Case studies

Rusal Aughinish Alumina

Project Summary

Service: Manufacturing, Installation & Commissioning

Duration: 26 Weeks

Background

RUSAL is a leading, global aluminum producer. The company’s main products are primary aluminum, aluminum alloys, foil and aluminum. RUSAL’s largest aluminum refinery, Aughinish Alumina (AAL) is one of the most technologically advanced and energy efficient facilities globally and is located in Askeaton, Ireland.

In a new partnering alliance in the UK, the combined Quartzelec operations of Swansea and Rugby worked hand-in-hand to secure and deliver a valuable order for the replacement of two up rated but "same size" Unipak II cage induction motors for Aughinish Alumina. They had previously established that an increase in production required a process change and in turn an increase in blower capacity. This related to a 20% up rate of the original 1,250kW motors purchased from GEC~Alsthom in 1994. They approached Quartzelec in Swansea, their usual Quartzelec point of contact and service provider to all the large drive motors located on the Askeaton site, to provide a solution.

The Project

The key element to AAL was that the motors were a physical “duplicate” of the existing DC450U1120 framesize, thus providing seamless “plug and play” replacements, whilst increasing the motors capability up to 1,500kW.

Quartzelec's Engineering Department based in Rugby reviewed and revised the original design and were able to meet AAL's exacting requirements, right down to the same precise positioning of the Quartzelec supplied and fitted CEGB/BEAMA mains terminal box.

AAL had a planned shutdown for changing out the first of the two motors to be supplied in May 2013. Quartzelec, Rugby had the motor manufactured to the new design instructions and the Swansea operation delivered both motors to Askeaton in a timely fashion.

Due to Quartzelec's precise specification and project management, AAL were able to change out the first motor on schedule.

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