OPERATION, MAINTENANCE AND OVERHAULING OF AC MOTORS

By- M.M.Tiwari

IMPORTANT INFORMATION TO SHARE WITH > While sending feedback or seeking any kind of assistance regarding BHEL motors, please give following details for faster response: Rating details like kW, voltage, speed, frame and m/c Sl. No. If bearing problem is reported, inform size and type of bearing. Full Address of site indicating nearest railway station and / or name of District and route if site is in quite interior. Full name of contact person with telephone with STD code and extension number if any, fax / mob. number and E-mail address.

IMPORTANT INFORMATION TO SHARE WITH FOR OBTAINING MAXIMUM LIFE OF MOTOR: 1. OPERATE AT RATED CAPCITY & BALANCED POWER SUPPLY 2. REGULARLY LUBRICATE BEARINGS AT SPECIFIED INTERVAL 3. PROPER ELECTRICAL PROTECTION 4. SAFETY INTERLOCKING SHOULD BE FUNCTIONING 5. ELECTRICAL CONNECTIONS SHOULD BE PERIODICALLY CHECKED FOR TIGHTNESS / PROPER CONTACT 6. KEEP MOTOR SURROUNDINGS CLEAR & CLEAN 7. KEEP VENT SCREENS CLEAN AND IN PLACE 8. SHADE THE MOTOR TO KEEP IT COOLER 9. PROTECT MOTOR FROM EXTREME WEATHER CONDITIONS 11. MONITOR VIBRATIONS REGULARLY 12. CHECK MECHANICAL LOOSENESS, PERIODICALLY 13. ANY ABRUPT CHANGE IN OPERATING PARAMETERS SHOULD BE ANALYSED LOGICALLY WHICH MAY HAVE SERIOUS COSEQUENCE.

IMPORTANT INFORMATION TO SHARE WITH 14. BEARING & WDG RTD ALARM SHOULD BE OPERATIVE FROM INITIAL TRIAL RUN OF MOTORS 15. PARAMETERS LIKE VOLTAGE, CURRENT, BEARING / WDG TEMPERATURE , COLD / HOT AIR TEMP; AND VIBRATION LEVELS ARE RECORDED AND CHECKED PERIODICALLY TO ASSESS STATUS OF MOTORS. 16. ALL PARAMETERS SHOULD BE COMPARABLE WITH INITIAL COMMISSIONING PARAMETERS. 17. SPACE HEATERS SHOULD BE SWICHED ON IMMDTLY WHEN MOTOR IS SWITCHED OFF 18. OVERHEATING OF MOTOR SHOULD BE IDENTIFIED & ELIMINATE CAUSE AT THE EARIEST 19. ENSURE FREE FLOW OF COOLING AIR INTERMITTENTLY TO AVOID OVER OVERHEATING OF MOTOR 20. TRY TO MINIMISE NUMBER OF STARTS & STOPS

IMPORTANT INFORMATION TO SHARE WITH

21. CLEAN & OVERHAUL MOTORS AS NEEDED, WHICH DEPEND ON ENVIRONMENT, OPERATING CONDITIONS & CRITICALITY OF THE DRIVE 22. FOR MAXIMUM LIFE OF MOTOR CAUSE OF OVER HEATING SHOULD BE IDENTIFIED AND ELIMINATED. 23. USE COMMON SENCE, DO PROPER MAINTENANCE INSTEAD OF REPAIRS

Important factors to ensure trouble-free operation.

1. INITIAL INSTALLATION & COMMISSIONING DATA OF MACHINE SHOULD BE ACCESSIBLE FOR REFERENCE DURING OPERATION.

2. CLOSE EYE WATCH BY AN EXPERIENCED ENGINEER IS OF UTMOST IMPORTANCE TO MAINTAIN SMOOTH & SATISFACTORY OPERATION . 3. NEWLY COMMISSIONED MACHINE MAY BE KEPT UNDER REGULAR MONITORING TILL ITS OPERATING PARAMETERS ARE ESTABLISHED ON LOAD.
4. IR VALUE OF WINDING SHOULD BE LOGGED PERIODICALLY AT SPECIFIC VOLTAGE WITH MAINS MEGGER REGULARLY AND TREND OF IR SHOULD BE STUDIED OVER A PERIOD AND CAUSE OF LOW IR VALUE SHOULD BE IDENTIFIED & ELIMINATED

Important factors to ensure trouble-free operation.

DURING A FRESH START OF MOTOR AT SITE ENSURE THE FOLLOWING:

1. SURROUNDING OF MOTOR IS CLEAR & CLEAN. 2. IR VALUE OF WINDING IS HEALTHY.

3. BALANCE POWER SUPPLY IS AVAILABLE.

4. TRIP CIRCUIT IS HEALTHY. 5. SIMULATION CLOSING / TRIPPING OF BREAKER IS OK, IF BREAKER TROLLEY IS CHANGED.

Important factors to ensure trouble-free operation.

6. 7. 8. 8. 9. 10. 11.

BEARING LUBRICATION IS OK. ROTOR IS MANUALLY FREE TO ROTATE ALL SAFETY INTERLOCKS ARE OPERATING. COOLING AIR SYSTEM IS HEALTHY. COOLING WATER SUPPLY SYSTEM IS HEALTHY. ALL INDICATING LAMPS / METERS ARE OPERATING ANY ABRUPT CHANGE IN ANY OF THE OPERATING PARAMETERS SHOULD BE NOTED AND LOGICALLY ANALYZED FOR REQUIRED PREVENTIVE / CORRECTIVE ACTION.

Important factors to ensure trouble-free operation. Electric motors fail for a number of reasons (wholly unrelated to their age and no. of hours run). Problem with power supplies, overheating, contamination, unsuitable /insufficient/ over greasing and unusual loads can all play their part in impairing the efficient operation of the motors, leading to premature failure. Voltage imbalance is a common and damaging source of over heating. A rule of thumb for the effect of voltage imbalance is the percent of motor temperature rise equals two times the square of the percentage of voltage imbalance. For example, a 3% voltage imbalance can result in an 18% (calculated as: 2 X (3%)2 ) temperature rise in the motor.

Important factors to ensure trouble-free operation.

SPECIFIED REGULATED VOLTAGE AND FREQUENCY IS RARELY ACHIEVED WHICH CAN POSE FOLLOWING PROBLEMS: HARMONICS CAUSES OVERHEATING & DECREASED EFFICIENCY OVER VOLTAGECAUSES LOW POWER FACTOR & REDUCED EFFICIENCY UNDER VOLTAGECAUSES INCREASED CURRENT & OVER HEATING VOLTAGE IMBALANCECAUSES OVER HEATING & REDUCED EFFICIENCY

2.

3.

4.

Important factors to ensure trouble-free operation. 1. Harmonics in power line causes induced shaft voltages.

2. Other causes of induced shaft voltage include magnetic imbalance, improperly grounded electric arc welding and static electric charge from the driven system like fan, pumps & compressors.
3. Higher shaft voltage more than 350mv causes pitting on bearings with circulating current.

PATH OF SHAFT CIRCULATING CURRENT

Important factors to ensure trouble-free operation.

When an electric current passes through the contact zone of a bearings rolling elements and raceway, the energy of the electric discharge generates heat, causing localized melting of the surface. The effect on a bearing is almost like a series of small lightning strikes which melt and retemper internal bearing surfaces. The outcome is that some surface material flakes away and spalls out to create noise in the bearing and potentially shortened service life. Cratering is perhaps the most commonly experienced effect of electric arc damage. This type is characterized by molten pit marks (invisible to the eye). A dull gray surface of the rolling element will send a visual warning sign of cratering to telegraph that bearing deterioration is present.

Important factors to ensure trouble-free operation.

Once electric arc bearing damage has begun, excessive vibrations, increased heat, increased noise levels, and the reduced effectiveness of the lubricant will shorten a bearings service life. The extent of damage to bearings will depend on the amount of energy and its duration. However, the effect usually will be the same: pitting damage to the rollers and raceways, rapid degradation of the lubricant, and premature bearing failure.

Important factors to ensure trouble-free operation.

Even if a bearing is not directly influenced by electric discharge, the bearings lubricant may become a target and begin to degrade with dire consequences. This is because localized high temperatures can cause additives in lubricants to char or burn the base oil and, in turn, additives will be consumed more quickly and the lubricant will turn black and hard. The ensuing rapid breakdown can drastically shorten grease life and lead to secondary bearing damage due to poor lubrication.

Important factors to ensure trouble-free operation.

Antifriction bearings should perform normal for around 35000 hours under ideal operational condition. However, it is experienced that bearing failure is common cause of motor failure and it is the root cause for majority of downtime of electric motors. Bearings failures take place on account of lubrication problems like: Contaminated lubricant, lack of lubrication, excessive lubrication, mixing of different grade /make of lubricants. Chemical attack or thermal condition can decompose or breakdown lubricant and lubricants can become contaminated with non-lubricants such as water condensed water traces and or rust from bearings themselves.

Important factors to ensure trouble-free operation.

When the motor is shut down, moisture and condensation can collect on the surface of the bearing components. Eventually, this water breaks through the oil and grease barrier, contacts the metal parts of the bearing, and produces tiny particles of iron oxide. These rust particles make an excellent grinding compound when mixed with the grease, reduces life of bearing because of surface degradation.

ANTIFRICTION BEARING ARRANGEMENT (HORIZONTAL MOTORS)

Electrical pits are another indication of bearing currents. If left unchecked, this will eventually result in fluting.

When current is broken at the contact surface between the rolling elements and the raceways, it produces arcing damage.

Fluting, an accumulation of pits, is a sure indicator of bearing currents. Once started, fluting is self-perpetuating until the bearing fails.

MAINTENANCE Preventive Maintenance: Scheduled Preventive Maintenance is to be done at regular interval which include cleaning, inspection and lubrication. Log record of operating parameters are maintained to study its behavioral changes. Routine Maintenance: Routine Maintenance should identify and correct the more common conditions which may negatively effect the performance include insufficient ventilation, high ambient temperature, excessive mechanical mis-alignment, improper belt tension, improper lubrication, excessive vibration. Routine work of servicing / inspection can be done in assembled motor.

MAINTENANCE Above conditions may decrease efficiency and reduce overall system efficiency. The end results are increased energy consumption, decreased reliability and reduced operating life. Predictive Maintenance: Predictive maintenance is a data base program. It consists of plotting of trend of values periodically recorded for insulation and vibration. Trend lines can then be projected to determine when corrective action would be necessary. Equipment wise written records indicating date items inspected, problem attended / corrective action taken and condition of motor are important to decide detailed predictive maintenance to be carried out during forth coming shut down.

MAINTENANCE Motor operational problems are a common cause of downtime and maintenance headaches.

Good troubleshooting skills help to identify the root cause of motor problems and avoid their recurrence. Take time when handling a motor failure to carefully diagnose the situation and gain a complete understanding of the source (or sources) of the problem.
Analyzing application issues and applying long-term corrective solutions will help to minimize your operational disruptions.

MAINTENANCE General plant equipment maintenance schedule is usually sufficient for driven equipments. Frequency of routine maintenance widely varies between application. It also depends on surrounding environment and criticality of drive. However, motor may require additional or frequent attention if break down would cause health or safety problems, severe loss of production, damage to expensive equipment or lead to other serious losses.

MAINTENANCE

Vibration analysis is extremely helpful tool in extending useful life of machine. Regular checking of vibrations detect bearing wear, mechanical looseness, mis-alignment, defective rotors, electrical unbalance among other things. This will help pinpoint source and probable cause of trouble. To be effective, the vibration must be checked at a fixed interval of say 6 months. Results should be recorded for comparison with future readings. Early detection of vibrations can reduce the number of unscheduled shutdown and help to prevent avoidable damage to the motor.

MAINTENANCE Wipe, brush, vacuum or blowout accumulated dust, dirt from frame and air passage of motor. Dirty motors run hot with thick dirt accumulation on body & clog air passage reducing cooling air flow. Excessive heating reduces life of insulation & eventually may cause pre-matured electrical failure. Feel air being discharged from cooling tubes. If flow is weaker or unsteady needs to be cleaned periodically, depends on environment it is working.

MAINTENANCE When ever motor comes under shut down its IR value should be recorded in hot condition for a period of time by which one can analyze condition of motor winding. The motor should be meggered with motorized megger at particular voltage only. The health of motor should be analyzed with reference to other operating parameters and trouble shooting experienced with the motor during the interval of service. Space heaters should be put-on when motor is kept idle and its rotor should be rotated by 90 deg. every fortnight when kept idle to avert damage to its bearings due to false brinelling.

MAINTENANCE
> Apart from measurements, it is worth to have actual feel of satisfactory running of machine. If performance parameters are studied & interpreted properly, it will not only ensure smooth / trouble-free running but also eliminate unanticipated breakdown. Standard schedule of maintenance & overhauling is given in O&M manual of motors. But it would be more appropriate to suitably reschedule it considering environmental operating conditions & duty of drive.

>

>

Motors working under odd condition a thorough inspection or overhauling in an year may not be considered to be time/money wasted.

FACTORS INFLUENCE BEARING TEMPERATURE

WINDING TEMPERATURE LUBRICANT TEMPERAYURE MOTOR THERMAL CIRCUIT (COOLING PATH / METHOD) OIL/GREASE VISCOCITY BRG. SEALS, SHIELDS & TYPE OF LUBRICANT AMT. OF GREASE IN BRG. & CAVITY INTERNAL CLEARANCES OF BRG. AMBIENT CONDITIONS INCLUDING CONTAMINATION BEARING TYPE & SIZE

COMMON PROBLEMS DURING OPERATION

1. EXCESSIVE TEMPERATURE ON ANTIFRICTION EARINGS. 2. EXCESSIVE TEMPERATURE ON SLEEVE BEARINGS. 3. EXCESSIVE VIBRATIONS. 4. EXCESSIVE WINDING TEMPERATURE. 5. BEARING OIL LEAKAGE. 6. EXCESSIVE WEAR OF CARBON BRUSHES. 7. WEAR & DAMAGE TO SLIPRING

BEARING FAILURES

BEARING FAILURES NOT ATTRIBUTED TO FATIQUE ARE USUALLY CLASSIFIED AS PRE-MATURE FAILURES, CAUSED DUE TO: 1. INCORRECT / SPURIOUS BEARING. 2. HIGHER AMOUNT OF MIS-ALIGNMENT. 3. ASSEMBLY PROBLEM. 4. EXCESSIVE THRUST OR REDIAL FORCE. 5. AXIAL INDENTATIONS. 6. ELECTRICAL PITTING. 7. INSUFFICIENT / BOUNDRY LUBRICATION. 8. OVER LUBRICATION. 9. PRESENCE OF MOITURE / CONTAMINENTS. 10. INCORRECT GRADE OF GREASE. 11. MIXING OF DIFFERENT GRADE / MAKE OF GREASE. 12. NOISY / DAMAGED / DEFECTIVE BEARING. 13. LOOSE / DEFECTIVE COUPLING.

EXCESSIVE TEMPERATURE ON SLEEVE BEARINGS

1. LOW OIL LEVEL IN RING LUBRICATED BEARING 2. STICKY OIL RINGS. 3. NO AXIAL CLEARANCE ON EITHER SIDE OF DE BRG. 4. IMPROPER MIXING OF GRADE OF OIL. 5. SUSPENDED IMPURITY IN LUBRICTING OIL. 6. USE OF EXPIRED OIL.

EXCESSIVE TEMPERATURE ON SLEEVE BEARINGS 7. 8. THINNING OF OIL. IMPROPER BEARING CLEARANCE

9.
10.

EXCESSIVE MISALIGNMENT.
SCORED BEARING

11.
12. 13. 14. 15.

HIGHER SHAFT DEFLECTION.

DISTORTED BEARING SHELL. IMPROPER BEDDING OF BEARING LINER. INCORRECT LEVELING OF ROTOR ROUGH FINISH OF SHAFT JOURNAL

EXCESSIVE VIBRATION
1. LOOSE HOLDING BOLTS. 2. FOULING OF STATINERY 3. EXTRA PROJECTION OF KEY BEYOND 4. RUBBING BETWEEN STATOR & ROTOR 5. LOOSE CORE OR LOOSEBAR 6. POSSIBLE RESONANCE IN SYSTEM 7. IMPROPER CONTACT AREA / UN SUPPORTED FEET 8. INADEQUATE / IMPROPER SHIMMING. 9. EXCESSIVE MISALIGNMENT OR IMPROPER COUPLING 10. RESIDUAL UNBALANCE IN COUPLING 11. IMPROPER / WEAK FOUNDATION. 12. BOUNDRY LUBRICATION. 13. DAMAGED BEARING. 14. IMPROPER BEARING ASSEMBLY.

SYMPTOMS OF DEFECTS IN ANTIFRICTION BEARINGS CORROSION, EROSION & TRACES OF RUSTING. OVERHEATING / DECOLOURATION MARKS BLACK GREASE, DRY GREASE OR NO GREASE. ROUGHNESS ON BALLS / ROLLERS AND OR RACES. INDENTATION MARRKS ON ROLLING ELEMENTS. BRENELLING MARKS ON ROLLING SURFACES. CREEPAGE SIGNS ON BEARING OUTER RACE / HSG. SIGNS OF CHIPPING, CRACKING OR FLAKING.

SYMPTOMS OF DEFECTS IN ANTIFRICTION BEARINGS

FREE ROTATION OF BEARING (CATCHING PHENOMENON SHOULD NOT BE THERE DURING ROTATION BY HAND)

DEFECTIVE BEARINGS NEED TO BE REPLACED BY THE

SPECIFIED DESIGNATED BEARINGS, PROCURED FROM

VERY RELIABLE SOURCE OR DIRECTLY FROM THE MANUFACTURER OF BEARING OR SUPPLIER OF MOTOR

NOTHING CAN RUIN BEARING MORE QUICKLY THAN DIRT , GRIT OR SUSPENDED ABRASIVE PARTICLES.

CAUSES OF BEARING DEFECTS

CORROSION & ERROSION DUE TO IDLING OF M/c IN SALTY & MOISTURISED ATMOSPHERE.
IF BRGS. ASSEMBLED WITH PERSPERATING HANDS IT CAN LEAD TO PREMATURED FAILURE. BLACK GREASE/ DRY GREASE WITH DEPRESSION MARKS ON ROLLING ELEMENTS IS GENERALLY CAUSED DUE TO WELDING CURRENT OR HIGHER SHAFT VOLTAGES. ROUGHNESS ON ROLLING ELEMENTS INDICATES PRESENCE OF DUST,DIRT OR GRIT IN GREASE. CREEPAGE SIGNS LOOSENESS OR RECONDITIONED BRGS.

CAUSES OF BEARING DEFECTS

CHIPPING / FLAKKING INDICATES MATERIAL DEFECT COULD BE DUE TO OVER HEATING AND INADEQUATE ASSY.OF BRGS. BRINNELING MARKS-DUE TO IDLING OF M/c FOR LONGER DURATION ON RESIDUALLY VIBRATING FLOOR. WEAR ON BRGS. INDICATES EXCESSIVE LOADING DUE TO INADEQUATE ASSY. AND/OR HIGHER MISALIGNMENT.

ABNORMAL NOISE FROM BEARINGS GENERALLYCAUSED DUE TO LACK OF GREASE, IMPROPER / DEFECTIVE BRGS.OR EVEN ON ACCOUNT OF ASSY. NOT SQUARE TO SHAFT.

PRECAUTIONS
NO CHANGE IN BEARING ASSY COMPONENTS / HSG .

NO PRICK PUNCHING OR KNURLING ON BORE / /JOURNAL

DO NOT USE ABRASIVE EMERY BELT / STONE TO POLISH. USE ONLY CORRECTLY IDENTIFIED ASSY. COMPONENTS. DONOT ASSEMBLE WITH PERSPERATING HANDS. IDLING OF M/c IN SALTY & MOISTURISED ATMOSPHERE LEADS TO EROSION & CORROSION.

USE OF RECONDITIONED BEARINGS PROHIBITED.

DE BEARING ASSEMBLY

MAINTENANCE OF WINDING
>

CHECKING OF OVERALL PHYSICAL STATUS OF WINDING.

INSPECTION OF LEAD JOINTS & BRAZED COIL CONNECTIONS CLEANING OF WDG. WITH DRY COMPRESSED AIR / MARKIN CLOTH / SOAKED WITH MILD SOLVANT & SQUEEZED CLOTH. CLEARING OF COOLING DUCTS.

RECORDING OF IR VALUES
IF NECESSARY WINDING CAN BE GIVEN A SPRAY COAT OF EPOXY RED GEL & CURED BY HEATING TO 50 60 DEG. C.

AFTER OVERHAULING & REASSY CHECK THE FOLLOWING IR VALUES OF STATOR & ROTOR WINDING RESISTANCE OF BOTH THE WINDINGS CURRENT BALANCE TEST ON STATOR WDG. AT 440V OPEN CIRCUIT VOLTAGE TEST ON ROTOR. HV TEST ON WINDING NOT RECOMMENDED AT SITE. IF ANY REPAIRS CARRIED ON WDG. HV MAY BE DONE AT 1.75 TIMES RATED VOLTAGE IN CONSULTATION WITH MANUFACTURER.

DRY OUT OF WINDING

EXTERNAL HEATING BY HOT BLOWER, CARBON LAMPS, INFRARED LAMPS AND HEATERS BETWEEN 70 TO 80 DEG.

BY PASSING REGULATED WELDING CURRENT.

BY APPLYING LOW VOLTAGE WITH ROTOR LOCKED. TEMP. RISE SHOULD BE GRADUAL , MONITORED THRO RTDs

OVER HAULING OF AC MACHINES

PRIMARY REQUIREMENT: (NOTE THE FOLLOWING) RATING PLATE DETAILS WITH SERIAL NUMBER OF MACHINE DATE OF FIRST COMMISSIONING LOAD CURRENT ON WHICH MACHINE OPERATES NORMALLY MAXIMUM WINDING TEMPERATURE ONRUNNING LOAD MAXIMUM DE & NDE BEARING TEMPERATURES WITH AMBIENT VIBRATION RECORDS, IF AVAILABLE ON NOLOAD & LOAD

OVER HAULING OF AC MACHINES

PHYSICAL INSPECTION: IF MACHINE IS COUPLED WITH DRIVE OBSERVE ALL RUNNING PARAMETRS ON LOAD & TAKE NOTE OF SPECIFIC OBSERVATION , IF ANY. DECOUPLE THE MACHINE, RUN UNCOUPLED & HAVE FIRST HAND PRACTICAL FEEL OF NOISE FROM BRGS,QUANTITY OF COOLING AIR, OVERALL SOUND & RECORD RUN DOWN TIME. PAST HISTORY OF MACHINE TO BE REVIEWED, IF DETAILS AVAILABLE. NOTE SHOULD BE MADE WHEN & BY WHOM THE MACHINE WAS OVERHAULED, DURING PAST. IF REQUIRED, CHECK AND RECORD ALIGNMENT READINGS.

OVER HAULING OF AC MACHINES

BEFORE REMOVAL OF MOTOR FROM ITS BASE FOLLOWING WORK TO BE CARRIED OUT: DISCONNECT ALL ELECTRICAL/ EARTHING CONNECTIONS & MECHANICAL FITTINGS LIKE PIPE JOINTS ETC TAKEOUT THE INSTRUMENTS FROM MACHINE BY MARKING CORRESPONDING LOCATIONS ( PUT MATCH MARK WHERE EVER FELT NECESSARY) BEFORE DISTURBING MOTOR FROM ITS POSITION ON FRAME HAVE EXACT LOCATION MARKED, IF IT IS NOT DOWELLED. REMOVE ALL DE & NDE COVERS, SPEED SWITCH PROBE etc , IF PROVIDED

OVER HAULING OF AC MACHINES

CHECK & RECORD THE FOLLOWING: IR VALUE OF STATOR WDG./ HT CABLE TO EARTH IR VALUE BETWEEN PHASES IF NEUTRAL IS SAPERABLE RESISTANCE OF ALL WINDING AND BEARING RTDs STATUS OF DIAL THERMOMETERS, IF THESE ARE OK OR NEEDS REPLACEMENT. MAKE SUITABLE ARRANGEMENT OF PULLERS FOR COUPLING, FAN / FAN HUB, BEARINGS REMOVAL. KEEP ADVANCE PLANNING FOR STANDARD TOOLS AND CONSUMABLES LIKE GAS & TORCH, MARKIN/ LONG CLOTH etc TO MINIMISE WAITING TIME .

OVER HAULING OF AC MACHINES

INSPECTION- SLEEVE BEARINGS OIL PIPES TO BE DISCONNECTED ALONG WITH ITS ACCESSORIES LIKE FLOW INDICATOR, LEVAL GAUGE etc BEFORE REMOVING BOTTOM HALF LINER REMOVE THE FITTINGS LIKE RTD/ BTDs

REMOVE SPEED SWITCH,VIBRATION MONITORING PROBE FROM TOP HALF BEARING.

TAKE DUE CARE OF INSULATION IF THE NDE BEARING OR/ AND DE BEARING ARE INSULATED. PUT SUITABLE MATCH MARK BEFORE DISMANTLING BEARING ASSEMBLY

OVER HAULING OF AC MACHINES

INSPECTION- SLEEVE BEARINGS TAKE CARE THAT INNER BRG CAP & BEARING SEALS ARE NOT DAMAGED DURING DISMANTLING / HANDLING.

AFTER REMOVAL OF TOP HALF BRG. LINER OIL RING TO BE REMOVED, IF IT IS IN TWO HALVES.
NOW JACK THE SHAFT CENTRALLY IN AVAILABLE MINOR GAP & REMOVE BOTTOM HALF LINER BY SLIDING UPWARDS THOROUGHLY CLEAN THE BEARING, BRG. HSG./ PEDESTAL AND RINSE BY CLEAN OIL AND COTTON CLOTH. ALSO CLEAN THE ALL OIL PASSAGE HOLES. CHANGE THE BEARING OIL IF FOUND UNFIT FOR REUSE. CHECK & ENSURE PROPER FUNCTIONING OF FOL SYSTEM.

OVER HAULING OF AC MACHINES

INSPECTION-ANTIFRICTION BEARINGS DISMANTLE DE & NDE BEARINGS ONE AFTER THE OTHER IN THE FOLLOWING ORDER. BEARING SEALS,OUTER BEARING COVER, CIRCLIP, FLINGER, BEARING HOUSING (AFTER REMOVING HOLDING BOLTS & JACKING BY TWO SCREWS AGAINST END SHIELD SUPPORTING THE SHAFT PROPERLY) & BALL BEARING / INNER RACE ON DE AND ONLY INNERRACE FROM NDE SIDE WITH THE HELP OF SUITABLE PULLER. NOTE: NO DIRECT FLAME HEATING TOBE USED TO PULL OUT BEARING FROM SHAFT,INSTEAD HOT OIL CAN BE POURED FOR HEATING RACES OF BEARING.

OVER HAULING OF AC MACHINES

DE AND NDE END SHIELDS CAN BE UNSCREWED AND REMOVED BY JACKING OUT FROM SPIGGOT RACESS, SUPPORTING IT SUITABLY. NOTE:WHILE PUSHING OUT END SHIELD CARE TO BE TAKEN THAT AIR GUIDES (MADE OF FIBRE GLASS) ARE NOT DAMAGED NOW,STATOR WINDING CAN BE CLEANED THOROUGHLY AND FOLLOWING STEPS MAY BE FOLLOWED: VENTILATING DUCTS & OVERHANG PORTION OF WINDING TOBE CLEANED BY DRY COMPRESSED AIR. IF WINDING IS GREASY,CLEAN THE SAME BY CLEAN DRY CLOTH MANUALLY & IF REQUIRED USE SUITABLE MILD SOLVANT. CHECK AND ATTEND WEAKNESS IF FOUND ON BRACING/LASHIING, PUTTY, LEADS / JUMPERS etc

OVER HAULING OF AC MACHINES

DEPENDING ON THE CONDITION OF OVERHANG WINDING IT MAY BE APPLIED WITH EPOXY RED GEL COAT TO GET SMOOTH FINISH. BEFORE APPLYING RED GEL PREHEAT THE WINDING TO 50 DEG. C. ALLOW THE EPOXY RED GEL TO CURE BY LAMP HEATING. AFTER CURING, RECORD THE IR VALUE OF WINDING. ALSO RECORD THE RESISTANCE OF WINDING. SEQUENTIALLY NOW THE MACHINE MAY BE REASSEMBLED.

COMMISSIONING CHECKS FOR AC MACHINES (with antifriction bearings)

ACTIVITY M/c PART RECORDS ACCEPTABLE LIMIT REMKS RTD Res. St.&Brg. 1to12 & 1to 2 R to E Y to E B to E Ph to Ph 100 OHMS at 0 deg c (1 OHM=2.6 deg c) Min. 50 M Ohms Value in Ohms Use 1 kv megger

IR Value

Stator

when Neutral Separable To be equal in all phases By milliohm meter

Wdg Res

Stator / Rotor

Ph---m. ohms

COMMISSIONING CHECKS FOR AC MACHINES

ACTIVITY M/c PART RECORDS ACCEPTABLE LIMIT Lub check Brgs DE & NDE Ref relevant drawing REMKS GreaseServo Gem-3 OilVG-46 By Precision Lev. --------

Leval Check Dire. Of Rotation

Motor

---------

Should be 0.02mm/m

Motor

---------

Ref relevant drawing

COMMISSIONING CHECKS FOR AC MACHINES

ACTIVITY M/c PART RECORDS ACCEPTABLE LIMIT
Alarm & Trip Settings Term box

REMKS

St.Wdg & Ref relevant drawing Rotor Wdg Wdg-Alarm- 125 deg,Trip-130deg Brg-Alarm- 85 deg, Trip-90 deg

Note: 1. Alarm & Trip settings to be reset after sufficient period of run for the Wdg as well as Brg temp. as follows: Alarm- Temp Setting = # + 5 deg. C,| When # - Continuous operating Trip- Temp Setting = # + 5 deg. C,| temp at max. Amb. Temp. 2.Radial & Axial alignment should be within accuracy of 0.05mm.

COMMISSIONING CHECKS FOR AC MACHINES

3. Check all Electrical connections for tightness in ( Main Terminal box Aux. Terminal box, CT Secondary connections, Earthing etc)

4. Check &ensure tightness of all fixing bolts,nuts and screws.

5. Check the anchoring elements of machine for tightness.

6. Check the rotor shaft is free by manual rotation.

THANK YOU