Hybrid Solutions Group successfully delivered and installed a custom-built 600-amp ABB fan motor for a 20-year-old tunnel ventilation system, overcoming challenges with obsolete parts, restricted site access, and complex logistics.
Located within the southbound Blackwall Tunnel, they managed the entire process, from international sourcing to specialist lifting, they minimised downtime, avoided costly modifications, and ensured a seamless experience for the client.
The problem
When our client needed a replacement motor for a 20-year-old tunnel ventilation system, they faced a big hurdle: the original ABB motor was no longer in production.
Finding a like-for-like replacement wasn’t just a matter of convenience, it was essential to avoid costly modifications and reduce downtime during their scheduled maintenance.
Adding to the complexity:
- The motor was a powerful 600-amp unit designed for heavy-duty industrial use – this really is not something you can pick off the shelf.
- Access to the motor was extremely limited, requiring it to be moved 3 metres up and 20 metres into a shaft, weighing in at 4500kg.
- Traditional delivery methods simply wouldn’t work, and a carefully planned, cost-effective solution was needed.
How we fixed it
We took full ownership of the project, coordinating every detail to ensure the motor replacement was smooth, safe, and stress-free for the client.
We started by collecting all the technical details and working with ABB to commission a one-off motor built to the exact original specifications. This meant no structural changes were needed to the existing fan, saving time and money.
We brought everyone together, organising meetings with the client, Principal Contractor, and ABB’s technical team to make sure everything was aligned.
From there, we handled the logistics of transporting the motor from Finland, brought in a trusted specialist lifting contractor, and developed a bespoke lifting plan after a thorough site visit. Thanks to careful planning and teamwork, the entire delivery and installation was completed in just one day.
The result
The client got exactly what they needed – a seamless motor replacement with minimal disruption and zero surprises. By managing the project from start to finish, we made a complex task feel simple and delivered a solution that was safe, efficient, and cost-effective.
