Catching Wind: TWMC, TECO Global R&DCatching Wind: TWMC, TECO Global R&DRRetretrofiofit Ft Faiailed Generled Generatorsators

The Royal Swedish Air Force is nowtraining its fighter pilots in their recentlycommissioned, state-of-the-art, Dynamic

Flight Simulator (DFS). The simulatorallows a pilot to "fly" as if being in the air-craft experiencing heavy g-forces, as well

as being able to see out-of-the-window scenery, targetsand other aircraft via thelarge monitors in the cockpit.

The DFS, located inLinkoping, Sweden, is basi-cally a full sized fighter cock-pit mock-up mounted in a 10-foot gondola at the end of a30-foot centrifuge arm that isdriven by a high-performancevertical DC motor. TWMCdesigned and supplied the1900 kW, vertical DC motorto California-based WyleLaboratories, who hadturnkey responsibility for theproject. Continued on page 2

TORQUE REPORTINSIDE THIS ISSUE:INSIDE THIS ISSUE:

TORQUE REPORT 1

* MA7200 Product Expansion ........ 3

* Rep. Gattis Visits TWMC .............. 3

* 2004 Tradeshow Update ............. 3

* TWMC Cyclists Ride, Raise Support

for Multiple Sclerosis .................. 3

* Don’t Be Caught Without A Spare ... 4

* TECO Tech Tip ............................. 4

* Bearing Lubrication Testing ........ 4

* MAX-E1, MAX-E1/31 Power

Fybroc Aquarium Project ........... 5

* Implats: Planning Ahead for

Expansion ................................... 5

* Lightning Strike Leads to On-time

Quality Repair .............................. 5

TORQUE REPORT

DECEMBER 2004DECEMBER 2004

TWMC Mining, Metals, and Marine General Manager, Jim Misage, takes atrial run in the new Dynamic Flight Simulator, which doubles as a fighter-pilottrainer and a medical laboratory for researching the stresses of high-g combat.

With petroleum and other fuelresources gradually diminishing,expansion to alternative and renew-able energy sources is becomingmore and more critical. Wind energyis an important and feasible renew-able energy source that is drawingmore attention and is increasing in itsapplications around the world.

TECO's Global R&D Center, headquartered atTWMC in Round Rock, Texas, has undertaken a proj-ect with a leading global wind energy company to retrofit failed, ASD-driven,double-fed 750 kW wind generators. Global R&D team members in Round Rock as wellas in Wuxi, China and Taipei, Taiwan have made joint efforts toward this project. Usingdetailed investigations of previous failures for existing installed wind generators com-bined with creative thinking, TECO's Global R&D team has come up with solid and inno-vative designs that not only solve the previous generator problems, but also meet the cus-tomer's most stringent wind generator requirements. Continued on page 2

TWMC DC Motor Powers AdvancedSwedish Air Force Flight Simulator

TWMC CompletesSaudi Aramco ValueEngineering Program

TWMC was one of only fourlarge electric motor companiesaround the world invited toattend and actively participate inSaudi Aramco's Project Supportand Controls Department ProjectPerformance Optimization ValueEngineering Program.

The week-long program washeld in Al-Khobar, Saudi Arabiain March of this year, and began

with a brief training programprovided by Saudi Aramcothat outlined the basic meth-ods of Value Engineering,emphasizing that the compa-

ny demands and expects largeelectric motors that employ

low life-cycle cost.After the training, the entire

group went through the firsttechnical Saudi Aramco specifi-cation, analyzing each paragraphto determine its validity and con-tribution to a product that wouldenjoy low life cycle cost.

Continued on page 2

Retrofitted750 kW wind

generator.

Value EngineeringCollaboration BringsPaybacks Continued from page 1

Designed for exceptional flexibility andrealism, the DFS doubles as a JAS 39Gripen fighter-pilot trainer and a medicallaboratory forresearching thestresses of high-gcombat. The sys-tem is capable ofs i m u l t a n e o u sacceleration, pitchand roll at thesame rate as anactual fighterplane, ensuring anexperience thatdiffers little from actual flight, and allow-ing pilots to pull up to 9g.

The DFS construction is unique in thatthe main axis is directly driven with a largevertical DC motor, and the arm is madefrom riveted aluminum,much like an airplanewing. The arm and gon-dola weight is supportedby a 10-foot diameterball bearing assemblythat transfers the loadingdirectly to the ruggedmotor stator structure.

During maneuvers, thehigh-torque TWMC DCmotor can deliver sevenmegawatts of peak

power in approximately 100 millisecondswhen the pilot pulls sharply on the simula-tor's cockpit control stick. The motor is

capable of supply-ing over one mil-lion foot-poundsof torque for thisdemanding appli-cation. Wyle hasdemonstrated thatthe performanceof the machineexceeds the toughs p e c i f i c a t i o nrequirements of

10g per second onset and offset accelera-tion rates, and the unit was actually testedto 15g per second acceleration rates.

Since its commissioning, an estimated160 pilots have used the DFS equipment.

TORQUE REPORT2

The group was then broken intoteams composed of Saudi Aramcopersonnel along with a mix of therepresentatives from all of the par-ticipating motor manufacturers.Each team worked in-depth on theparagraphs that had been identi-fied, and the group reconvenedafterwards to analyze each team'srecommendation. The action forchanging, or not changing, anyspecific paragraph was left up toSaudi Aramco.

During the week, the group uti-lized the same process and com-pleted reviews of the large induc-tion and synchronous motor speci-fications, along with several sub-specifications. The event conclud-ed with a detailed tour throughSaudi Aramco's on-site museum.

The invited motor manufacturerswere either a NEMA manufactureror an IEC manufacturer. TECO /TECO-Westinghouse Motor Companywas the only NEMA and IEC man-ufacturer invited. Delegates weresent from TWMC, as well as fromvarious TECO offices globally.

When asked for his thoughts onthe Value Engineering Process,TWMC delegate MichaelBachmeyer stated, "Any companythat uses the Value EngineeringProcess, and devotes the timerequired to conclude the process,will greatly benefit. The paybackscan be tremendous."

DC Motor ExDC Motor Exceeds DFS Rceeds DFS Requirequirements ements Continued from page 1

Retrofitting Success Demonstrates BearingInsulation Design Effectiveness Continued from page 1

The 30-foot centrifugal arm of the DFS is driven by a vertical DCmotor that can supply over one million foot-pounds of torque.

Participants in the week-long ValueEngineering Program at Saudi Aramcoincluded delegates from TWMC as well asvarious TECO offices globally.

In March of this year, the new TWMC wind generator prototype successfully passedthe numerous required witness tests at the TWMC plant in Round Rock. Installation ofthe wind generator was finished in July of this year in Iowa. Since then, the generator hasbeen running at full power and has been trouble-free.

Running onsite at full power also demonstrates the effectiveness of TWMC's new bear-ing insulation design concept, as bearings from other wind generator manufacturers havefailed in the past. The end user was impressed by the small size of the capacitance ofTWMC's bearing insulation. The bearing insulation capacitance is a very importantdesign parameter that stops high frequency bearing currents that are inherent for ASD-driven machines. Patent applications have been filed for TWMC's new bearing insulationand removal designs.

The success of this wind generator retrofitting project has allowed TWMC to penetratethe wind generator market worldwide. More wind generator projects are ongoing, anddesign concepts are continually being developed by the TECO Global R&D team.

Editorial Statement: “Torque Report” is a periodical publication of TECO-Westinghouse Motor Company. Its editorial mission is to inform our readership in the areas of motor application industries,as well as business and world affairs that have an impact on our mutual concerns. Comments, inquiries and suggestions should be directed to: Torque Report, TECO-Westinghouse Motor Company,

5100 N. IH-35, Round Rock, TX 78681 USA. Phone: 1-800-451-8798. FAX: 512-244-5512. E-mail: torquereport@tecowestinghouse.com. Website: www.tecowestinghouse.com.

Four new TECO-Westinghouse motorswere installed in anatural gas process-ing plant nearMonument, NewMexico. The 3250 HP,8 pole, 4 kV, WPIImotors are coupled toreciprocating compres-sors. TWMC workedclosely with Hanoveron this project.

Monumental Motors

TWMC sponsoreda team of 14 cyclists toparticipate in the 15thAnniversary HEB MS150 Bike To TheBeach bike tour eventthat took place fromOctober 2 - 3, 2004.

Approximately150 miles in length,the two-day bike tourstarted in San Antonio,

TX, with riders crossing the finish line in Corpus Christi, TXat the Texas State Aquarium.

Proceeds raised from the tour go to the National MultipleSclerosis Society - Lone Star Chapter. According to the MS 150website, "the mission of the National Multiple Sclerosis Societyis to end the devastating effects of Multiple Sclerosis. Through

its nationwide network of chapters, the NationalMultiple Sclerosis Society supports researchefforts, educates, provides a variety of empow-ering programs, organizes fund-raising events,and advocates for people with disabilities."

In addition to corporate sponsorship from TWMC, the teamalso received a sponsorship donation from MSC Software.This year, the team raised over $3,300 to go toward the totalevent goal of over $1.0 million. The team participated in thesame MS 150 event last year, raising approximately $2,000.

TWMC teams have participated in the last five annual MS150 Bike To The Beachevents, and plans are beingmade to form a team to ridein the upcoming BP MS 150Houston to Austin bike tour thatwill take place on April 16 -17, 2005.

For more informationabout the Texas MS 150bike tours, visitwww.ms150.org.

TORQUE REPORT 3

TWMCTWMC Cyclists Ride, RaiseCyclists Ride, RaiseSupport for Multiple SclerosisSupport for Multiple Sclerosis

2004 Tradeshow Update

Above: Members of the TWMC cycling teampulling into the finish at the MS150 Bike to theBeach event. Right: TWMC cycling team ridersduring the two-day tour.

TWMC recently announced the expansionof the MA7200 Variable Frequency Drive prod-uct line. The MA7200 AC Drive has beenexpanded from 20 HP to 40 HP at 230V andfrom 20 HP to 75 HP for 460V ratings.

The MA7200 utilizes sensorless vector tech-nology for precise speed and torque control fordemanding motor and drive applications. Otherkey features include an English LCD operatorthat can be used as a parameter copy unit, PIDcontrol function, and built-in pulse generatorinterface. All MA7200 ratings are available instandard NEMA 1enclosures, or canbe modified tomeet customer-specified packag-ing requirements.

NEMA 4 ver-sions of the MA7200will be in stock andavailable for sale inJanuary 2005. TheMA7200 NEMA 4product includes allof the features andfunctionality of the standard MA7200, but ispackaged in a compact NEMA 4 enclosure thatallows the end user to place the AC drive inmost washdown environments.

MA7200 ExpansionOn July 1, 2004, Texas State

Representative Dan Gattis visitedthe TECO-Westinghouse MotorCompany manufacturing facility inRound Rock, Texas. Taking anextended tour of the plant, Gattisasked many questions regarding thevarious processes he observed.

Gattis expressed appreciation forthe value of the Round Rock facility, not only to the local residents andeconomy, but also to the entire nation. Realizing that there are only a fewfacilities of this size and expertise, Gattis stated that the TWMC facility is astrategic asset to the health, energy and military needs of the United States.

Proud to have TWMC in his district, Gattis said that he would be work-ing closely with US Congressman John Carter (who visited the plant in2003) to be sure that both the state and federal governments are aware of theimportance of keeping this facility functioning at peak capacity.

Gattis Visits TWMC

In September 2004, TWMCparticipated in several tradeshows:

The Association for Iron & SteelTechnology (AIST) 2004 showtook place in Nashville, TN whereTWMC featured its DC and syn-chronous motor lines and steelmill table motors.

Held in San Francisco, CA,TWMC engineers presented tech-

nical papers and participated inindustry meetings at the Petroleumand Chemical Industry Committee'sIEEE/PCIC 2004 Conference.

TWMC wrapped up the monthin Las Vegas, NV at MINExpoInternational 2004, spotlighting itsDC motors for draglines, and theMAX-HT motor and SA7 starterfor crusher applications.

Texas State Representative Dan Gattis observesa rotor in the manufacturing process at TWMC.

In a time when productivi-ty is the top priority, spareparts and components for crit-ical machinery can play anintegral role in a plant's con-tinuous operation, in additionto helping to reduce unneces-sary downtime and additionalexpenses often associated withunplanned outages. Althoughmotors are designed for anextended life expectancy, manycomponents are subject to wearas the result of normal operation.

Take the following scenar-ios for example:

A 3000 HPmotor in Oklahomais at a local shopfor routine main-tenance during ascheduled shut-down, and it isdetermined that thein-board bearingrequires replace-ment. The bearingfor this 1968 vin-tage motor is anon-stock item andthe end user's shut-down is extendedfor two days whilethe bearing is sentout for re-pouring.The unplannedadditional days cost the enduser hundreds of thousands ofdollars in lost production.

A 7500 HP motor is givinga refinery in Philadelphia, PAintermittent starting problems.A TWMC Renewal PartsGroup employee assists alocal repair facility to identi-fy and source replacementcontrol wheel parts for theWestinghouse synchronousmotor that was built in 1984.

Since everyone does nothave the luxury of owning aspare motor for each criticalmotor in their plant opera-tions, an economical alterna-

tive is to keep an updatedinventory of critical compo-nents readily available forboth unexpected and plannedoutages. In one out of the twoinstances above, the end userwas fortunate that parts werein TWMC inventory. While itis virtually impossible toanticipate customer needs orto keep every possible compo-nent part in inventory, theTWMC Renewal Parts Groupworks with end users daily toefficiently respond and supply

them with the bestquality parts theyneed to maintainproductivity.

Beyond sup-plying replacementparts, TWMC'safter-market serv-ices include: shoprepair of largerotating apparatus,application andm a i n t e n a n c eproblem resolu-tions, engineeringstudies for designand/ or applica-tion verification,engineering stud-ies for uprates andmodi f i ca t ions ,

field startup services, drop-inreplacement components andsub-assemblies, contract man-ufacturing and onsite training.

With access to more than400,000 original designs anddrawings to large Westinghousemotors and generators manu-factured at the Round Rockand former Buffalo and EastPittsburgh manufacturing facil-ities, TECO-WestinghouseMotor Company is a suresource for genuine Westinghouseand TECO-Westinghouserenewal parts.

Plan ahead… don't becaught without a spare.

TORQUE REPORT4

In determining the proper temperature limits touse when setting a motor's bearing tempera-ture protection devices, the type of lubricant,not the bearing materials, should be used asthe restraining factor. This is because as thetemperature of the oil increases, the oil beginsto oxidize, resulting in a loss of its lubricatingcharacteristics. The specific temperature atwhich this lubrication breakdown takes placedepends on the type of oil and its addi-tives, but this temperature will bemuch lower than the maximumallowed by the bearing materials.

TECO Tech TipDon’t Be Caught Without a Spare...

When the Reliabil-ity Division of theirPort Arthur, TexasRefinery neededassistance withspecialized testing,Premcor (an inde-pendent petroleumrefiner) came toTECO-Westinghouse.Always looking fornew ways to improve, Premcor wanted to determine ifusing different manufacturers' brands of oils (in the sameISO grade) for bearing lubrication would have an impacton energy consumption.

TWMC provided modified test motors, coordinatedtesting with Premcor personnel, and recorded and ana-lyzed all of the data that was collected. Through thisextensive testing it was determined that in real-world con-ditions, across the cost spectrum, no single lubrication oilconserved more energy than the next.

TWMC is working with Premcor to present papers thatdiscuss the details of the research conducted at selecttechnical conferences in 2005.

TWMC is a sure source for geni-une Westinghouse and TECO-Westinghouse renewal parts.Above: Bearing Components.Below: Electronic Components.

Bearing Lubrication Testing

TWMC Test Engineer Bryan Evans workswith Premcor representatives in a study ofvarious bearing lubrication oils.

Home A LongWayFromHome...

Two large Totally-Enclosed-Air-To-Air-Cooled (TEAAC) motorswere recently manufactured by and shipped from TWMC to drivepropane compressors for a major U.S.-based integrated oil and gascompany. Rated at 6000 HP and 1800 RPM, these low in-rush motorsutilize a winding voltage of 13,200 volts. The complete package, withthe two motors, was delivered to the customer for a development proj-ect in Equitorial Guinea.

At Impala Platinum Holdings (Implats), mining, processingand refining platinum group metals (PGM) - primarily plat-inum, palladium and rhodium - and associated base metals areall part of the business. The group has extensive operations inthe Bushveld Complex in South Africa and the Great Dyke inZimbabwe, the two most significant PGM deposits in theworld, with total resources of 254 million ounces of platinum.

Impala Platinum Limited (Impala), Implats' primary operat-ing unit, placed an inquiry requesting a duplicate of an 8177HP, 34-pole synchronous motor. The original motors weredelivered in 1993 and were placed immediately into productionat the company's Rustenburg refinery. Pleased with the originalhorizontal ball mill motors, the customer started planning foradditional expansion in 1998.

The contract for the duplicate motor was accepted in Octoberof 2003, and manufacturing proceeded ahead of schedule withan early delivery of long lead-time items including bearingsand frame fabrication. Uponcompletion of construction, themotor received a comprehen-sive engineering test and wasshipped to the customer fiveweeks ahead of schedule.Although ordered as a sparemotor, future growth in itsZimbabwe operations givesImplats the flexibility to use thismotor at any of its facilities.

Implats produced about 3.7million ounces of PGMs in the2004 financial year, of which 1.9million ounces were platinum.

An advanced technology pumpmanufacturer, Met-Pro Corporation'sFybroc Division specializes in fiber-glass-reinforced centrifugal pumps thatare designed to handle corrosive andother difficult liquids. The largest singleorder in the company's history, Fybrocwill be supplying 180 corrosion resist-ant, fiberglass centrifugal pumps to anew aquarium being built in Atlanta,Georgia. TWMC was selected to supplyover 90 percent of the electric motorsthat will be used in the pump systems.

The TWMC motors, ranging from 5HP to 50 HP, are an integral part of theoverall pump systems that will be usedfor seawater circulation and filtration -both processes are critical to propermanagement of the aquarium's life sup-

port system. A mix of TWMC's MAX-E1 C-face and horizontal motors, as wellas MAX-E1/31 motors, will provide thenecessary flexibility at times when thecontrol system at the aquarium needs tovary the speed of any of the pumps.

Motor requirements for the projectwere quite stringent. However, FybrocPurchasing Manager Gil Hulme saidthat he "felt quite comfortable withTWMC's products and capability tomeet the required specifications."

"TWMC offers outstanding,efficient customer service,"said Hulme.

Scheduled to open in 2005,the $200 million GeorgiaAquarium is designed to looklike an ark, and will include

400,000 sq. ft. of aquatic exhibitions,with a total water volume of more thanfive million gallons of fresh and marinewater. It will be one of the largest aquar-iums in the U.S., featuring more than55,000 aquatic animals representingabout 500 species fromaround theworld.

TORQUE REPORT 5

MAX-E1, MAX-E1/31 Power Fybroc Aquarium Project

In August of this year,TWMC completed an urgentrepair on a 16,000 HP induc-tion motor driving the mainair blower at a major eastcoast oil refinery. A light-ning strike did more damageto the Westinghouse motor'sinsulation system than 27years of demanding service.TWMC was chosen for theemergency stator rewindbecause of its competitivebid, acceptable turnaroundtime, expert knowledge ofthe specific winding designutilized in the stator, and theability to perform the cus-tomer requested tempera-ture rise test (heat run).

Conductor material forthe new coils was orderedbefore the motor arrived atTWMC’s manufacturing andrepair facility in Round Rock,TX. Manufacturing of newOEM-design Thermalastic®

coils was completed by thetime burnout and stripping ofthe old coils from the stator

was finished, allowing wind-ing to start immediately.

After the rewinding andtwo-cycle Vacuum PressureImpregnation (VPI) process,the motor was reassembledand subjected to commercialoperating tests at full voltage,plus a heat run in accordancewith customer requirements.The repaired motor wasshipped 15 days after arriv-ing at TWMC's facilities,meeting the quoted turn-around time.

TWMC "completed a qualityjob, on schedule, meeting ourbest up-front expectations,and for the quoted price,"wrote the customer refinerymanager in a letter of appre-ciation. "A significant part ofour success in getting therefinery back on line after theAugust 11th lightning strikewas the outstanding responseby [TWMC’s] staff in com-pleting the repair of our16,000 HP Westinghousemain air blower motor!"

Lightning StrikLightning Strike Leads toe Leads toOn-time QualOn-time Qualiitty Ry Repairepair

Rotor placement for the 8177 HPduplicate synchronous motor.

MAX-E1 andMAX-E1/31 motors

were among those thatTWMC supplied for the

aquarium’s pump systems.

Implats: Planning Ahead for Expansion

CONEXPO - CON/AGGand IFPE 2005 Las Vegas, NV

March 15 - 19, 2005Booth 15205

TTORQUEORQUE RREPORTEPORTDDECEMBERECEMBER 20042004

5100 N. IH-35Round Rock, TX 78681

1-800-451-8798

If you are interested in receiving futureissues of TTORQUEORQUE RREPORTEPORT, please visit

www.tecowestinghouse.com/torquereport.htmor send an e-mail to

torquereport@tecowestinghouse.com.

Come see TWMC at theseupcoming conferences:

AHR ExpoOrlando, FL

February 7 - 9, 2005Booth 4936

AISTech 2005Charlotte, NC

May 10 - 12, 2005Charlotte Convention Center

Orange County Convention CenterOrlando,Florida • February 7-9, 2005

TWMC recently manufactured four 5500 HP,6.6 kV, 8 pole motors and four 4000 HP, 6.6 kV,8 pole motors for Santee Cooper, a large SouthCarolina power company. The Induced Draft(ID) fan TWMC motors were purchased for usein a Selective Catalytic Reduction (SCR) retrofitat the customer's 1200 MW generating station.

With TWMC's ability to build identical productsutilizing manufacturing plants in Round Rock,Texas and Taiwan, the decision was made to buildtwo 5500 HP and two 4000 HP motors at each ofthe two TWMC plants simultaneously in order tomeet the customer’s short delivery requirements.

The first 4000 HP motors shipped from RoundRock in September of last year and were installedin time for the station’s fall outage in October2003. Two of the 5500 HP motors went on line inNovember of this year, and according to TomKierspe, Santee Cooper’s Manager for Generation Projects, "with respect to themotors, the start-ups have been flawless and they have been running without issue."

TWMC Meets Short Delivery Requirementsfor Induced Draft Fan Motors

One of the eight Induced Draft (ID) fanTWMC motors installed at the customer’s1200 MW generating station.

The International ElectrotechnicalCommission (IEC) held its annualTechnical Committee (TC) 98 andTC2 meetings from October 11 - 14,2004 in Wuxi, China.

Hosted and co-sponsored by theTECO Group, the meetings broughttogether over 26 industry specialists fromcountries worldwide to develop inter-national standards related to electricinsulation systems and rotating machines.

TECO-Westinghouse Motor Companydelegates participated in the meetings,and represented the United States indiscussions in the insulation area.

TECO Group is committed to par-ticipate and support international tech-nical standard development. The IECis the leading global organization thatprepares and publishes internationalstandards for all electrical, electronic,and related technologies.

TECO Group Hosts Annual IECTC98/TC2 Meetings in Wuxi