Our approach to every overhaul programme is the same — treat each one differently

Our local support services and resources provide the highest level of client service and world-class performance and reliability with OEM materials and repairs to return your assets back to revenue service faster, while reducing your overall cost of ownership.

We customise each overhaul to provide the best and most comprehensive support, while optimising the total package to meet client operational and financial targets.

So, whether you are looking for a short-term ‘material and labour’ overhaul or a longer-term collaborative arrangement, UGL has a solution that meets each operator’s evolving business requirements.

OVERHAULElectrical equipment

Through-life-support

OverhaulELECTRICAL EQUIPMENT

Safe, efficient, cost effective solutions

UGL’s workshops are the only GE certified workshops in Australia for the overhaul of AC & DC rail components

Electrical component and overhaul services are provided across a wide-range of Original Equipment Manufacturers (OEM’s) components for both EMD and Siemens.

Commercial test capabilities of our AC & DC back-to-back test bays ready overhauled equipment for return to service.

UGL offers a complete solution for the overhaul of passenger and freight rail applications including cleaning, overhaul and repair, VPI, painting and testing of:

• AC & DC traction motors

• Air compressor motors

• Alternators

• Ancillary electric motors such as water pumps and clutch drives

• Blower motors

• Dynamic brakes

• Generators

• Radiator fan motors

In 2013, UGL overhauled in excess of 300 EMD components from fleets across Australia, including:

• Traction Motors - D29, D77, D78 and D87

• Alternators - AR10 and AR11

OUR SERVICES• Armature rewinding and repair

• Brush change-out and repair

• Dynamic balancing

• Manufacture of cable assemblies

• Motor and circuit board thermal imaging

• PdMA motor diagnostics

• Stator rewinding – form and random coil

UGL’s support services provide an end-to-end asset management solution designed by maintaining asset value and reducing the need for capital expenditure.

Reliability and qualityAt UGL we continually strive for improvement in service delivery

Motor reliabilityUGL is currently working with multiple clients to improve in-service reliability of their electric motors by:

• Working to improve overhaul specifications for specific applications

• Providing dedicated engineers who complete FMECA analysis on motor fleets and deliver direct feedback on technology improvements to OEM’s

• Tailoring maintenance solutions and motor overhaul plans

In partnership, these projects have delivered improved reliability results through:

• Improved asset availability

• Fewer in-service failures

• Lower cost of long-term overhaul

All service work conducted is completed in-house at UGL’s facilities to assure quality of outcome. Our processes are subject to rigorous continual testing and refinement in order to provide the best possible outcome. UGL’s skilled workforce uses fit-for-purpose machinery controlled by Australian Quality Assurance (QA) and business management systems.

Repair and overhaul facilities at Broadmeadow, New South Wales; Mackay, Queensland; and Bassendean, Western Australia are open for inspection to view first-hand ISO9001:2008 accredited QA systems which feature:

• Strip-down and assembly (Broadmeadow)

• Design control and specification management under a systems engineering framework

• Motors inspected and certified by independent Quality Control Inspectors

• Motor overhauls completed in line with OEM maintenance instructions

• Components and sub-assemblies, sourced through accredited suppliers

• Motor testing by trained technicians

All electrical component repairs and overhauls receive a Certificate of Conformance to Australian Standards.

All motors tested are fully document and include a test certificate.

Rotables exchange planUGL is developing a rotables exchange programme to meet operational needs in respect of Australian GE and EMD fleet availability. Using a rotables exchange model, clients have access to a pool of UGL spares to temporarily replace a motor coming out of service for repair or overhaul.

Flexibility and convenience

Multiple service centre locationsUGL workshops provide the same high level of quality and competitive pricing through:

• A client focused, experienced maintenance workforce

• An efficient and timely turnaround of motor overhauls

• GE approval and certification

• Mobile repairs

• On-site cleaning, blasting, baking ovens and paint facilities

• Technical support and asset management

UGL can facilitate suitable transport to and from all service centre locations.

Australia

Mackay

Broadmeadow

Bassendean

BASSENDEAN, WESTERN AUSTRALIA• AC and DC test bays with commercial test

capability to meet the requirements of GE, EMD and Siemens components

• B Stage, resin rich epoxy or polyester solids Vacuum Pressure Impregnation (VPI) treatment available

• Commutator spin seasoning

• Dynamic balancing

• Fabrication and pressing

• Horizontal boring

• Machining capability including lathes, milling machine, surface grinders and radial drill

• Overhead cranes to 50t capacity

• Warehousing and inventory management

UGL is able to organise cost effective transport from anywhere in Australia to one of our overhaul facilities. Daily transport is available between Sydney and Melbourne to Broadmeadow, the Pilbara region to Perth and Brisbane to Mackay.

All motors tested are fully documented and include a test certificate.

OverhaulELECTRICAL EQUIPMENT

Australia

Mackay

Broadmeadow

Bassendean

MACKAY, QUEENSLAND

• Machining capability - lathes from 1500mm centres and 300mm to 6000mm centres and 1000mm swing

• Overhead cranes to 40t capacity

• Rewinding and clean winding room

• Toshiba authorised repairer

• Vertical boring to 7m diameter

• Warehousing and inventory management

• B Stage, resin rich epoxy or polyester solids Vacuum Pressure Impregnation (VPI) treatment available

• CNC vertical boring

• Dedicated motor test centre

• Dynamic balancing

• Fabrication and pressing

• Horizontal boring to 15t

• Induction and flame hardening

BROADMEADOW, NEW SOUTH WALES

• AC & DC test bays with commercial test capability to meet the requirements of GE, EMD and Siemens components

• Automatic commutator undercutter

• B Stage, resin rich epoxy or polyester solids Vacuum Pressure Impregnation (VPI) treatment available

• Back-to-back testing facilities

• Commutator spin seasoning

• Dalic plating system

• Dynamic balancing and 1000kW dynamometer

• Horizontal boring

• Machining capability including lathes, milling machine, surface grinders and radial drill

• Overhead cranes to 20t capacity

• Warehousing and inventory management

UGL has an established, tailored maintenance programme of time-based examinations, supported by carefully managed time and duty based overhauls. Designated service intervals minimise outage and significant failure events. Our comprehensive maintenance programme helps to increase life cycle asset availability and reliability.

UGL aligns maintenance activities to an asset’s usage patterns to maintain operational requirements.

The key to achieving these optimal results is the use of Reliability, Availability, Maintainability and Safety (RAMS) techniques. On introduction to a new motor, UGL will monitor the key attributes of the asset with respect to its operating duty cycle and adjust the service interval subject to an engineering review.

OUR SERVICESThe services within an asset maintenance programme may include:

• Component Change Out (CCO) and overhaul

• Field service support providing periodic reliability checks

• Inventory, logistics, and site expenses

• Maintenance management and planning, including technical support and reliability management contract administration

• Scheduled services at agreed intervals

• Unscheduled maintenance covering components and materials not supported by a scheduled maintenance or CCO programme are changed on condition and in service failures

UGL’s full maintenance offering can be both scheduled and unscheduled. Maintenance plans are tailored to the individual requirements and can be accomplished through a joint workshop to discuss and align with operational business needs.

Optimising motor availabilityUGL provides complete maintenance plans to protect valuable assets

OverhaulELECTRICAL EQUIPMENT

Proven delivery performanceExperience in electrical component overhauls and a client focus approach

UGL has a standardised service approach; tailoring service offerings to meet critical industry needs and the delivery of high quality product solutions.

To reduce turnaround times, UGL continually reviews our service performance and our workshop efficiency.

UGL provides low-risk, reliable and repeatable services through:

• Adoption of 5s and LEAN techniques across the implementation of point-of-use tooling and consumables

• Implementation of rigorous project management disciplines to achieve standardised governance methods with full accountability to deliver contracted client requirements

• Underpinning services by material forecasting arrangements, local inventory holdings and logistical arrangements

Average turnaround timeframes for the completion of standard overhauls from date of work approval:

TYPE OF STANDARD OVERHAUL

EX WORKS TURN-AROUND TIMEFRAME

AC traction motor 1—2 weeks

DC traction motor with Utube 3—4 weeks

DC traction motor with axle caps 3—4 weeks

Air compressor 3—4 weeks

Generator 5—6 weeks

Radiator fan motor 5 days

Alternator 2 weeks

Dynamic brake motor 5 days

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