TPS-59 Radar Power System Restoration
Project Overview
Objective: Restore and upgrade 7 KATO Motor Generators (Model 22328000) to ensure reliable 400Hz power for radar operations.
Key Interventions
- Mechanical: Bearing replacements, rotor balancing, shaft alignment
- Electrical: Stator rewinding, insulation upgrades, NEC-compliant wiring
- Control Systems: Modernization of panels with digital meters, breakers, and timers
- Structural: Corrosion treatment, epoxy coatings, vibration damping
Site-Specific Repairs & Outcomes
Repair Locations & Results
| Site | Repair Focus | Outcome |
|---|---|---|
| Port Said | Complete motor overhaul | Restored 24/7 operational readiness |
| El Mansura | Exciter stator rewiring | Eliminated voltage fluctuations |
| Balteem | Rotor dynamic balancing | Reduced vibration by 40% |
| Sidi Barani | Structural reinforcement | Extended service life by 10+ years |
| Inshas | Control panel modernization | Enabled remote monitoring capabilities |
| Zaafrana | Full insulation enhancement | Achieved >7 GΩ post-repair (from 0.5 GΩ) |
| RBW 1 (Cairo) | OEM-grade bearing replacements | Noise reduction and improved efficiency |
Technical Interventions
A. Mechanical Repairs
- Replaced SKF military-grade bearings in all units
- Rotor dynamic balancing (Zaafrana, Balteem)
- Shaft eccentricity checks and machining
B. Electrical Upgrades
- Stator insulation enhancement (varnish, epoxy, anti-flash coating)
- Surge protector and rectifier diode replacements (Zaafrana, Inshas)
- Leakage current reduced to <10nA (from 236nA in Zaafrana)
C. Control System Modernization
- Replaced analog meters with digital displays (voltage, current, frequency)
- Installed star-delta timers and 600A breakers
- New wiring with labeled conduits (NEC compliance)
D. Structural Improvements
- Corrosion-resistant painting (all units)
- Sheet metal repairs (Zaafrana, Sidi Barani)
- Vibration-dampening mounts (Port Said, RBW 1)
Execution Strategy
Phased Deployment
- Survey (2018): Thermographic, speed, and insulation tests
- Repair (2020–2021): Staggered by site (Zaafrana first, RBW 1 last)
- Testing: 72-hour load tests post-repair
OEM Collaboration: KATO-certified technicians for critical units
Documentation & Deliverables
- Per-Site Reports: Detailed documentation (e.g., Zaafrana Report Rev. 1.docx)
- Test Exhibits: RMS voltage/current graphs (input/output)
- Performance Data: Thermographic comparisons (e.g., 55.8°C → 30.7°C)
- Validation Tests: Motor speed tests (1500 RPM achieved)
Information About the Project
| Locations |
Port Said, El Mansura Balteem, Sidi Barani Inshas, Zaafrana RBW, Cairo |
| End-User | Egyptian Armament & Ammunition Department |
| Award Date | September 2020 |
| Contract | M67854-20-R-2032 |
The contractor continues to enhance their resources and expand their workforce with skilled tradespeople. Their safety plan, approved by the CEMED Safety Officer, demonstrates their safety commitment. The contractor's Safety Officer executes the plan diligently, with excellent coordination between Safety Office and RE.
The job-site supervisors' empowerment has increased effectiveness. The contractor implemented an organized tracking system to fully record, follow up, and warranty items. They've also improved reporting systems. As a result, the customer is extremely satisfied with the quality relative to cost.
Interdyne’s proactive management, strong communication, and tireless efforts to meet and exceed timelines have reflected very positively on the company.
Contractor overcame issues like unavailable parts and executed the tasks smoothly with full compliance. Performance met all contractual requirements.
Interdyne practiced the 3 C’s: Communicate, Coordinate, and Cooperate. Delivered 100% quality to USACE standards under extreme conditions.