Looking towards any integrated steel plant scenario, the importance of an Electr

ical Repair
Shop can be very well visualized. It is one of the major service shops which car
ries out
repair of all electrical machines used inside the plant; there are around 42000
electrical machines installed and running continuously years together, in diffe
rent processes of production, in Bhilai Steel Plant. General maintenance like cl
eaning, greasing and physical inspection / checkup is done by concerned shops wh
ere the machines are used. All major repairs like winding repairs, mechanical re
pairs, modification in existing winding and periodic overhauling etc. are being
attended by Electrical Repair Shop either at site or at ERS.
SCOPE OF WORK :
Electrical Repair Shop carries out repairs of motors, generators, welding and co
ntrol
transformers, load lifting magnets, brake & control coils of all types and capac
ities. It also
manufactures a large number of spare parts like contact materials, switches, com
ponents,
busbar and various other electrical spare parts. Repair of load lifting magnets,
welding
transformers, control transformers and rectifiers are carried out in magnet and
transformer
repair shop (MTRS). MTRS also fabricates load lifting magnets of all varieties u
sing all in-house
technology and resources including the design concept. Traction motors and roll
table motors
from various Rolling Mills are overhauled in Motors Overhauling and Repair Secti
on (MORS)
adjacent to MTRS.
PRODUCTION TARGETS :
E.R.S. on an average repairs 380 motors and generators, manufactures / reclaims
535
nos. coils, repairs 17 nos. load lifting magnets, 28 nos. welding & control tra
nsformers per
month. The monthly repair work in case of motors and generators is given below i
n tabular
form :
Upto 10 Kw Machines > 10 Kw Machines Total Machines
Rewinding jobs 130- 140 Nos. 70- 80 Nos. 200- 220 Nos.
Medium repair jobs 70- 80 Nos. 90- 100 Nos. 160- 180 Nos.
Total 200- 220 Nos. 160- 180 Nos. 360- 400 Nos.

Some repair work is off loaded to outside agencies strictly on need basis, such
as core staggering, shaft change etc. for which repair facilities are not availa
ble in ERS. Such repairs are limited in number (5 - 10 machines per year) and ap
plicable for big size and critical machines only.
MAN POWER :
ERS has a present manning of 234 non-executives and 13 executives of various gra
des. The shop is headed by DGM ( E - ERS ).
METHODOLOGY AND PROCESS FLOW :
Electrical machines are received from various shops within plant, township areas
, mines etc. alongwith its work order. The work order contains the machine speci
fication, its defect, previous job no. and any specific requirement by the conce
rned department. Receipt & Issue section (R&I) of ERS allots a job No. to each a
nd every machine after proper verification of the machine and its accompanying w
ork order. The number is painted on motor body and on all dismantleable parts. T
hereafter the machine is traced in ERS by that job number only. R&I section inti
mates to the concerned sections through internal job register for repair of thes
e machines or components on day to day basis.
To facilitate a systematic repair process the shop is divided into different sec
tions. These are :
1. R & I section
2. Computer section
3. Assembly and dismantling section
4. Winding section
5. Varnishing section
6. Testing section
7. Machine section
8. Spare parts manufacturing section
9. Commutator repair section
10. Stores
11. Shop maintenance
12. Magnet & Transformer Repair Shop (MTRS)
13. Motor Overhauling and Repair Section (MORS)

ASSEMBLY & DISMANTLING SECTION :

Machines after dismantling are subjected to preliminary check-up (Meggering and
visual inspection). Accordingly these components are sent to various sections on
the basis of
the repair work involved. The healthy components are cleaned thoroughly and varn
ished in
varnishing section before being sent to testing section for preliminary test. Th
ese components
after testing, are sent to respective assembly sections. The defective component
s are sent to
respective winding sections for repair / rewinding . The assembly sections take
s those
components of a machine for assembly which are ready in all respects. Before ass
embly the
components are thoroughly checked to ensure whether all the repairs as mentioned
in work
order or as noticed by assembly group are carried out or not. In case there is s
ome omission, it
is sent to concerned section for further repair. All the windings are meggered t
o ensure healthy
IR value and continuity in winding. All the mechanical parts like end covers, gr
ease cups,
bearings and their seatings are thoroughly cleaned before final assembly. The as
sembly group
also conducts certain post assembly checked like freeness of rotor / armature, p
roper brush
seating, tightness of rocker arms and their corresponding assembly in case D.C.M
achine,
meggering of components, tightness of body bolts etc. before sending the jobs to
testing section
for final testing.
WINDING SECTION :
Winding sections take up jobs either for rewinding or partial repair. Before rew
inding the soundness of core laminations is ensured by "Flux Test". In case ther
e is some abnormal heating of at some patches as detected by "Flux Test" core re
pair is done to rectify it . Components are recommended for rewinding unless sou
ndness of core is ensured. The components rewound / partially repaired are subje
cted to a set of tests as per norms like high voltage test, current balance test
, magnetic field test, checking of all joints etc. for their soundness. These co
mponents, if passed through all these standard tests are preheated, varnished an
d cured in furnace for a period of 16 - 18 hours. Finally covering varnish is ap
plied on these windings before sending to respective assembly sections.
TESTING SECTION :
Testing section conducts the following tests on all repaired machines on no load
at ERS besides conducting a set of tests on all machine components in intermedi
ate stages. These include :
AC SQUIRREL CAGE INDUCTION MOTOR :
Meggering, physical inspection, HV test, no load running test (for 30 minutes),
inter turn insulation test (for 2 minutes)

AC SLIP RING MOTOR :

Meggering, physical inspection, HV test, ratio test no load running test (for 30
minutes), inter turn insulation test (for 2 minutes), supply to rotor.
D.C. MOTOR :
Meggering, physical inspection, no load running test (for 30 minutes), over spee
d running test (120% of rated speed for 3 minutes), load test (for 5 minutes).
All these machines during " No Load Test " should draw current as per prescribed
norms and there should not be any abnormal heating, vibration, sound etc. so as
to be declared fit for despatch. D.C. machines in addition to these should run
sparkless and speed fall should be within reasonable limits on load condition.
Testing group after ascertaining all quality checks despatches these machines to
R & I.
MAGNET & TRANSFORMER REPAIR SECTION (MTRS):
MTRS repairs all load lifting magnets, control transformers, welding transformer
s, rectifiers. It also fabricates load lifting magnets of all varieties. The des
ign of these magnets is developed by planning & technical department ( P.T.D. )
with the development of drawing for shell, centre pole, coil and non magnetic pl
ates. The magnet shell is cast from high permeability steel. Centre pole is an i
ntegral part of the shell and the pole shoe is bolted to the shell. Shell and ce
ntre pole shoe have been cast in Foundry shop and machined to dimension in machi
ne shop - I as per the drawing developed by P.T.D.. These machine shells are tes
ted by various ultrasound testing techniques and found acceptable. After insulat
ing and curing the shell, coils are assembled into the shell with suitable inter
coil insulation. Heat resistant compound is poured into the shell to make all t
he internals monolithic. These magnets after fixing nonmagnetic plate and provid
ing terminal boxes are delivered to shops after testing on no-load and load test
at M.T.R.S.. These magnets are working satisfactorily at various shops.
MOTOR OVERHAULING & REPAIR SECTION (MORS) :
MORS does overhauling of traction motors and roll table motors received from var
ious rolling mills..
PERFORMANCE HIGHLIGHTS :
_ Machines waiting for repairs in ERS is 529 as on July'2002 as against 949 i
n Oct.'1998,
without any offloading support and additional manning.
_ 10 to 15 nos. magnets are being fabricated annually since 1998 usin
g all in-house
resources. Purchase of new magnets are totally stopped resulting in substantial
saving.

_ Recent achievement of ERS in form of successful repair of big size and crit
ical
machines which were previously repaired by BHEL and others include the f
ollowing :
_ Repair of 3M1, 7100 Kw Armature of Plate Mill.
_ Repair of 3M1, 6300 Kw Armature of finishing stand of Plate Mill.
_ Repair of 4000 Kw Armature of roughing stand of Plate Mill.
_ Repair of 640 Kw Screw Down Armature of Plate Mill, 180 Kw Screw Down
Armature of Blooming & Billet Mill.
_ Repair of 1300 Kw Armature and 1200 kw armature of Wire Rod Mill.
_ Repair of 150 Kw Armature of Left Manipulator of Rail & Structural Mill.
_ Modification of terminal board of 280 Kw D.C. Motor of casting crane of
Continuous Casting Shop.
_ Repair of 1375 KW, 11 KV, H.T. Ventilation motor of Continuous Casting S
hop.
_ Repair of 375 KW, 6.6 KV, H.T. Ventilation motor of Convertor Shop.
MAIN EQUIPMENTS INSTALLED AT ERS
1. Three E.O.T. Cranes 5 Ton, 15/3 Ton and 10 Ton ( Reclamation )
2. Four Cantilever cranes ( 1 ton each )
3. Two induction regulators
4. One H.T. & L.T. D.O.L.. starter
5. One load testing equipment ( Dynamometer - upto 50 kw.)
6. One load testing equipment ( Load generating system - 150 kw, 1000 r.p.m
.)
7. Nine numbers coil winding machines
8. Six numbers lathes of various sizes
9. Five numbers furnaces
10. One bandaging machine
11. One balancing machine
12. One shaping machine
13. One stator coil forming machine
14. One coil cutting and pulling machine

15. Five telphers, 1 Ton each

16. Four drilling machines
17. Three grinding machines
18. One punching machine
MAIN EQUIPMENTS INSTALLED AT MTRS
1. One 20 Ton E.O.T. crane
2. One coil making machine
3. One furnace
4. One grinding machine
MAIN EQUIPMENTS INSTALLED AT MORS
1. One 20 Ton E.O.T. crane
2. One Hydraulic press
3. One bandaging machine
4. One lathe
5. One furnace