Facilities

Assembly

Each unit is assembled in accordance with SANS 10242 and SANS 60079/1/15 and SANS 60079/1/15.

Assemblers are each equipped with a full toolbox of the latest tools and trained continually with new technology.

Hexagon has a SKF Induction Bearing Heater and a full set of fitting equipment for fitting seals.

Additional services

We can accommodate customers’ certification for equipment done at Hexagon for use underground, i.e. flame proofing of complete drill rigs, as well as fitting and commissioning of equipment for use in Exd locations.

Hexagon also manufactures skids to customer requirements.

Design program

Hexagon uses the most up-to-date design program, designed by a Professor from the University of Witwatersrand, making it possible to redesign electrical motor windings to suit any application.

Design office

Hexagon has a fully equipped design office with a research and development department:

  • Inventor and AutoCAD used as design program.
  • Simulate design operations and verify designs before issued to production for fabrication.
  • Simulate stresses to designs to ensure that there are no premature failures happening at the customer.

Dispatch

Units ready for dispatch are individually wrapped and painted as per customer requirements and are fitted with anti-bernelling devices and placed on pallets.

Dynamic balancing

Hexagon carries out 2 plane balancing with two Shenck machines which can perform 3 Ton, low balancing @ 1500 rpm up to 450kW. Each unit receives an automatic print-out which is placed in a Data Book. This is issued to the customer on request. All testing is carried out in accordance with SANS 10242.

Engineering workshop

All machining, drilling, milling etc. are done in-house. Hexagon possesses the following equipment:

  • 3x centre lathes
  • 1x surface grinder for sharpening of tools
  • 1x 1.5m vertical boring mill
  • 1x 2.5m vertical boring mill with 2m swing
  • 1x milling machine for cutting of key ways

Electrical assessment including core testing

Cores are tested for electrical properties, winding, connection etc.

The motor is tested for any electrical errors and failures.

External power

Hexagon can accommodate customers without losing any time during load shedding as we have an External Power Back Up in the form of a 600kVA diesel powered Perkins Gen Set which is able to power the full facility at the click of a switch.

Fabrication facility

Hexagon Electricals’ assembly facility consist of a well-equipped boiler shop with a 125-Ton press brake, plasma cutter, welding equipment, and 12 x 2000 mm Guillotine, all of which are used in everyday processes to support the manufacturing of electrical panels, substation enclosures, transformer radiators and tanks.

Final inspection

All motors, panels, cable reels, etc. are inspected for outline sizes, shaft extensions, spigot size, mounting holes, nameplates etc. For every product leaving Hexagon, an inspection form is issued and signed off.

Flame proof inspection

Hexagon has 6 accredited Flame Proof Inspectors carrying out patrol inspection on units being assembled in accordance with SANS 60079-0 and SANS 60079-1.

Lifting capabilities

The current layout of the factory has four operating bays:

  • Bay 1 has a 5 ton double girder crane servicing the Winding bay and Flame Proofing bay.
  • Bay 2 has a 5 ton double girder crane servicing the Machine bay, the Assembly bay the Final Testing and Dispatch bay.
  • Bay 3 has a 5 ton double girder crane servicing the Incoming bay, Fabrication and Press Shop.
  • Bay 4 has a 25 ton double girder crane.

All four cranes are remotely operated, serviced and maintained by  Daytona Cranes and full records are kept.

Lamination punching workshop

Full design facility designed by a Professor from the University of Witwatersrand from the Electrical Engineering Faculty.

  • Hexagon manufactures rotor and stator packs for use in the mining industry, as well as a full range of pad mount flameproof motors for the ventilation market.
  • Hexagon fabricates copper barred rotor for re-engineered motors and is capable to replace a die cast rotor with a copper barred rotor.
  • Core and rotor punching done in-house according to electrical design for motors up to 500kW.

Mechanical assessment

The individual parts are inspected for any faults and marked for repair or part replacement.

Stripping, cleaning and assessment area

All products are disassembled, cleaned and assessed. Burn-out oven with computer control to avoid over temperatures.

Spray bays

Hexagon provides high-quality spray bays designed for precision and efficiency, ensuring optimal conditions for professional spray painting.

 
 

Test facility

We test motors at full load 460kW, 6.6kV with 630kVA generator set and a complete fan test facility with conical and ventured columns. Our submersible pump test bay is capable of up to 110kW for water pumps and fans.

Hexagon possesses the following equipment:

  • Various Transformers with tap settings to allow Test Voltages – 0 to 6600 V up to 800 kVa
  • 460 kW Schenk Dynamometer
  • Fan Test Column up to Æ1076 mm at 30 m2, testing according to ISO 5801 and ISO 13347-1
  • 2 x ITIG II Winding Analyzer up to 12 kV
  • FAG Vibration Analyzer with PC Interface
  • HV Meter
  • Ratiometer and Insulation Tester
  • Separate Source up to 70 kV
  • Current Source up to 1500 A
  • High Frequency Meter at 2 x Hz up to 33 kV (Induced Frequency)
  • DC Motor Testing up to 1000 A
  • Single Phase and Three Phase micro-ohm meters

Transport

Hexagon has a fleet of vehicles ranging from

  • 1 x 16 Ton
  • 1 x 8 Ton with 4 Ton Crane
  • 1 x 2 Ton
  • 2 x LDV’s

VPI Varnish tank and curing oven

Hexagon has a full V.P.I. (Vacuum Pressure Impregnation) System using a state of the art resin, with separate double dip varnishing facility.

Winding department with all electrical test equipment

State of the art electrical winding design facility designed by a Professor from Wits University Electrical Engineering Faculty, which enables us to form and manufacture formed coils.

All our testing is carried out in accordance with SANS 10242 with the following equipment:

  • 2x ITIG Instruments to carry out pre-varnishing testing, P.I. testing of winding and surge testing.
  • Core testing and rotor bar inspection equipment with PC interface.

 

All instruments are calibrated at set intervals and records are traceable to an approved ATL.

An Electrical Data Book is issued for each unit leaving Hexagon Electrical.

Certifications

Setting New Standards

We are very proud to own the following certifications: SABS Certification, SA Flameproof Association, SEIFSA Certificate, MASC Certification, COID Letter of Good Standing and BEE Certificate. You can view and download all our certificates here.

Please Note:

We will be closed from 20 December 2024 until 6 January 2025.

Merry Christmas and
Happy New Year!