CAW has a large super facility located at Killarney Gardens, Cape Town in South Africa. The CAW super facility specialises in electric and mechanical repair to all types of AC and DC motors, alternators, generators and submersible pumps. With its 3 000m2 floor space, it is the newest and largest of its kind in the Western Cape with all motor repairs done in-house and on-site, ensuring a quicker turn-around time and guaranteeing clients a total and cost-effective solution.
Advanced Testing Facilities
The CAW super facility is fully-equipped with state-of-the-art test equipment for both AC and DC motors ensuring customers motors are being repaired using the best available techniques and services.
Our Testing capabilities include a Motor Analysis Test Facility, Load Test Facility, Core Tester, Vibration Analysis, Thermal Imagery Of Motors & Panels, Laser Testing Of Belt Tensions, Stator & Rotor Core Testing, and PI Testing.
- AC LV up to 800 kw
- DC Motors up to to 3000 kw
- MV Motors (3,3KV-6,6KV) 185KW – 5000 kw
- Alternators up to to 7000 kva
- Submersible Pumps up to to 450 kw
- Vibrator Motors
- LV Brakes & Transformers
- Field & Interpole Coils
- Traction Motors
At CAW we pride ourselves in having the Western Cape’s most comprehensive full-service electrical motor repair and rewinding facility. With 3000m2 of factory floor space, we offer you the complete solution. The CAW super facility is fully equipped with state-of-the-art equipment – ensuring our customers’ motors are being repaired using the best available techniques and services.
40 Ton + Lifting Capacity
CAW’s facility has overhead cranes capable of lifting 40 tons, and large workshop entry areas for ease of access for larger motors. For smaller motors there are 8 ton, and two 2 ton cranes, 5 ton and 12 ton crane trucks.
We have ensured and guaranteed that we experience no work interruptions or delays, in the case of Eskom load shedding or power failure. Our generators can power our entire operation so that we continue to offer our normal turnaround times and testing during these events.
CAW’s two sandblasting bays are used to remove rust, paint, grease, corrosion from any metal on motors.
CAW facility has three baking ovens, large enough to contain larger stators and rotors after the removal of grease, oil, dirt and water.
Our burnout oven is used for stripping and burning out the winding and varnishes from motors.
VPI Varnish System
CAW uses a fully automated Vacuum Pressure Impregnation System (VPI).
300 Ton Press
CAW’s 300 ton press used for removing broken shafts from rotors.
Computerised Balancing Machine
CAW’s computerized Balancing Machine features hard-bearing balancing , allowing the machine to be exactly calibrated. The balancing machine remains calibrated for any rotor with the capacity and speed range of the machine. The balancing machine is equipped with a printer, giving us the ability to print reports for our customers.
Our dedicated field service teams are at your site whenever you need us, working for you around the clock. We are dedicated to ensuring fast turnarounds and high-quality field service. CAW has delivered many years of successful field services to our customers. As part of our objective to improve the value added services we offer, we assure our clients that we are their partner for a complete solution – safe, cost-effective, and technically experienced.
24/7 Emergency Support
Customers can count on around-the-clock assistance from our dedicated field service personnel. In case of an emergency breakdown, CAW will mobilize our expert emergency breakdown teams. Our staff can be at your site as soon as possible with fully-equipped mobile workshops to provide repair services for electric AC and DC motors, generators, alternators and pumps.
Our emergency field services include:
- On-site assistance, providing technical teams and equipment as soon as possible
- On-site repairs
- On-site troubleshooting
- On-site motor circuit analysis (MCA)
- On-site predictive maintenance
Mobile Field Service Workshop
You need fast and reliable services on-site to reduce downtime and minimize cost. We provide fast and flexible on-site services with our mobile workshop, fully-stocked with the latest technology. Crews come to your site ready and equipped to work for you. The mobile field service workshop is used predominantly for projects in the marine, mining and oil and gas industries. The workshop provides a secure and organized work space to ensure that repair projects are completed efficiently and on time.
CAW offers comprehensive testing and analysis of motor performance to ensure that equipment is put back into operation in perfect condition. Our facility is fully-equipped with state-of-the-art test equipment for both AC and DC motors, generators, alternators, and pumps, ensuring that equipment is being repaired using the best available techniques and services for our customers.
Here is a brief description of some of our onsite and offsite test equipment and capabilities:
CAW’s Vibrator Motor Test Facility is a new addition and advancement to the super facility. It was designed to test 11kw/8p vibrator motors. Already valued at R1.4 million, the facility will be further developed in early 2016 to incorporate other KW and speed vibrator motors. After each repair, vibrator motors are put to the test in this facility and customers are given computer printout test reports.
CAW customers will now have peace of mind that repaired vibrator motors will operate and function according to OEM specifications. Besides the cost benefits, most importantly, downtime will be minimised.
CAW super facility features the only Load Testing facility of it’s kind in the Western Cape, that can test AC/DC, and traction motors providing guaranteed motor efficiency. The state-of-the-art water-cooled Eddy Current Dynamometer can simulate actual motor load conditions while, at the same time, measure horsepower and torque output – thereby simulating marine applications. The data then becomes a validated written performance test through the use of a digital readout and test report printer. Ensuring this service will be performed to the highest quality, lower cost, and within quicker turnaround times, local clients now no longer have to send their motors to Johannesburg for load testing on this scale. All load testing in conducted by highly skilled engineers and experienced load testing staff experts on site.
Load Test Specifications: 1600 amp | 220 – 720 volts | 50 & 60 Hertz | 3300 – 6600 volts | temperature monitoring | Lock rotor for 25, 50, 75 percent and full load tests up to 450 kw in both directions.
Submersible Pump Testing
Setting a new standard for repairs to submersibles, CAW can offer customers the precise performance of their pump and motor set, through this state-of-the-art facility – the only pump testing facility of its kind in the Western Cape. CAW has extensive experience in the successful repair of numerous different makes of submersible pump sets including for the City of Cape Town’s submersible sewage pumps and large Pleuger platform pumps for the off-shore industry. For more information on pumps, please visit CAW Pumps.
Computerized Core Loss Testing
CAW uses a fully automated computerized core tester to determine core losses found in stators, rotors, and armatures. Core loss is the major cause of wasted electrical energy which can result from overheating during operation, motor pre-mature failure, and physical damage such as rotor drag. Without core loss testing, it is impossible to determine that a motor is capable of operating at rated efficiency. Motors are tested and a printout of results is provided to customers.
Winding Analysis Surge Test
Surge testing is a part of a comprehensive maintenance program. Without maintenance and repair all motors will eventually fail either electrically or mechanically. Surge testing will predict motor burn-out due to turn-to-turn or phase-to-phase shorting. A winding analysis surge test by CAW will detect turn to turn insulation failures far in advance of an electrical breakdown – giving you the power to confirm faults and take preventative action.
Motor Circuit Evaluation (MCE)
Motor Circuit Evaluation is an off-line test for motors that yields inductive balance, resistive balance, resistance and capacitance to ground as an indicator of motor stator winding health. The test is also useful in diagnosis of faulty or broken rotor bars, eccentricity, insulation system health and defective or deteriorating motor connections.
Vibration Analysis is a predictive maintenance method which allows early problem detection in rotating machinery. Vibration Analysis will identify component faults – such as defective bearings & misalignment – and enable you to take maintenance action before a failure in service brings your plant to a halt.
CAW uses infrared thermography as a powerful predictive maintenance tool, to detect problems in electric motors. Our testing process uses instrumentation to read surface temperature to determine operating conditions. By detecting thermal anomalies (areas hotter or colder than they should be), our experienced technicians can locate and define a multitude of problems within the machinery.
Polarization Index Test
Polarization index testing is performed on electric motors and generators by CAW, and is regarded as a useful tool in evaluating windings for build up of dirt or moisture, deterioration of the insulation and suitability for further operation.
Locked Rotor Testing
CAW performs locked rotor test (which is equivalent of a short circuit test for a generator) to verify the maximum current handling capability of the motor, and as such is performed on the motor as part of the final acceptance test.