ES-14-902-05

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Electrical Rotating Machine Repair

ES-14-902-05

Version No. 5 Page 1 of 16

Document last modified: 11 December 2001. PDF Created: 10 November 2005.

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: ELECTRICAL ROTATING MACHINE REPAIR

Number: ES-14-902-05

Owner: Simon Orton

Authoriser: Phil Talbot

Version Details: Revision 5.

Eye bolt testing added. Sections 4.9i and 4.11.7 added, Appendix

2 "work performed" section modified to suit.Eye bolt testingadded. Sections 4.9i and 4.11.7 added. Appendix 2 section "work

performed" modified to suit.

TABLE OF CONTENTS

1. SCOPE........................................................................... .......................................................... ...... 3

2. STANDARDS.................................................................................. .............................................. 3

3. SERVICE CONDITIONS............................................................................................ ................ 4

4. TECHNICAL REQUIREMENTS.................................................................... .......................... 4

4.1 FRAME SIZE.......................................................... ......................................................... ...... 4

4.2 INSULATION AND TEMPERATURE RISE.................................................................... ... 4

4.3 TEMPERATURE DETECTORS ................................................................... ........................ 4

4.4 WINDINGS......... ........................................................... ........................................................ 5

4.5 ANTI-CONDENSATION HEATERS ....................................................... ............................ 5

4.6 BEARINGS AND LUBRICATION....................................................................... ................ 5

4.7 SHAFTS ............................................................. ........................................................ ............ 5

4.8 VIBRATION AND BALANCE QUALITY ............................................................ .............. 64.9 INITIAL INSPECTION .......................................................... ............................................... 6

4.10 DATA SHEETS .................................................. ........................................................... ........ 7

4.11 ASSEMBLY...................... ................................................................ ..................................... 7

4.12 PAINTING ........................................................... ............................................................ ...... 8

4.13 IDENTIFICATION TAG......................................................... .............................................. 8

4.14 REPAIR ORDER NUMBER TAG .................................................................... .................... 9

4.15 RATING PLATE.................................................. ........................................................... ....... 94.16 PERFORMANCE CHARACTERISTICS .................................................................. ........... 9

4.17 DOCUMENTATION............................................................. ................................................ 9

5. TESTING....................................................... ............................................................... ................ 9

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

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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

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1. SCOPEThis Standard defines the minimum requirements for the repair and testing of rotating electricalmachines at the Contractors works.

2. STANDARDSAustralian 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 6Pt 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 ePt 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 ThermalEndurance

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 General Requirements for Rotating Electrical Machines

BS5000 Rotating Electrical Machines of Particular Types or for Particular Application

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CSBP Engineering Standards

ES-14-102-12 Protective Coatings

ES-14-903-12 Electric Motors

3. SERVICE CONDITIONSMotors 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. TECHNICAL REQUIREMENTS4.1 FRAME SIZEFrame 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 RISEAll 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 DETECTORSWherever 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 kWWhere 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 kWAll 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 kWAll LV motors rated at 45kW and up to and including 190kW shall be provided with two sets of

PTC thermistor sensors, two per phase.

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4.3.4 LV Motors Rating: 200 kWAll 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 shallbe 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 WINDINGSAll 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 HEATERSWhere fitted, anti-condensation heaters shall be checked for operation and repaired/replaced if

necessary.

4.6 BEARINGS AND LUBRICATIONBearings 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 TypeBearings shall be of a sealed type by the following manufacturers:

FAG

SKF

4.6.2 Lubrication TypeMobil 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 SHAFTSShafts 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.

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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 QUALITYAll 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 INSPECTIONThe 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. Megger test windings and record results. Note condition of windings and record findings.

b. Inspect the following for mechanical damage:

End shields

Stator housing

Shaft extension

Mounting feet/flange

Terminal box housing

Fan cowling

Cooling fan

c. Check bearing fit - record type.

d. 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. Check and establish winding condition.

f. Check stator laminations for damage.

g. Check material of fan cowling. If made of plastic or fibreglass then remove and discard.

h. 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.

i. 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.

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4.10 DATA SHEETSAll rotating electrical machines shall be repaired as per the manufacturers specification and in

accordance with any additional technical details, specifications or modifications as indicated onMotor 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 ASSEMBLY4.11.1 Machined FacesMachine faces on end plates and bearing housings shall receive a rust preventative film such as

Tectyl 506.

4.11.2 Shaft ExtensionShaft 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 GasketsGaskets 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 SealsShaft 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 HousingsReplacement 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 TerminationLeads 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.

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4.11.7 Eye BoltsBased 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 ananti-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 PAINTINGRepaired 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. Metric, non-hazardous rated:

AS2700S G13 Emerald Green

b. Metric, hazardous rated (Ex e, Ex n, Ex d):

AS2700S X15 Orange

c. Imperial, non-hazardous rated:

AS2700S N53 Blue Grey

d. Imperial, hazardous rated:

AS2700S N53 Blue Grey with two stripes 100mm wide colour X15 Orange

around stator.

Note: 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.

4.13 IDENTIFICATION TAGPrior 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.

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5.1.2 LV Slipring Motorsa. 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.

b. Brush tension.

c. Rotor volts - open circuit.

d. Stator and rotor current - locked rotor (short circuit test).

e.

No load test.f. High voltage test as per AS1359.101 Clause 8.1.

g. Balance quality as per Section 4.8.

h. RPM at nameplate specified frequency.

5.1.3 HV Motors Squirrel Cage and Slipringa. Resistance measurement - at ambient temperature:

Phase to earth.


Stator winding resistance.

Thermistor resistance.

Rotor winding and slipring to earth.


Brush holders to earth.

Polarisation Index.

b. Brush tension.

c. Rotor volts - open circuit.

d. Stator and rotor current - locked rotor (short circuit test).

e. No load test.

f. Check phase sequence and terminal markings.

g. High voltage test.

h. Test all accessories for correct function.

i. Balance quality as per Section 4.8.

j. RPM at nameplate specified frequency.

5.1.4 DC Motors and Generatorsa. Resistance measurement - at ambient temperature.

1. Field insulation resistance.

(a) Shunt

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(b) Series

(c) Interpole

2. Field resistance

(a) Shunt

(b) Series

3. Commutator to earth

4. Commutator between segments

5. Brush gear to earth

b. Stall current test - with shunt field open circuit.

c. Overspeed and winding test per AS1359.101 Clause 8.5.

d. Tacho volts per revolution.

e. Commutation tests per AS1359.101 Clause 8.8.

f. Balance quality as per Section 4.8.g. RPM at nameplate rated voltage and current.

5.1.5 AC Generators - LVa. Resistance measurement - at ambient temperature.

Phase to earth.


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.

b. High voltage test as per AS1359.101 Clause 8.1.

c. Balance quality as per Section 4.8. Rotor balancing to be carried out prior to final assembly

of machine.

Note: The Contractor shall perform the following tests only if machine construction permits. Ifthe Contractor is unable to perform these tests, then CSBP is to carry out the tests when

recommissioning the unit after final assembly.

d. Brush tension - slipring and DC exciter machines.

e. No load test.

f. Full load test.

g. Momentary overload - AS1359 Part 41, Clause 41.4

h. Overspeed test - Clause 60.5 AS1359.

5.1.6 AC Generators - HVa. Resistance measurement - at ambient temperature:

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Phase to earth.


Auxiliary winding resistance.

Auxiliary winding to earth.

Auxiliary windings to phase windings insulation resistance.

Thermistor or thermocouples resistance and continuity.


Rotor winding to earth.

Sliprings to earth (where fitted).

Polarisation Index.

b. High voltage test per AS1359.101 Clause 8.1.

c. Balance quality as per Section 4.8.

d.

Check phase sequence and terminal markings.e. 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 :

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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 andlarger. The schedule shall be forwarded to the Company at time of dispatch of therepaired motor.

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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 Screwed

Haz/Area Rating: Ex n Ex e Ex d

WORK PERFORMEDHas Motor Been Previously Rewound? Yes No Unknown

Eye Bolt Hole Suitable for Re-Use? Yes No

New Bearing NDE New Bearing DE Rewind Armature

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 / /

MOTOR TESTING

All insulation resistance readings to be of one minute duration.

STATOR ROTOR/ARMATURE FIELD

INSULATION RESISTANCE INSULATION RESISTANCE INSULATION RESISTANCE

A-E: Sliprings/Commutator: Shunt to series:

B-E: To Earth: Shunt to earth:

C-E: Series to earth:

A-B: WINDING RESISTANCE I/pole to earth:

A-C: Between Sliprings

B-C: A-B: FIELD RESISTANCEB-C: Shunt:

WINDING RESISTANCE C-A: Series:

A1-A2:

B1-B2: NO LOAD TEST RUN-AMPS VIBRATION TEST

C1-C2: A: DE Bearing mm/sec:

B: Horizontal:

THERMISTOR RESISTANCE C: Vertical:

Set 1 Ohms: rpm: Axial:

Set 2 Ohms: NDE Bearing:

Horizontal:

Vertical:

Axial:Test Certified By: Signed Date / /

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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.

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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

Documents

ES-14-902-05