Es 14 902 05

Electrical Rotating Machine Repair ES-14-902-05
This is a Controlled Document that complies with Wesfarmers CSBP Ltd formatting and Quality Control guidelines. Please check that this is the latest available version before use. Title: Number: Owner: Authoriser: Version Details:
ELECTRICAL ROTATING MACHINE REPAIR ES-14-902-05

Simon Orton Phil Talbot Revision 5. Eye bolt testing added. Sections 4.9i and 4.11.7 added, Appendix 2 "work performed" section modified to suit.Eye bolt testing added. Sections 4.9i and 4.11.7 added. Appendix 2 section "work performed" modified to suit.
TABLE OF CONTENTS
1. 2. 3. 4. SCOPE........................................................................................................................................... 3 STANDARDS................................................................................................................................ 3 SERVICE CONDITIONS............................................................................................................ 4 TECHNICAL REQUIREMENTS .............................................................................................. 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 5. FRAME SIZE......................................................................................................................... 4 INSULATION AND TEMPERATURE RISE....................................................................... 4 TEMPERATURE DETECTORS ........................................................................................... 4 WINDINGS............................................................................................................................ 5 ANTI-CONDENSATION HEATERS ................................................................................... 5 BEARINGS AND LUBRICATION....................................................................................... 5 SHAFTS ................................................................................................................................. 5 VIBRATION AND BALANCE QUALITY .......................................................................... 6 INITIAL INSPECTION ......................................................................................................... 6 DATA SHEETS ..................................................................................................................... 7 ASSEMBLY........................................................................................................................... 7 PAINTING ............................................................................................................................. 8 IDENTIFICATION TAG ....................................................................................................... 8 REPAIR ORDER NUMBER TAG ........................................................................................ 9 RATING PLATE.................................................................................................................... 9 PERFORMANCE CHARACTERISTICS ............................................................................. 9 DOCUMENTATION ............................................................................................................. 9
TESTING ...................................................................................................................................... 9 5.1 TESTS AT CONTRACTORS WORKS ............................................................................... 9
Version No. 5 Page 1 of 16 Document last modified: 11 December 2001. PDF Created: 10 November 2005.
APPENDIX 1 - ELECTRIC MOTOR REPAIR DATA STATOR REWIND DATA .................. 12 APPENDIX 2 - ELECTRIC MOTOR REPAIR DATA SHEET ................................................... 14 APPENDIX 3 - TYPICAL MOTOR IDENTIFICATION TAG .................................................... 15 APPENDIX 4 - TYPICAL MOTOR PURCHASE ORDER TAG ................................................. 16
1.
SCOPE
This Standard defines the minimum requirements for the repair and testing of rotating electrical machines at the Contractors works.
2.
STANDARDS
Australian Standards AS1023 Low Voltage Switchgear & Controlgear Protection of Electric Motor Pt 1 - Built in Thermal Detectors and Associated Control Units AS1359 Rotating Electrical Machines - General Requirements Pt 10 - Designations and Dimensions Pt 31 - Three-Phase Induction Motors Operation on Unbalanced Voltages Note: AS1359.31 is superseded in part by AS1359.101 Sections 5 and 6
Pt 41 - General Characteristics Pt 101 - Rating and Performance AS1360 Rotating Electrical Machines of Particular Types or for Particular Applications AS1939 Degrees of Protection provided by Enclosures for Electrical Equipment AS2380 Electrical Equipment for Explosive Atmospheres Explosive Protection Techniques Pt 2 - Flameproof Enclosure - Type of Protection d Pt 6 - Increased Safety - Type of Protection e Pt 9 - Non Sparking - Type of Protection n AS2625 Rotating and Reciprocating Machinery - Mechanical Vibration Pt 1 - Basis for Specifying Evaluation Standards Pt 2 - Test and Measurement Conditions for Rotating Electrical Machines AS2381 Electrical Equipment for Explosives Atmospheres Selection, Installation and Maintenance Pt 1 - General Requirements Pt 2 - Flameproof Enclosure d Pt 6 - Increased Safety e AS2768 Electrical Insulating Materials - Evaluation and Classification Based on Thermal Endurance AS/NZS3800 Electrical Equipment for Explosives Atmospheres - Overhaul and Repair AS4307 Rotating Electrical Machines - Repair and Overhaul Pt 1 - Low Voltage Machines British Standards BS4999 BS5000 General Requirements for Rotating Electrical Machines Rotating Electrical Machines of Particular Types or for Particular Application
CSBP Engineering Standards ES-14-102-12 ES-14-903-12 Protective Coatings Electric Motors
3.
SERVICE CONDITIONS
Motors shall be suitable for connection to a 415 volt, 3 phase, 50Hz supply with solidly earthed neutral and operate in an ambient temperature of 40oC at an altitude less than 1000m. The motors shall be suitable for operation under the service and operating conditions outlined in AS1359.101 Sections 5 and 6.
4.
4.1
TECHNICAL REQUIREMENTS
FRAME SIZE
Frame sizes are in metric dimensions to BS5000, Part 10, IEC Publication 71-1 and 71.2 or AS1359 Part 10.
4.2
INSULATION AND TEMPERATURE RISE
All insulation shall be Class F in accordance with AS2768. Temperature rise shall be in accordance with Table 6 of AS1359.101 Class B - 80C in an ambient temperature of 40 C and an altitude of less than 1000m above sea level
4.3
TEMPERATURE DETECTORS
Wherever possible, thermistors shall give Class 1 protection with reference temperatures in accordance with Table 2 of AS1023 - Part 1. 4.3.1 LV Motors Rating: < 7.5 kW
Where it is found that a motor of less than 7.5kW is already fitted with thermistors then in this case thermistors shall be maintained and replaced if necessary during repairs. 4.3.2 LV Motors Rating: 7.5 to 37 kW
All LV Motors rated at 7.5kW and up to 37kW inclusive shall be provided with three PTC thermistor sensors, one per phase. 4.3.3 LV Motors Rating: 45 to 190 kW
All LV motors rated at 45kW and up to and including 190kW shall be provided with two sets of PTC thermistor sensors, two per phase.
4.3.4
LV Motors Rating: 200 kW
All LV motors rated at 200kW and above shall be fitted with six resistance temperature detectors (RTD) included in the stator windings (two per phase). The resistance temperature detectors shall be of the three-wire type, category 2 with a resistance of 100 ohms at 0C. The nine leads shall be brought out to a terminal block in a terminal box fitted to the body of the motor adjacent to the main terminal box.
4.4
WINDINGS
All LV and HV motor windings shall be Delta connected unless otherwise specified. The burning out of windings shall be carried out within a temperature-controlled environment. The maximum temperature permitted shall be 350C
4.5
ANTI-CONDENSATION HEATERS
Where fitted, anti-condensation heaters shall be checked for operation and repaired/replaced if necessary.
4.6
BEARINGS AND LUBRICATION
Bearings shall be replaced with the size, form and tolerance as per the motor manufacturers specifications or as specified on CSBPs motor data sheet. 4.6.1 Bearing Type
Bearings shall be of a sealed type by the following manufacturers: FAG SKF 4.6.2 Lubrication Type
Mobil HP or BP LC2 high temperature grease shall be used unless otherwise stated. All grease nipples used are to be of the round button type.
4.7
SHAFTS
Shafts shall be straightened by heating or jacking such that shaft eccentricity at rated speed shall be within the ranges specified by the manufacturer. The journal or seal areas shall be finish-machined to a standard size set by the bearing manufacturer to accept the bearing or seal. Knurling, peening or adhesives shall not be used as a means of retaining bearings to the shaft. Shaft extensions, keyways and keys shall be in accordance with manufacturer specifications.
The shafts of all motors shall be drilled and tapped in accordance with AS1359 Part 10, Table 5. The tapped hole shall be plugged with a grub screw and a suitable adhesive such as Loctite shall be used to ensure the grub screw remains in place. Note: Motors that have stepped shafts shall not be drilled and tapped.
4.8
VIBRATION AND BALANCE QUALITY
All motors shall be dynamically balanced before leaving the Contractors works. The balance quality shall be in accordance with values specified in AS2625.2.
4.9
INITIAL INSPECTION
The Contractor shall carry out an initial inspection for superficial damage following receipt of a machine at the Contractors works During disassembly of a machine and, prior to the commencement of repair, preliminary checks shall be carried out that include at least the following: a. b. Megger test windings and record results. Note condition of windings and record findings. Inspect the following for mechanical damage: End shields Stator housing Shaft extension Mounting feet/flange Terminal box housing Fan cowling Cooling fan Check bearing fit - record type. Following removal of rotor, check rotor bars, shorting rings for cracks or distortion, check rotor laminations for deformation, e.g. poling. For wound rotors, check: winding condition, slip rings/commutator, connections, and laminations. e. f. g. h. Check and establish winding condition. Check stator laminations for damage. Check material of fan cowling. If made of plastic or fibreglass then remove and discard. Check cast iron fans for evidence of cracking and also use of rivets to repair the fan or to affix balance weights. When cracking is found or rivets have been used then the fan shall be discarded. If fitted with an eye bolt, remove the bolt and clean out the threads of the stator frame/eye bolt with a wire brush and re-tap/die if necessary. Visually inspect the hole for signs of excessive corrosion or cracking which indicates that an eye bolt must not be installed. If the eye bolt hole is OK but the eye bolt condition is poor, has incorrect threads or incorrect thread length, then discard and re-supply a new eye bolt. Record findings on the Motor Repair Data Sheet.
c. d.
i.
4.10
DATA SHEETS
All rotating electrical machines shall be repaired as per the manufacturers specification and in accordance with any additional technical details, specifications or modifications as indicated on Motor Data Sheets or accompanying drawings. The above shall be supplied by the Responsible Officer and shall include, where possible, copies of previous history sheets complete with all detail. Manufacturers data shall also be included where available.
4.11
ASSEMBLY
4.11.1 Machined Faces Machine faces on end plates and bearing housings shall receive a rust preventative film such as Tectyl 506. 4.11.2 Shaft Extension Shaft extension is to be coated with a rust preventative film (as per 4.11.1) that can be easily removed with solvent. 4.11.3 Gaskets Gaskets between terminal box and motor carcass are to be made with Neoprene cork or equivalent of appropriate thickness to prevent the ingress of chemicals. 4.11.4 Shaft Seals Shaft seals, where fitted, shall be replaced as per the manufacturers specification or as specified on the CSBP Motor Data Sheet. Machining modifications for seals, if required, will be specified on a separate CSBP drawing. 4.11.5 Cooling Fans and Housings Replacement fans for Hazardous Area Motors shall be as per manufacturers specifications. Replacement fan housings shall be either cast iron or pressed steel and painted to CSBP specifications. Note: Plastic or fibreglass fan housings shall not be used.
4.11.6 Cable Termination Leads between stator slipring or commutator brush connections and terminal box/boxes shall be run in Belden stranded tinned copper conductor silicon rubber glass braid temperature rated 200C or CSBP approved equivalent. Cables shall, in all cases be flexible. Where terminal posts are not fitted, cables shall be left unlugged for on site termination.
4.11.7 Eye Bolts Based on the initial inspection, if the eye bolt hole was determined to be unsuitable for an eye bolt to be fitted then a standard bolt shall be installed into the hole. The threads shall be coated with an anti-seizing grease. If the initial inspection indicated that the motor frame is not expected to fail if lifted using the eye bolt then anti-seizing grease shall be applied to the threads and the eye bolt installed. Once installed, then the integrity of the eye bolt shall be tested. The test shall require the motor to be lifted by the eye bolt and then additional weight equal to half the motor weight added. The weight applied and the result of this test shall be recorded on the Motor Repair Data Sheet. On completion, a tag, duly completed with the name of the tester and the date, shall be affixed to the eye bolt stating:"Eye bolt tested by:- Date:- .."
4.12
PAINTING
Repaired motors shall have surface treatment applied to external surfaces in accordance with CSBP Engineering Standard Protective Coatings (ES-14-102-12) - System D. Colour shall be as follows: a. b. c. d. Metric, non-hazardous rated: AS2700S G13 Emerald Green Metric, hazardous rated (Ex e, Ex n, Ex d): AS2700S X15 Orange Imperial, non-hazardous rated: AS2700S N53 Blue Grey Imperial, hazardous rated: AS2700S N53 Blue Grey with two stripes 100mm wide colour X15 Orange around stator. Where stators have been coated with varnish due to the re-varnishing of windings then, unless otherwise directed, the Topcoat of paint applied to the stator will be sufficient. All other parts including end shields and fan cowlings will be painted as required by this Standard.
Note:
4.13
IDENTIFICATION TAG
Prior to abrasive blast cleaning and painting remove motor identification tag and replace after painting ensuring correct tag is re-fitted to motor. In the event that a motor has not got a tag fitted then the Contractor shall supply and fit a tag in accordance with the details contained in Appendix 3. The number shall be nominated in the Purchase Order.
4.14
REPAIR ORDER NUMBER TAG
Following repairs the Contractor shall supply and fit a Tag in accordance with Appendix 4 to the repaired motor. The Contractor shall stamp on the Tag the date of the repairs and the Purchase Order number.
4.15
RATING PLATE
Prior to abrasive blast cleaning and painting remove motor rating plate and replace after painting. When the rating plate is missing or illegible then the Contractor shall supply and fit a stainless steel plate complete with stamped ratings including; kW, Poles, Frame Size, RPM, Hz, Volts, Amps, phases, Insulation Class and Duty Rating. Where a motor is found to be of Imperial standard then the word Imperial shall be included on the plate. All fixings shall be 316 stainless steel.
4.16
PERFORMANCE CHARACTERISTICS
Each repaired Motor shall give similar performance characteristics to the original Motor.
4.17
DOCUMENTATION
The Contractor shall supply the following information for each repaired motor as appropriate: a. b. c. Electric Motor repair data as listed in Appendix 1. Electric Motor repair data sheet Appendix 2. Hazardous Area Motor repair date as per AS/NZS3800 in addition to (b) above.
5.
TESTING
All LV and HV motors shall be subject to Routine Check Tests in accordance with BS5000 and AS1359, Part 60-1974, after repairs and prior to dispatch. The contractor shall provide certified evidence that the following tests have been carried out. Such evidence shall include the voltage levels at which tests have been conducted.
5.1
TESTS AT CONTRACTORS WORKS
The following tests shall be carried out at the Contractors works. 5.1.1 a. LV Squirrel Cage Motors Resistance measurement - at ambient temperature: Phase to earth. Phase to phase insulation resistance. Stator winding resistance. Thermistor resistance. Resistance temperature detectors. Short circuit test (locked rotor). No load test. High voltage test as per AS1359.101 Clause 8.1. Balance quality as per Section 4.8. RPM at nameplate specified frequency.
b. c. d. e. f.
5.1.2 a.
LV Slipring Motors Resistance measurement - at ambient temperature: Phase to earth. Phase to phase insulation resistance. Stator winding resistance. Thermistor resistance. Rotor winding and slipring to earth. Rotor winding resistance. Brush holders to earth. Resistance temperature detectors. Brush tension. Rotor volts - open circuit. Stator and rotor current - locked rotor (short circuit test). No load test. High voltage test as per AS1359.101 Clause 8.1. Balance quality as per Section 4.8. RPM at nameplate specified frequency. HV Motors Squirrel Cage and Slipring Resistance measurement - at ambient temperature: Phase to earth. Phase to phase insulation resistance. Stator winding resistance. Thermistor resistance. Rotor winding and slipring to earth. Rotor winding resistance. Brush holders to earth. Polarisation Index. Brush tension. Rotor volts - open circuit. Stator and rotor current - locked rotor (short circuit test). No load test. Check phase sequence and terminal markings. High voltage test. Test all accessories for correct function. Balance quality as per Section 4.8. RPM at nameplate specified frequency. DC Motors and Generators Resistance measurement - at ambient temperature. 1. Field insulation resistance. (a) Shunt
b. c. d. e. f. g. h. 5.1.3 a.
b. c. d. e. f. g. h. i. j. 5.1.4 a.
b. c. d. e. f. g. 5.1.5 a.
(b) Series (c) Interpole 2. Field resistance (a) Shunt (b) Series 3. Commutator to earth 4. Commutator between segments 5. Brush gear to earth Stall current test - with shunt field open circuit. Overspeed and winding test per AS1359.101 Clause 8.5. Tacho volts per revolution. Commutation tests per AS1359.101 Clause 8.8. Balance quality as per Section 4.8. RPM at nameplate rated voltage and current. AC Generators - LV Resistance measurement - at ambient temperature. Phase to earth. Phase to phase insulation resistance. Auxiliary winding resistance. Auxiliary windings to earth. Auxiliary windings to phase winding insulation resistance. Thermistor resistance. Rotor winding resistance. Rotor winding and sliprings to earth. Brushless alternator rotor resistance to be taken before connection to diodes. Exciter components applicable to particular machine. High voltage test as per AS1359.101 Clause 8.1. Balance quality as per Section 4.8. Rotor balancing to be carried out prior to final assembly of machine. The Contractor shall perform the following tests only if machine construction permits. If the Contractor is unable to perform these tests, then CSBP is to carry out the tests when recommissioning the unit after final assembly. Brush tension - slipring and DC exciter machines. No load test. Full load test. Momentary overload - AS1359 Part 41, Clause 41.4 Overspeed test - Clause 60.5 AS1359. AC Generators - HV Resistance measurement - at ambient temperature:
b. c.
Note:
d. e. f. g. h. 5.1.6 a.
b. c. d. e.
Phase to earth. Phase to phase insulation resistance. Auxiliary winding resistance. Auxiliary winding to earth. Auxiliary windings to phase windings insulation resistance. Thermistor or thermocouples resistance and continuity. Rotor winding resistance. Rotor winding to earth. Sliprings to earth (where fitted). Polarisation Index. High voltage test per AS1359.101 Clause 8.1. Balance quality as per Section 4.8. Check phase sequence and terminal markings. Machine shall be subjected to full commissioning tests on site.
APPENDIX 1 - ELECTRIC MOTOR REPAIR DATA STATOR REWIND DATA

Number of slot Number of groups Number of coils per group Overhang of winding DE Overhang of winding NDE Type of winding Connections Size of wire Coil pitch Number of turns Connection cables Number of poles Slot liner insulation Type dimensions Intercoil insulation : : : : : : : : : : : : : : :
Shape dimensions Inter group insulation Shape dimensions Slot wedges Shape dimensions Coil former Shape dimensions Note:
: : : : : : :
The Contractor shall complete this schedule for motors of 200 kW capacity inclusive and larger. The schedule shall be forwarded to the Company at time of dispatch of the repaired motor.
APPENDIX 2 - ELECTRIC MOTOR REPAIR DATA SHEET

Manufacturer: Contractor: Serial No.: Contractor Ref. No.: Model No.: CSBP P.O. No.: Type: CSBP Item No.: Output kW: CSBP EWN: Voltage/Phase/Hz: Amps Sator: Frame: Bearing No.: Insul/Class Pole/RPM: DE: Voltage Rotor: Mounting: NDE: Amps Rotor: Duty Cycle: Seals No.: Insul/Class Rotor: IP Rating: DE: Connection: NDE: Shaft: Standard Tapped Stepped Ex n Haz/Area Rating: Ex e Ex d WORK PERFORMED Yes No Unknown Has Motor Been Previously Rewound? Eye Bolt Hole Suitable for Re-Use? Yes No New Bearing DE Rewind Armature New Bearing NDE Repair Bearing HSE NDE Repair Bearing HSE DE Skim Commutator Replace Vee Seal NDE Replace Vee Seal DE Undercut Commutator Replace Fan Replace Fan Cowling New Brushes Balance Fan Balance Rotor Repair Rotor Shaft Full Spec Paint Revarnish Stator Top Coat Spec Paint New Leads New Lugs Motor weight _______ kg Eye Bolt Test _______ kg Rewind Stator Replace Thermistor Sets 1 2 Other Repairs (specify) Repairs Certified By: Signed Date / /
Screwed
MOTOR TESTING All insulation resistance readings to be of one minute duration. STATOR ROTOR/ARMATURE INSULATION RESISTANCE INSULATION RESISTANCE A-E: Sliprings/Commutator: B-E: To Earth: C-E: A-B: WINDING RESISTANCE A-C: Between Sliprings B-C: A-B: B-C: WINDING RESISTANCE C-A: A1-A2: B1-B2: NO LOAD TEST RUN-AMPS C1-C2: A: B: THERMISTOR RESISTANCE C: Set 1 Ohms: rpm: Set 2 Ohms:
FIELD INSULATION RESISTANCE Shunt to series: Shunt to earth: Series to earth: I/pole to earth: FIELD RESISTANCE Shunt: Series: VIBRATION TEST DE Bearing mm/sec: Horizontal: Vertical: Axial: NDE Bearing: Horizontal: Vertical: Axial: Date / /
Test Certified By:
Signed
APPENDIX 3 - TYPICAL MOTOR IDENTIFICATION TAG
Material Stainless steel, grade 316, 2mmthick sheets. Numerals Gothic 12mm high x 1.5mm wide x 1mm deep and centred to plate width. Fill numerals to 1mm depth, with Black two-part Epoxy Paint. Finish Ensure tag is smooth, clean and free from burrs and sharp edges. Fixings 4mm diameter x 10mm long, 316 stainless steel round-head screws. Drill and tap to suit. Generally tags will be mounted in the vertical plane on the opposite side to the terminal box and centred between feet.
APPENDIX 4 - TYPICAL MOTOR PURCHASE ORDER TAG
ORDER NO.
DATE
ORDER NO.
DATE
Material Stainless steel, grade 316, 0.4mm thick sheet. Letters Times New Roman. Finish Stainless steel letters, black epoxy background. Fixings Use two (2) off stainless steel U drive pins. Generally the Tag will be mounted adjacent to the Motor Identification Tag. Dimensions Long = 80mm Broad = 40mm

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Electrical Rotating Machine Repair ES-14-902-05

ELECTRICAL ROTATING MACHINE REPAIR ES-14-902-05

TESTING ...................................................................................................................................... 9 5.1 TESTS AT CONTRACTORS WORKS ............................................................................... 9

Electrical Rotating Machine Repair ES-14-902-05

Electrical Rotating Machine Repair ES-14-902-05

Electrical Rotating Machine Repair ES-14-902-05

CSBP Engineering Standards ES-14-102-12 ES-14-903-12 Protective Coatings Electric Motors

INSULATION AND TEMPERATURE RISE

Electrical Rotating Machine Repair ES-14-902-05

LV Motors Rating: 200 kW

BEARINGS AND LUBRICATION

Electrical Rotating Machine Repair ES-14-902-05

VIBRATION AND BALANCE QUALITY

Electrical Rotating Machine Repair ES-14-902-05

Electrical Rotating Machine Repair ES-14-902-05

Electrical Rotating Machine Repair ES-14-902-05

REPAIR ORDER NUMBER TAG

TESTS AT CONTRACTORS WORKS

Electrical Rotating Machine Repair ES-14-902-05

Electrical Rotating Machine Repair ES-14-902-05

Electrical Rotating Machine Repair ES-14-902-05

APPENDIX 1 - ELECTRIC MOTOR REPAIR DATA STATOR REWIND DATA

Electrical Rotating Machine Repair ES-14-902-05

Electrical Rotating Machine Repair ES-14-902-05

APPENDIX 2 - ELECTRIC MOTOR REPAIR DATA SHEET

Test Certified By:

Electrical Rotating Machine Repair ES-14-902-05

APPENDIX 3 - TYPICAL MOTOR IDENTIFICATION TAG

Electrical Rotating Machine Repair ES-14-902-05

APPENDIX 4 - TYPICAL MOTOR PURCHASE ORDER TAG

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