.

“Due to the bespoke nature of the machine and the technical challenge of replacing the RTDs with a superior substitute, the project required a high level of engineering expertise. This was amply demonstrated by the Sulzer design team, which then fed into the rebuild and equipment procurement, efficiently smoothing the rebuild process,” says Mark Prestt, Project Manager for National Grid.

“We offer a shorter lead time and enhanced technical support compared to our competitors,” says David Rudd, Customer Support Manager at Sulzer. “As we provide turnkey electromechanical engineering services, we were able to manage and complete the project entirely in-house. This meant the challenging works could be delivered faster and with added value to the customer – both important benefits for a national utility.”

By helping to secure maximum availability for the critical gas booster station infrastructure, Sulzer has helped National Grid provide reliable power to millions.

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