Electrical Motor

MAINTENANCE PROCEDURE
R-3&4-EMP-50100-01
NUCLEAR POWER CORPORATION

(A Govt. of India Enterprise)
RAJASTHAN ATOMIC POWER STATION 3&4

ELECTRICAL MAINTENANCE UNIT
MAINTENANCE PROCEDURE FOR ELECTRICAL MOTORS

(PROCEDURE NO. R-3&4 EMP5010001)
Prepared by : (C.P. Sharma) SO/E (EM)

Checked by & Reviewed By : Approved by :
(Vivek Jain) SME (E)

Revision No. Rev 0 Date March, 2002 Prepared/Revised By Reviewed By
(P.K.Datta) MS
Approved By
Rev. No. 0 Feb. 2002
-1-
R-3&4-EMP-50100-01
INDEX
S No. 0.0 1.0 1.1 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9 1.3 1.3. 1.3.2 1.3.3. 1.4 1.5 2.0 2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 2.2.9 2.2.10 2.2.11 2.2.11.1 2.2.11.2 2.3 2.3.1 2.3.2 Rev. No. 0 Feb. 2002 TITLE Title Scope Category of Equipment/Maintenance Criteria General Description General Stator Rotor & Bearings Lubrications Bearing replacement Drying out End shield Fan & fan guards Terminal box Technical Details 1 Applicable Standards Quantity of Grease Quantity of Grease List of Equipment sub Assemblies List of References and Drawing Maintenance Procedure Condition Monitoring Preventive Maintenance Frequency of Preventive Maintenance Pre-requisite Tools/Instruments Required Consumable & spare requirement Man Power Required Expected time of completion Initial observation before starting the job Safety instruction and precautions Dismantling procedure Test on Equipment Return to service Re-assembly No load run Break down Maintenance Frequency of over hauling Pre-requisite -2PAGE No. 4 4 5 5 5 6 6 7 7 8 8 9 9 9 9 9 10 10 11 11 11 11 11 11 11 12 12 12 12 12 12 13 13 13 13 14 15 15
S No. 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.3.8 2.3.9 2.3.10 2.3.11 3.0 4.0
R-3&4-EMP-50100-01
TITLE Tools and special instrument Man Power Expected time of completion Consumables and spare requirement Initial observation before starting the job Safety instruction and precautions Dismantling procedure Test on equipment Return to serve Trouble shooting Annexure
Annexure-1 Annexure-2 Annexure-3 Annexure-4 Annexure-5 Preventive Maintenance Check list Preventive Maintenance Check list Preventive Maintenance Check list Preventive Maintenance Check list Preventive Maintenance Check list EMP-50100/01/PM/01 EMP-50100/01/BM/02 EMP-50100/01/PM/03 EMP-50100/01/BM/04 EMP-50100/01/BM/05
PAGE No. 15 15 15 15 15 15 15 18 15 16 18 19 23 27 30 34
-3-
0.0 TITLE : Maintenance procedure for Electrical Motors. 1.1 SCOPE:
R-3&4-EMP-50100-01
Approximately 2000 Nos. of LT / HT motor are installed alongwith pumps & fans in various systems in the plant. They are fed from HT / LT switchgears and MCCs, depending upon size of the motor and are reasonably protected against various expected faults. In order to ensure smooth operation of motors and also to prevent development or propagation of any deficiencies in the motors, they are being given preventive maintenance regularly. Still, if some motor breakdown, then it get rewinded / repaired. The scope of this manual covers maintenance requirements and procedural aspects of preventive & breakdown maintenance checks to be performed on motors. Apart from this manual, specific references is to be made to the relevant maintenance instructions of the respective manufacturer. The following make & sizes of motors are installed at RAPS-3&4 :i) HT (6.6 KV) Motors - M/s Kirloskar / NGEF / BHEL make of size above 200 KW to 2800 KW. ii) LT (415V) Motor - M/s Kirloskar / NGEF / SIEMENS/ GEC / BHARAT BIJLEE / CROMPTON GREAVES / ABB of sizes from fractional KW to 200 KW Details of important loads is as follows :-
S.No. 1 2 3 4 5 6 7 8 9 10 11 12 13
Description Primary circulating pump motor Boiler feed pump motor Condense extraction pump motor Active low pressure process water pump motor Chiller motor Condenser cooling water pump motor Primary feed pump motor Plant water pump motor HP Aux. Oil pump motor Active HP process water pump motor Moderator pump motor Shut down cooling pump motor Fueling machine supply pump motor
Make NGEF BHEL KEC NGEF NGEF KEC NGEF KEC BHEL NGEF Crompton Greaves Crompton Greaves NGEF
KW 2800 1450 720 335 435 965 350 720 375 170 132 80 93
Volt 6600 6600 6600 6600 6600 6600 6600 6600 6600 415 415 415 415
No. of motors (both Unit) 8 6 4 6 3 6 4 2 2 8 10 4 4
-4-
S.No. 14 15 16 17 18 19 Description Active process cooling water pump Auxiliary boiler feed pump motor Compressor motor Fire water pump motor ECCS pump motor Exhaust fan SFB, RAB, RB Make NGEF NGEF KEC NGEF NGEF GEC Alstom KW 160 130 140 100 130 125
R-3&4-EMP-50100-01
Volt 415 415 415 415 415 415
No. of motors (both Unit) 8 4 6 2 8 3
1.1
CATEGORY OF EQUIPMENT / MAINTENANCE CRITERIA:

Motors covered in this manual will fall under all categories of station equipment classification i.e. Category A, B, C or D, depending upon the respective process system. Frequency of maintenance of these motors, depending upon their usage, application, availability of shutdown accessibility to location etc., shall be i) Preventive Maintenance : Yearly- for safety related loads ( Cat. A) Two yearly- for non-safety related (Cat. B,C &D) Breakdown Maintenance : Need based
ii)
The above suggestive schedules may have to be reviewed for better performance depending upon factors like Running Time of the motor, maintenance intervals and lubrications intervals etc., as recommended by the respective manufacturer.
1.2 1.2.1
GENERAL DESCRIPTION : GENERAL

i) ii) iii) Ensure that the motor is isolated from the power supply source and physically confirm at the switchgear / MCC end Request MMU to take pre-maintenance alignment values, if required by them. Inspect the power terminal box for any abnormality, like loose connections, loosening of cable lugs, de-colorization of cables due to overheating or any other sign of overheating and disconnect the cable. Insulate the cable lugs with insulation tape. Note down the RYB sequence of terminal connections before disconnecting the cable. Do the disconnection of space heater, if provided, in a similar way, Ensure handling equipment / manpower are ready for shifting the motor to maintenance area. Request MMU to de-couple the load, Loosen the foundation bolts of the motor and remove it away from the platform. If any foundation packing material like copper shims or vibration arresting pads are provided, mark them with proper identification marks (which would help in relocationg them at the right place during reinstallation) and secure them at a safe place, vii) Shift the motor to the motor maintenance area or shop as required. Check pre-maintenance IR values of winding, Record the pre-maintenance value of winding resistance / inductance. Record space heater resistance and IR values, if applicable. Record the RTD / Thermistor values, if applicable. Prior to dismantling, make match marking on the stator body and the end shields on both sides, to avoid human error during reassembly, Remove the fan cover and subsequently the fan,
iv) v) vi)
viii) ix) x) xi) xii) xiii)
-5-
xiv) xv) xvi)
R-3&4-EMP-50100-01
xvii)
xvii)
Remove the coupling pully and secure it along with the key safely. Loosen the end shield mounting bolts diagonally and gradually, Use suitable pullers, wooden block or mallet while dismantling or assembling. Avoid using hammers in the process as these may damage end shield / motor body which are made of Cast Iron, Remove both the end shields. For large motors, suitable support should be provided to the shaft (while the end shields are being dismantled) so as to protect the shaft from getting bent or deformed, Separate the end shields, rotor and the stator bodies
1.2.2
STATOR
i) ii) iii) iv) Inspect the stator winding closely for any physical damage to the winding insulation / coils/ overhangs, Examine the inner surface of the stator slots for any abrasive marks, damage to the wedges etc., Ensure that winding overhangs are safely secured, Ensure terminal connections of the windings are healthy and tight. Take care to tighten the terminal stud nuts, lock nuts etc., and ensure flat and spring washers are positioned appropriately, Clean the stator core, windings, frames etc., with a suitable , lint free cloth etc., Measure resistance / inductance of the windings with the help of Motor checker and ensure these are balanced. If severe non-uniformity is found, locate the faulty winding and the location of fault by using a Growler. Rectify the fault if possible locally. Otherwise the motor must be sent for repair / rewinding and a spare motor should be put on the system, Check connection tightness of space heater connections and measure the resistance and insulation values, Check RTD resistance, if applicable and record their values along with ambient temperature at the time of testing, ix) Measure insulation resistance value of the winding and ensure it is more than 5 M ohm (when the stator is cold), If the insulation resistance is found to be below 2 M ohm, the motor should be dried out before returning to service. The methods of drying out are explained vide 1.2.6 of this manual. If Rotation Arrow plate is provided, ensure it is visible and clear and does not lead to any illusion.
v) vi)
vii) viii) ix) x) xi)
1.2.3
ROTOR & BEARINGS

i) Remove the dirt, dust from rotor by using brush cloth etc., or by compressed air / vacuum cleaner. Subsequently clean it with kerosene thoroughly. Inspect the cage rotor bars for any cracks or slackening, Ensure shorting rings at both the ends of the rotor are healthy and no sign of cracks is present. Inspect the bearings carefully and ensure they are free from any defect (If found defective, replace both the bearings as per procedure given in para 1.2.5). If the old grease is found to be dirty or deteriorated, greasing should be done afresh, as per the procedure laid down in 1.2.4 of this manual. Do the lubrication just before reassembly. Inspect the coupling key/ key way for any defect or damage, Whenever bearings are replaced, ensure inners of bearings covers are in place before installing new bearings on to the shaft. Follow procedures laid down in 1.2.5 of this manual during bearings replacement.
ii) iii) iv)
v)
vi) vii)
-6-
1.2.4 LUBRICATION
R-3&4-EMP-50100-01
Normally the original grease need not be removed unless it has become dirty or has deteriorated. The hands must be perfectly clean and smeared with good quality mineral oil before any bearing is handled. A small quantity of old grease will unavoidably be left in the bearings (when old grease is wiped out from the bearing) and if this is clean and in good condition it should be left rather than washed out with petrol. A good bearing can be ruined by rotating in the absence of lubricant. When washing out is essential, it should be carried out in a bath of clean benzene or petrol to which a small quantity of lubricating oil has been added. Before bearing is packed with grease, a few drops of clean lubricating oil should be introduced into the bearing. Never over-grease any bearing which may lead to overheating and spillage. Lithium based multipurpose grease conforming to grade 3 o f IS-1002-1956 amended up to date is recommended for all rotating machines fitted with anti-friction bearings. The approved grease among others is Castrol Ball Bearings Grease AP-3. The safe operating temperature for the above grease is 25C to 120C (approx. value)
1.2.5
BEARING REPLACEMENT
1) Removal of Bearings
The bearings along with its housing should be removed from the shaft using bearing puller, otherwise the bearing may get damaged. The endshied and the external bearing cap must first be removed, and then the small retaining screw in the split locking collar must be loosened, after which the collar can be unscrewed. If any difficulty is experienced, widen the split in the locking collar with say a screw-driver. The tapped holes in the housing may be used for fixing the withdrawing gear, studs and equal pressure must be put on each nut, otherwise the internal bearing cap may be distorted and damaged. When dismantling the inner ring of a ball bearing from the shaft on no account must the bearing be knocked off the shaft by hitting the outer ring of the bearing. The housing and the bearing may then be separated without any difficulty as a push fit is employed. 2)
Cleaning of Bearing
The bearing should be washed to remove all traces of old grease and dirt or foreign matter that may have crept in. The use of goods quality solvent or a mixture of eight parts of white spirit to one part of light grade machine oil is recommended for washing. Where a solvent is used for washing, all the parts should be dipped in good quality light machine oil after the washing is completed. If not immediately re-used, protect the bearing with grease paper wrapping.
3)
Assembly of Bearing
Ensure that all the parts are handled carefully to avoid entry of foreign particles. A bearing should not be removed from its housing until it is required for use. After cleaning the housing it should be smeared lightly with the specified grade of grease. In the case of roller bearing lay the housing flat on a clean level surface and insert the bearing outer ring by applying even pressure to the ring. Ensure that the bearing remains Square in the housing through out this operation. It may be necessary to tap the outer ring lightly into the housing in the final stage.
-7-
R-3&4-EMP-50100-01
Next slip the inner bearing cap correctly over the shaft after a small quantity of grease has been applied inside it. The inner ring of the bearing may now be fitted over the shaft by heating the bearing in a mineral oil to a temperature not exceeding 100C to enable easy mounting. Fit the split locking collar correctly on the shaft to clamp the inner ring, close the split on the collar by a gently blow on the same, and tighten the remaining screw firmly. Re-lubricate all parts as detailed in Appendix-2. Assemble the endshield containing the outer ring of the bearing and fasten to the inner bearing cap. Rotate the bearing housing by hand in both directions to check if the running is smooth. If this is the case fit the outer bearing cap firmly to the bearing housing. A small gap MUST be visible between the flange of the external bearing cap and the housing this gap confirms that the outer ring of the bearings is firmly clamped to prevent its creep during operation.
1.2.6
DRYING OUT
A convenient method of Drying out is to block the rotor so that it cant rotate and apply a very low voltage of about 10% of the rated value to the stator terminals. The heat generated in the winding is not easily dissipated and one part of the winding may be exceedingly hot before another part had time to expel the moisture. This may be deviated to some extent by taking every precaution to exclude draughts for the exposed parts of the winding. Second method of drying out is to keep the motor in an electrical oven. But the temperature shall not be allowed to exceed 60C. Other options are (i) blowing of hot air (ii) using electric radiators (iii) placing of carbon filament lamps inside the m/c. When placing hot bulb, care shall be taken that it is not in contact with the windings. If it is not possible to reach sufficient high temperature the ventilation may be reduced by covering the stator with a tarpaulin. Whichever of the above method of drying out is adopted the heating shall be continuous and shall be carefully monitored to ensure that it does not attain a temperature sufficiently high to damage the insulation. The maximum safe temperature of the windings measured by thermometer is 90C. At the same time the temperature should not be allowed to fall too low as otherwise re-absorption of moisture would take place. The insulation resistance will be found to drop considerably as the motor warms up will reach the minimum and then remain constant for sometime depending upon the dampness of the machine and as the drying progresses the insulation resistance will gradually rise. The drying out shall be continued as long as the insulation resistance rises or until a sufficiently high value has been reached which should not be less than 2M ohm by 500 volts megger (for LT motors). During the drying out period, readings of temperature and insulation resistance shall be taken at least once an hour in order to see how the drying out is progressing. The temperature of the motor shall be kept as constant as possible, otherwise the insulation resistance readings may be misleading. After drying out, air drying varnish should be applied by brush on the winding surfaces only and this should be applied when winding is in hot condition to prevent absorption of moisture. The length of drying time depends on the amo unt of dampness but in any case it should be at least six hours.
1.2.7
END SHIELDS
i) ii) Clean the end shields thoroughly Inspect the bearing housings for any damage or any abrasive mark. The bearings should fit tight in the housing.
-8-
iii) iv)
R-3&4-EMP-50100-01
If any grease- filling holes are provided, ensure these are clean and not choked. Clean them thoroughly Also ensure air gap inspection holes (closed with threaded metal plugs), if any provided are clean.
1.2.8
FAN & FAN GUARD

i) ii) iii) iv) Clean the fan and fan guard thoroughly. Ensure balancing weights, if any, provided on the fan are intact Inspect the fan closely for any crack. Ensure key/keyway/locking screw of the fan is healthy.
1.2.9
TERMINAL BOX
i) ii) iii) iv) v) vi) vii) Clean the terminal box thoroughly, Inspect the lugs for de-colorization, lug afresh, if conductor strand found burnt, Inspect the lead coming out from stator, for any damage to the conductor, If so, it must be repaired by strengthening insulation or by re-lugging (for LT motors only) Check terminals to be intact, Check glanding to be perfect, For HT motors, check condition of HT kit to be OK, Check tightness of cable connections.
1.3 1.3.1
TECHNICAL DETAILS : APPLICABLE STANDARDS

All the motor maintenance activities and post-maintenance testing shall conform to the following Indian standards as per the latest revision : i) ii) iii) iv) v) vi) vii) viii) Performance & Testing Insulation Method of cooling Type of construction & mounting Terminal markings Vibration level & measurement Noise level Testing IS : 325 IS : 1271 IS : 6362 IS : 2253 IS : 4728 IS : 4729 IS : 6098 IS : 4029
1.3.2
QUANTITY OF GREASE
Quantity of grease required per bearing and the re-greasing intervals for normal motor is as per the following table : Type AM 132 160 AJ 160 Amount of grease in cm3 4,6,8, & 10 pole 12 1500 16 1500 2000 To be injected after running hours 2 pole 4 pole 6 & 8 pole
-9-
Type AM 180 200 225 250 280 315 355 AJ 180 200 225 250 280 315 355 Amount of grease in cm3 4,6,8, & 10 pole 20 20 20 20 20 25 25 35 35 35 40 40 750 1200
R-3&4-EMP-50100-01
To be injected after running hours 2 pole 4 pole 6 & 8 pole
1500
For motors used in chemical industries, refineries and other industries where acid, alkali and saline atmosphere are predominant and for motors with IP 55 protection the re-greasing interval should be reduced by 20% 1.3.3 QUANTITY OF GREASE Grease Qty. (in Grams) 20 25 30 35 35 40 30 30 35 40 40 50 Re-greasing interval 3000 RPM 1500 1000 1000 1000 1000 1000 1000 1000 1000 1500 RPM and below 4000 2500 2500 2500 2500 2500 2500 2500 2500
Bearing Size 6313 6314 6315 6316 6318 6319 N315 N316 N318 N319 N221 N321 NOTE :
ALL TWO POLE MOTORS SHALL HAVE C-3 CLEARANCE BEARINGS. FOR VH SERIES MOTORS, TOP BEARING SHALL HAVE SPHERICAL ROLLER THRUST BEARING, WHICH IS OIL LUBRICATED.
1.4
LIST OF EQUIPMENT SUB-ASSEMBLIES:
This maintenance procedure shall be applicable to all the electrical motors in various systems, along with their corresponding power cable. The following are various parts / sub-assembly of motor i) ii) iii) Rotor Stator Bearings
- 10 -
iv) v) vi) vii) viii) ix) x) xi) End shield Terminal box Pulley Space heater (for motor of rating 30 KW & above) Space heater terminal box (for motor of rating 30 KW & above) Cable end alongwith gland and termination kit (for HT cable only) Cable supporting structure. Fan & fan guard.
R-3&4-EMP-50100-01
1.5
LIST OF REFERENCES AND DRAWINGS:

1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) Load schedule User hand book for induction motors (Kirloskar) MI for PHT motor MI for BFP motor MI for CEP motor MI for main chiller unit MI for plant water pump motor MI for moderator pump motor MI for S/D cooling pump motor MI for Air compressor (Kirloskar) MI for PFP motor MI for CCW motor MI for NAPW motor MI for Fire water motor MI for moderator motor. (EM-855) (EM 556) (EM 545) (EM 584) (EM 194) (EM 635) (EM 444) (EM 672) (EM 190) (MM - 1241) (Central Doc cell - 2748) (MM - 351) (MM - 691) (EM-1208)
2.0
MAINTENANCE PROCEDURE:
The objective of maintenance is to ensure smooth operation of all the electrical motors.
2.1 2.2 2.2.1
CONDITION MONITORING:
Not Applicable
PREVENTIVE MAINTENANCE: Frequency of Preventive Maintenance:

Yearly for safety related equipment (Cat. A) Yearly for non-safety related equipment (Cat B,C &D)
2.2.2
Pre-requisite:
1) Work permit should be taken. 2) Proper isolation has been provided. 3) Proper tools & equipment are available. 4) Consumable are available
2.2.3
Tools & Special Instruments:

a) Megger ( 500 V for LT motors & 5 KV for HT motors) b) Motor checker c) Screw Driver d) Spanner e) Wire brush
- 11 -
2.2.4 Consumables and Spare Requirement:
i) ii) iii) iv) v) vi) vii) viii) ix) Cleaning agent Lubricant Contact grease (Electrically conducting) Winding / Core cleaner Rust remover (Nut bolts) Paint & varnish remover Varnish For pasting / sticking gasket Repairs of stator winding (Patch-up work)
R-3&4-EMP-50100-01
CRC, OKS Sentinel synthetic lubricant Servogem contact gelly Lotoxane (Arnold make) Rustolene (M/s Hard Castle & Ward Mfg. Co.Ltd.) Action 100 (M/s Gunjan Organics Pvt. Ltd.) CrownRed insulating varnish (M/s Stanvac chemicals (I) Ltd.) LOCTITE (M/s Loctite India Pvt. Ltd.) Epoxy gelcoat (Red) (Dr. Beck+ co.)
2.2.5
Man Power:
Supervisor 1 Technician 2
2.2.6
Expected Time of Completion:

8 Hour.
2.2.7
Initial Observation Before Starting the Job:

1) 2) 3) Check the motor terminals & lugs for any over heating marks. Check the motor internal leads and cable leads for any crack / damage of insulation. Any abnormality in motor.
2.2.8
Safety Instruction and Precaution:

1) 2) 3) 4) 5) Avoid using slide wrench, Never use plier for opening a bolt / nut. Put proper marking on TB cover plate before opening. The plate may be too heavy to be handled by one person. All nut-bolts should be kept at one place, duly segregated size wise. Discharge cable before touching the terminals, as the same may be having static charge. While pulling rotor out from the motor, no damage to starter core/ winding should be ensured.
2.2.9
Dismantling Procedure:
The sequence of dismantling motors is given below : 1) Before dismantling any machine, obtain permit to work from authorities. 2) If required, arrange a crane of sufficient capacity and height to lift off the motor and taking to maintenance shop, 3) Disconnect supply cables at the terminal box, detatch terminal box from cable spreading box and support the latter against falling, 4) Uncouple the motor from the driven machine, 5) Unfasten the foundation bolts or nuts and lift the motor for removed to maintenance shop or elsewhere for further disassembly. 6) Collect all the hardware like bolts/nuts, shims used below machine foot (for alignment) etc., and keep them separately. Do not mix them with ordinary hardware. 7) Remove the grease extractors if fitted to bearings and remove all the old grease collected in it.
- 12 -
8)
R-3&4-EMP-50100-01
9) 10) 11) 12) 13)
14) 15)
The dowel pins used for location of motor should be removed carefully. The dowel pins should be stored more carefully as these are required to ensure correct repositioning of motor after overhauling. Remove the external fan cover and fan where fitted. Remove any cowls, canopies or other fitments fitted on the endshields. In the case of slipring motor, remove the slipring cover and dismantle the brushgear carefully. The slipring stud nuts are all the brass, store them carefully away from other steel hardware. Remove the endshields after the removal of fastening bolts, making use of the endshields removing screws provided. For bigger size of motors remove the rotor with the help of a crane. Ensure that this is done very carefully and that the rotor does not touch the stator winding overhand during this process to prevent damage to the windings. Remove any accumulated dust or dirt with a dry soft brush or bellows. Remove the outer bearing caps and the bearing housing at both ends and remove also all old grease from bearings to expose them.
Note : Where the bearings are oil lubricated, drain the oil before removing the bearing housing or endshield.
2.2.10 Test on Equipment:

Preventive maintenance test are to be carried out as per the following check lists : 1) EMP/50100/01/PM/01 - PM of HT Motor 2) EMP/50100/01/BM/02 - BM of HT Motor 3) EMP/50100/01/PM/03 - PM of LT Motor 4) EMP/50100/01/BM/04 - BM of LT Motor
2.2.11 Return to Service: 2.2.11.1 Re-assembly

1. 2. The procedure is practically the reverse of that followed for dismantling. After the assembly is completed, check the concentricity of the air gap through the air gap inspection holes, and close these with the plugs provided. Ensure that the rotor can rotate freely. Any difficulty in rotating the rotor or any unusual noise should be taken as sign of interference between stationary and mo ving parts. In such a case investigate and eliminate the cause of the trouble. Check the insulation resistance again. Realign the machine with the load but do not couple. Reconnect the machine to the supply cable acording to the terminal connection diagram fixed inside the terminal box cover. Ensure that the supply cable sockets make intimate contact with the motor cable sockets in the case of low voltage terminal box, there must be NO nut or washer of any kind between the sockets.
3. 4. 5.
2.2.11.2
No load Run :
1) A transient kick start may be given to ascertain the direction of rotation. If it is incorrect, stop the motor and inter change the connections to any two phases in the terminal box. Re-start the motor and examine carefully for any evidence of unusual sound, vibration, electrical or mechanical fault conditions and undue temperature rise of the bearings. Run the motor in uncoupled
- 13 -
R-3&4-EMP-50100-01
conditions and check the vibration level. Vibration measured on no load must be within 25 microns (peak to peak). Then run the motor in uncoupled condition with half-coupling pulley mounted on the motor shaft extension and check the vibration level. This vibration shall also be within 25 microns (peak to peak). Measure the no load current, though out its No Load run at a fixed regular intervals. The No Load current should remain constant and as thumb rule would be equal or less than 40% of full load current of the motor. Record the observations as per PM check list. No Load run for big motor shall preferably to done for a period till its bearing temp. stop rising further. This period may be 4 to 8 Hrs. 2) Couple the motor with the driven machine. Check that the driven machine is not loaded but see above point-1 for vertical high thrust motors. Start the motor and examine carefully for any evidence to unusual sound, vibration, electrical or mechanical fault. If no abnormality is observed, run the motor for a few hours. Check the bearing and the body temperatures. Load the driven machine. As far as possible increase the loading gradually. Allow the motor to run under full load conditions for a few hours, provided there is no indication of fault any where. During this period note the current drawn by the motor and the speed and check that the current does not exceed the rated value as stated on the motor name plate. If it does, reduce the load or stop the motor and determine the cause. It could be that the voltage is lower than that specified or the motor may have been overloaded. The motor should not be restarted until the cause of this problem has been eliminated. Check the vibration level in coupled condition on load. The increase in vibration level on load over that measured on no-load (in uncoupled condition) should not exceed the value given in the following table. Allowable increase in vibration amplitude (peak to peak in mm) when the motor is coupled to the load and tested over the vibration amplitude of motor tested in uncoupled condition. Synchronour speed re/min 3600 3000 1800 1500 1200 1000 900 750 720 600 500 428 375 Increase in vibration amplitude (peak to peak) microns 5 6 9 11 12 14 15 16 16 18 20 25 26
3)
2.3
BREAK DOWN MAINTENANCE :

Despite all precautions and preventive maintenance, if the motor insulation fails, then the motor is taken out for breakdown maintenance.
- 14 -
2.3.1 Frequency :
As and when required.
R-3&4-EMP-50100-01
2.3.2
Pre-requisites:
1) 2) 3) 4) Work permit is available Proper isolation has been provided Proper tools and equipment are available Consumables are available
2.3.3
Tools & Special Instrument:

Winding machine, former, brazing tool, oven screw guage, motor checker, spanner set, screw driver set.
2.3.4
Man Power:
Supervisor 1, Technician 2
2.3.5
Expected Time of Completion:

Not Applicable
2.3.6
Consumables & Spare Requirement:

Copper wire, insulating paper, binding wire, RTD, Lugs, varnish, PVC sleeve, bearings.
2.3.7
Initial Observation Before Starting the Job:

1) 2) Check the repairability of the fault. Efforts should be made to determine the root cause of failure of the motor. Any foreign material if recovered inside motor, the same must be immediately reported.
2.3.8
Safety Instruction & Precautions:

1) Prior to start of rewinding, hot spot in stator, if any, must be removed, 2) RTDs should be inserted during rewinding, 3) Winding coils must be properly tagged
2.3.9
Dismantling Procedure:
As envisaged in para 1.2.1
2.3.10
Test on Equipment:
As per check list No. 1) EMP/50100/01/BM/02 2) EMP/50100/01/BM/04 - BM of HT motor - BM of LT motor
2.3.11
Return to Service:
As per para 2.2.11
- 15 -
3.0
S.No. 1.
R-3&4-EMP-50100-01
TROUBLE SHOOTING:
Trouble Hot Bearing (General) Cause Excessive belt pull Pulley too far away Pulley dia too small Misalignment Bearing running dry Insufficient grease Excess lubricant Over loaded bearings Broken ball or rough races Motor connected but does No supply voltage not start One phase open Voltage too low Motor may be over loaded Control gear defective Starting torque of load is too high Remedy Decrease belt tension Move pulley closer to bearing Use larger pulley Correct by realignment of drive Re-grease the bearing Maintain proper quantity of grease in bearings Reduce quantity of grease (Bearing should not be filled more than half) Check alignment, side thrust and end thrust Replace bearings Check voltage on each phase Reduce load or try to start uncoupled from load Examine each step of the control gear for bad contacts or open circuit. a) If of squirrel cage type and with auto transformer starting, change to higher tap, b) If it is slipring type, lower the starting resistance Look for broken rings Free brushes in holders, change worn brushes Test with Megger Check contacts and connections. Check for loose connections to line, to fuses and to control a) Examine overload t rips and see that they are set correctly to approx. 150% full load current b) See that the dashpots are filled with correct quantity of oil Consult factory for proper type -- --
2.
Hot Bearings Ball or Roller
3.
4.
Motor runs and then dies down
Rotor Defective Brushes are not down due to sticking or worn brushes Short circuit to earth Fault in starters or star delta switch Power failure Over load
5.
Motor starts sluggishly speed falls when load is put on
Not applied properly Voltage is too low at motor terminals because of line drop If wound rotor, improper operations of secondary resistance Starting load torque too high Broken rotor bars
----
Check the load characteristic with motor speed torque a) Look for crack near the ring. b) New rotor may be required as repairs are usually temporary
- 16 -
S.No. Trouble Cause Open primary circuit 6. Motor starts with difficulty Load too high on star connection or not at Supply voltage low all Burning of contacts in stardelta starter Stator heats up quickly and Stator wrongly connected takes a large no-load Phase Short current Multiple earth Motor overheats while Overload running under load Motor may have one phase open Shorted stator coil Faulty connection High voltage Low voltage Rotor rubs stator bore Foreign material in airgap Motor operated on load cycle not in accordance with the rating particulars indicated in the Name plate after Motor mis -aligned Weak foundation Coupling out of balance Driven equipment unbalanced Defective ball or roller bearings Bearings not in line Balancing weights shifted Wound rotor coils replaced Excessive end play
R-3&4-EMP-50100-01
Remedy Locate fault with testing device and repair Reduce load or use larger motor Check supply line and cables to motor Overhaul starter Check connection Rewind Short-Rewind Reduce load Check to make sure that all leads are well connected Repair and then check watt meter reading Correct the connections Check terminals of the motor with voltmeter Recondition the rotor, replace worn bearings Dismantle and remove obstruction Run the motor on duty for which it is designated
7.
8.
9.
Motor Vibrates connections are made
Re-align. Maintain within 0.03mm Strengthen base Balance coupling Re-balance Replace bearing Line up properly Re-balance rotor Adjust bearings or add washer. Use proper shim for alignment. Use vibration mounts dampen external vibration Remove interference Clean fan Tighten holding bolts Check and correct bracket fit or bearings Correct or renew bearings Give pulley drive details to factory and check its suitability Re-balance
10
Scraping Noise
11. 12. 13.
Magnetic noise Shaft end breaks or Stator Rotor rubbing Heavy vibrations
Fan rubbing fan cover Fan rubbing insulation Loose on bed plate Air gap not uniform Loose bearings Excessive radial loads due to pulley drives Rotor unbalance
- 17 -
4.0 ANNEXURE.
1) 2) 3) 4) 5)
R-3&4-EMP-50100-01
Preventive Maintenance Check list of HT Motors EMP/50100/01/PM/01 Breakdown Maintenance Check list of HT Motors EMP/50100/01/BM/02 Preventive Maintenance Check List of LT Motors EMP/50100/01/PM/03 Breakdown Maintenance Check list of LT Motors EMP/50100/01/BM/04 Preventive Maintenance Check list of LT Motors EMP/50100/01/BM/05
- 18 -
R-3&4-EMP-50100-01
RAJASTHAN ATOMIC POWER STATION-3&4 ELECTRICAL MAINTENANCE UNIT PREVENTIVE MAINTENANCE CHECK LIST OF HT MOTORS
Sheet 1 of 4 UNIT NO. EQUIPMENT TAG NO. CATEGORY FREQUENCY DATE CREW : R3/R4/R-3&4 : : A/B/C/D : YEARLY/TWO YEARLY : : SUPERVISOR-1 TECHNICIAN-2 CHECK LIST NO REVISION ISSUE DATE PREPARED BY APPROVED BY RUN/SHUTDOWN CONDITION TOOLS : EMP/50100/01/PM/01 : 1 : DEC. 2002 : C.P.SHARMA, SO/E : VIVEK JAIN SME (E) : : MOTOR CHECKER, 5KV MEGGER, VACUUM CLEANER, SPANNER SET, SCREW DRIVER SET, WIRE BRUSH. : INSULATION TAPE, CLEANING AGENT, MASKING TAPE, LUBRICANT
DURATION JOB
OF : 08 HOURS
MATERIAL
A)
PREREQUISITES: (i) (ii) (iii) (iv) (v) Work permit is available ( No. . Dt---------------) Proper isolation has been provided on CB Proper tools & equipment are available. Consumable are available. Inform RT lab and switchgear group for taking up PM of their area. -
Note :Always stand on rubber mats while working on bus bars. B) Sl. No. 1.0 GENERAL: i) Clean motor body, fan, earthing connection with vacuum cleaner / cloth and cleaning re-gent Clean PM CHECKS: DESCRIPTION DESIGNED / EXPECTED VALUE AS FOUND AS LEFT REMARKS
ii) Check foundation bolt for tightness iii) Check healthiness of cooling fan iv) Check tightness of both the earthing connections
Tight No damage & Clean Earth at both side
- 19 -
R-3&4-EMP-50100-01
UNIT NO. : R-3/R-4 Sheet 2 of 4 CHECK LIST NO. : EMP/50100/01/PM/01 DESIGNED / EXPECTED VALUE Clean / No damage Tight No deformity / damage / over heating No overheating No crack, Properly installed No wear & tear Properly installed AS FOUND
Sl. No. 2.0
DESCRIPTION Terminal Box (Phase side) a) Check general condition of the terminal box/chambers. b) Check tightness of lugs c) Check HT kit for any abnormality
AS LEFT
REMARKS
d) Check cable lug for any overheating/ decolourisation e) Check insulator, separator etc., for cracks and correct installation f) Check gaskets of terminal box 3.0 Terminal box ( Neutral side) (if outside the motor) a) Check general condition of the terminal box b) c) d) 4.0 Check tightness of shorting links Check insulator/ separators etc. for cracks and correct installation Check gasket of terminal box
Clean Tight No crack No wear & tear Properly glanded, all connection tight, No decolourisation No overheating Tight No deformity/ damage/ overheating Calibrated
Space Heater Check space heater cable glanding, connectiontightness & overheating CB end (Tightness of Cable) a) Check lugs for over heating sign b) Check tightness of lugs c) Check any abnormality in the HT termination kit
5.0
6.0
CB end (Relay) Check corresponding relay(s) is/are calibrated (By RT lab)
- 20 -
R-3&4-EMP-50100-01
UNIT NO. : R-3/R-4 Sheet 3 of 4 CHECK LIST NO. : EMP/50100/01/PM/01
C) MEASUREMENT & TESTING : Note : Cross check the present measurement with the commissioning / design data and if difference of the order of 5% or more is observed, this may be informed immediately to group-in-charge In the column "DESIGNED / EXPECTED VALUE", the values obtained in the previous measurement should be filled DESIGNED / EXPECTED VALUE (See note above)
Sl. No. 1.
DESCRIPTION i) Measure winding resistance in M ohm. R-Y Y-B B-R ii) Space Heater (iii) Winding inductance in mH R-Y Y-B B-R iv) Insulation Resistance at 5 KV DC (*) R+Y+B to Earth a) 15 sec b) 1 Minute c) 10 Minute d) PI v) Capacitance & tan delta (By RT lab) a) Capacitance ( R+ Y+B) to Earth b) Tan delta ( R+Y+B) to Earth vi) Insulation resistance of space heater at 500V DC
AS FOUND
AS LEFT
REMARKS
D)
AREA CLEANING: Clean the work area and remove all defective consumable, spares etc.
(*) QA check point for category A equipment (PM carried out by) NAME & Designation : SIGNATURE (with Date & Time) (Checked by)
- 21 -
R-3&4-EMP-50100-01
Feed Back Session
: To be filled by Supervisor or above. (Checking Authority) (Use extra sheets if space is not sufficient) Observation Remark Write the name & Qty.
S. No. 1. 2. 3. 4. 5. 6. 7. 8.
Description Consumable used Spares used Duration of job Man power used Entry done Setting changed Area cleaned Other abnormality
Write the actual duration Write the name of man power History file/CMMS file Write any setting changed Switchgear area cleaned
Name & Signature Checking Authority
Name & Signature Reviewing officers
- 22 -
R-3&4-EMP-50100-01
RAJASTHAN ATOMIC POWER STATION-3&4 ELECTRICAL MAINTENANCE UNIT BREAK DOWN MAINTENANCE CHECK LIST OF HT MOTORS
UNIT NO. EQUIPMENT NO. CATEGORY FREQUENCY DATE CREW : TAG : : : : : SUPERVISOR-1 TECHNICIAN-2 A / B / C/ D NEED BASED R-3/4 CHECK LIST NO REVISION ISSUE DATE PREPARED BY APPROVED BY RUN/SHUTDOWN CONDITION TOOLS : : : : : : : MOTOR CHECKER, SPANNER SET, SCREW DRIVER SET COPPER WIRE, PAPER INSULATORS, VARNISH, SOLDERING/BRAZING EQUIPMENT, PREFABRICATED HT WINDING Sheet 1 of 4 EMP/50100/01/BM/02 1 DEC. 2002 C.P.SHARMA / S.P.GUPTA SO/E SO/E VIVEK JAIN SME (E)
DURATION OF JOB
08 HRS. TO 40 MATERIAL HRS.
A) (i) (ii) (iii) (iv) B) Sl. No. 1.
PREREQUISITES: Work permit is available ( No. . Dt---------------) Proper isolation has been provided on CB / MCC cell Proper tools & equipment are available. Consumable are available. BM CHECKS: DESCRIPTION Name plate - Details of Motor a) KW b) Voltage c) Full load current d) RPM e) Frame size f) Make g) S.No. h) Connection i) Bearing j) Class of insulation Pre & post repair inspection a) Insulation Resistance (M ? ) R-E Y- E B-E R-Y Y- B B-R DESIGNED / EXPECTED VALUE AS FOUND AS LEFT REMARKS
2.
- 23 -
R-3&4-EMP-50100-01
UNIT NO. Sl. No. : R-3/R-4 DESCRIPTION b) Winding Resistance (? ) R1-R2 Y1-Y2 B1-B2 R-Y R-B B-Y Winding Inductance (mH) R1-R2 Y1-Y2 B1-B2 R Y R B B Y d) RTD Resistance at ____?C RTD 1 RTD - 2 RTD - 3 RTD - 4 RTD - 5 RTD - 6 RTD - 7 RTD - 8 e) Space Heater Resistance (in ohm) IR Value (m? ) Condition of bearings No rusting smooth operation No rusting, No damage parts Sheet 2 of 4 CHECK LIST NO. : EMP/50100/01/BM/02 DESIGNED / EXPECTED VALUE AS FOUND AS LEFT REMARKS
c)
f)
g) General condition of motor 3.
Repair / Overhauling / Replacement of part/ Rewinding All dismentaled Dismantling of motor with properly tagged proper identification Tag
- 24 -
R-3&4-EMP-50100-01
UNIT NO. Sl. No. a) : R-3/R-4 DESCRIPTION Cleaning of stator / rotor with cleaning agent & air blower and bearing with turpentine oil and pre-post cleaning inspection Stator Rotor Temp. Sensor Space Heater Bearing Oil supply unit c) Varnishing of stator by class "F" varnish d) Rewinding i) Size of wire ii) No. of wires / slot iii) No. of slots iv) Single / Double layer v) Make & class of insulation vi) Make & class of varnish e) Baking of stator core in oven at 130 ? C f) Details of work (other than rewinding) carried out (like shaft metalising, replacement of fan, any major repair etc.) Post repair / rewinding measurement Note : Any variation of 5% or more from design values, shall be informed to group engineer a) HV test (KV for 1 min) (R+Y+B) - E b) Insulation resistance at 5KV DC (*) i) 15 Sec ii) 1 Minute iii) 10 Minute iv) PI Capacitance & tan delta (at 1 KV AC) (*) i) Capitance (R+Y+B) to E ii) Tan delta (R+Y+B) to E Sheet 3 of 4 CHECK LIST NO. : EMP/50100/01/BM/02 DESIGNED / EXPECTED AS AS REMARKS VALUE FOUND LEFT
Clean Clean Clean Clean Clean Properly varnished
Completed
4.
? ? ? ?
100 M ? 100 M ? 100 M ? 1.8
c)
- 25 -
R-3&4-EMP-50100-01
UNIT NO. Sl. No. : R-3/R-4 DESCRIPTION d) No load current R - Phase Y - Phase B - Phase e) f) Speed Operation of motor As per Name plate Smooth without any noise & vibration Sheet 4 of 4 CHECK LIST NO. : EMP/50100/01/BM/02 DESIGNED / EXPECTED VALUE As per Name plate AS FOUND AS LEFT REMARKS
C)
AREA CLEANING: Clean the switchgear area and remove all defective consumable, spares etc. (*) QA check point for category A equipment
(BM carried out by) NAME & Designation : SIGNATURE (with Date & Time) Feed Back Session
(Checked by)
: To be filled by Supervisor or above. (Checking Authority) (Use extra sheets if space is not sufficient) Observation Remark Write the name & Qty. Write the actual duration Write the name of man power History file/CMMS file Write any setting changed Switchgear area cleaned
S. No. 1. 2. 3. 4. 5. 6. 7. 8.
- 26 -
R-3&4-EMP-50100-01
RAJASTHAN ATOMIC POWER STATION-3&4 ELECTRICAL MAINTENANCE UNIT PREVENTIVE MAINTENANCE CHECK LIST OF LT MOTORS
Sheet 1 of 3
UNIT NO.
: R-3/R-4/R-3&4
CHECK LIST NO.

REVISION ISSUE DATE
: EMP/50100/01/PM/03
: 2 : DEC. 2002 : C.P.SHARMA, SO/E : VIVEK JAIN, SME (E) : : MOTOR CHECKER, VACUUM CLEANER, SPANNER SET, SCREW DRIVER SET, WIRE BRUSH. : INSULATION TAPE, CLEANING AGENT, MASKING TAPE , LUBRICANT :
EQUIPMENT NO. CATEGORY FREQUENCY DATE
TAG : : : : A/B/C/D YEARLY/ YEARLY
PREPARED BY APPROVED BY TWO RUN/SHUTDOWN CONDITION TOOLS
CREW
SUPERVISOR-1 TECHNICIAN-2
MATERIAL
DURATION JOB A)
OF :
4 HOURS-UPTO 90 KW MOTOR 8 HOURS-UPTO 200 KW MOTOR
PREREQUISITES : i) Work permit is available ( No. . Dt---------------)
ii) Proper isolation has been provided on CB / MCC cell iii) Proper tools & equipment are available. iv) Consumable are available. v) Inform CB/MCC group & protection group for taking up the PM. B) PM CHECKS : Note : Always stand on rubber mats while working on Bus bar. Sl. No. 1. DESCRIPTION VISUAL INSPECTION : Thoroughly inspect motor body, earthing connection, fan, cable, lugs, terminals etc., for any damage, corrosion, dust deposition, loose connection, over heating, blackening and tension. CLEANLINESS/TIGHTNESS CHECKS a) Clean motor body, fan, earthing connection withvacuum cleaner/cloth and cleaning re-agent b) Check foundation bolt for tightness. DESIGNED / EXPECTED VALUE No loose connection / No damage / No over heating sign AS FOUND AS LEFT REMARKS
2.
Clean
Tight
- 27 -
R-3&4-EMP-50100-01
UNIT NO. : R-3/R-4 Sheet 2 of 3 CHECK LIST NO. : EMP/50100/01/PM/03 DESIGNED / EXPECTED VALUE Properly glanded, No tension, No overheating sign. Clean, No damage All connection tight & clean All connection tight & clean No overheating Sign, No loose connection No cracks, properly installed Installed no wear & tear Sealed AS FOUND AS LEFT
Sl. No.
DESCRIPTION c) Check general condition of the terminal box d) Checks power cable for glanding and inside condition. e) Check cable terminal tightness f) Check star / delta link tightness (If accessible) g) Check cable lug for any overheating / decolourisation h) Check insulator, separator etc., for cracks and correct installation i) Check gaskets of terminal box
REMARKS
j) Check extra holes for proper sealing
k) Check space heater cable for proper All connection tight glanding, connection, tightness etc. (for 30KW & above) l) Check cooling fan & cover for any No damage properly damage & correct installations. installed, clean m) Check tightness of both the earthing Earthed at both points points. n) At CB end, check connection of lugs for No over heating / No over heating sign / loose connection (for loose connection CB fed motors) o) Check that thermal overload relay is Set to _____A calibrated (for MCC fed motors) p) Check that motor protection relay is Comp leted calibrated (by RT lab) (for CB fed loads) q) Check that PM check of corresponding Completed MCC cell/ CB is completed.
C) : MEASUREMENT & TESTING Note : Cross check the present measurement with the conditioning / design data and if any difference more than 5% is observed this may be informed immediately to group-in-charge
- 28 -
R-3&4-EMP-50100-01
Sl. No. 1.
*To be filled from commissioning data / history file DESIGNED / AS DESCRIPTION EXPECTED FOUND VALUE i) Measure motor winding resistance in ohm. along with cable from source end. R-Y Y-B B-R Space heater resistance ii) Measure motor winding inductance in mH along with cable from source end. R-Y Y-B B-R iii) Measure motor winding I R at 500 V DC along with cable from source end. (**) a) (R+Y+B) to earth ? 20 ? b) Space Heater terminal to ? 20 ? earth
AS LEFT
REMARKS
D) AREA CLEANING: Clean the area and remove all defective consumable, spares etc. (**) QA check point for category A equipment. (PM carried out by) NAME & Designation : SIGNATURE (with Date & Time) Feed Back Session: To be filled by Supervisor or above. (Checking Authority) (Use extra sheets if space is not sufficient) S. No. 1. 2. 3. 4. 5. 6. 7. 8. Description Consumable used Spares used Duration of job Man power used Entry done Setting changed Area cleaned Observation (Checked by)
Remark Write the name & Qty. Write the actual duration Write the name of man power History file/CMMS file Write any setting changed Switchgear area cleaned
Other abnormality
Name & Signature Checking Authority Name & Signature Reviewing officers
- 29 -
R-3&4-EMP-50100-01
RAJASTHAN ATOMIC POWER STATION-3&4 ELECTRICAL MAINTENANCE UNIT BREAK DOWN MAINTENANCE CHECK LIST OF LT MOTORS
UNIT NO. EQUIPMENT NO. CATEGORY FREQUENCY DATE CREW DURATION OF JOB : TAG : : : : : : SUPERVISOR-1 TECHNICIAN-2 08 HRS. TO 40 HRS. A/B/C/D NEED BASED R-3 / 4 CHECK LIST NO REVISION ISSUE DATE PREPARED BY APPROVED BY RUN/SHUTDOWN CONDITION TOOLS MATERIAL Sheet 1 of 4 : EMP/50100/01/BM/04 : 1 : DEC. 2002 : C.P.SHARMA / S.P.GUPTA SO/E SO/E : VIVEK JAIN SME (E) : : MOTOR CHECKER, SPANNER SET, SCREW DRIVER SET : COPPER WIRE, PAPER INSULATORS, VARNISH, SOLDERING/BRAKING EQUIPMENT
A)
PREREQUISITES:
Work permit is available ( No. . Dt---------------) i) Proper isolation has been provided on CB / MCC cell ii) Proper tools & equipment are available. iii) Consumable are available.
B)
Sl. No. 1.
BM CHECKS:
DESCRIPTION DESIGNED / EXPECTED VALUE AS FOUND AS LEFT REMARKS
Name plate - Details of Motor k) KW l) Voltage m) Full load current n) RPM o) Frame size p) Make q) S.No. r) Connection s) Bearing j) Class of insulation 2. Pre & post repair inspection (*) Insulation Resistance (M ? ) R-E Y- E B-E R-Y Y B B-R (*) QA check point (post repairs) applicable for category A equipment
- 30 -
R-3&4-EMP-50100-01
UNIT NO. Sl. No. 2. : R-3/R-4 Sheet 2 of 4 CHECK LIST NO. : EMP/50100/01/BM/04 DESIGNED / EXPECTED VALUE R1 - R2 Y1 - Y2 B1 - B2 R-Y R-B B-Y v) Winding Inductance ( mH ) R1 - R2 Y1 - Y2 B1 - B2 R-Y R-B B-Y vi) RTD Resistance at _______ ? C RTD 1 RTD 2 RTD 3 RTD 4 RTD 5 RTD 6 RTD 7 RTD 8 vii) Space Heater Resistance (? ) IR Value (M ? ) viii)Condition of bearings xi) General condition of motor Repair / Overhauling / Replacement of part/ Rewinding a) Dismantling of motor with proper All dismantled identificationTag parts properly tagged b) Cleaning of stator / rotor with cleaning agent & air blower and bearing with turpentine oil and pre-post cleaning inspection Stator Clean Rotor Clean Temp. Sensor Clean Space Heater Clean Bearing Clean Oil supply unit Clean AS FOUND AS LEFT
DESCRIPTION iv) Winding Resistance ( ? )
REMARKS
3.
- 31 -
R-3&4-EMP-50100-01
RAJASTHAN ATOMIC POWER STATION-3&4 ELECTRICAL MAINTENANCE UNIT BREAK DOWN MAINTENANCE CHECK LIST OF LT MOTORS Sheet 3 of 4
UNIT NO. Sl. No. : R-3/R-4 CHECK LIST NO. : EMP/50100/01/BM/04 DESIGNED / EXPECTED VALUE Properly varnished AS FOUND AS LEFT
DESCRIPTION c) Varnishing of stator by class "F" varnish d) Rewinding i) Size of wire ii) No. of wires / slot iii) No. of slots iv) Single / Double layer v) Make & class of insulation vi) Make & class of varnish e) Baking of stator core in oven at 130 ? C f) Details of work (other than rewinding) carried out (like shaft metalising, replacement of fan, any major repair etc.)
REMARKS
Completed
4.
Post repair / rewinding measurement With stand Note: Any variation of 5% or more from design successfully value shall be informed to group engineer. g) HV test (1KV for 1 min) * (R+Y+B) to E b) No load current As per name plate details R phase Y phase B phase c) Speed As per name plate details d) Operation of motor Smooth without noise & vibration * - QA check point for category A equipment. C) AREA CLEANING: Clean the area and remove all defective consumable, spares etc.
(BM carried out by) NAME & Designation : SIGNATURE (with Date & Time)
(Checked by)
- 32 -
R-3&4-EMP-50100-01
UNIT NO. Feed Back Session : R-3/R-4 Sheet 4 of 4 CHECK LIST NO. : EMP/50100/01/BM/04
S. No. 1. 2. 3. 4. 5. 6. 7. 8.
Write the actual duration Write the name of man power History file/CMMS file Write any setting changed Switchgear area cleaned
- 33 -
R-3&4-EMP-50100-01
RAJASTHAN ATOMIC POWER STATION-3&4 ELECTRICAL MAINTENANCE UNIT PREVENTIVE MAINTENANCE CHECK LIST FOR VENTILATION FAN Sheet 1 of 2
UNIT NO. EQUIPMENT NO. FEEDER NO. TAG : : R-3/4 CHECK LIST NO. REVISION : EMP/50100/01/PM/05 : 0
ISSUE
DATE
CATEGORY
A/B/C/D
PREPARED BY APPROVED BY RUN/SHUTDOWN CONDITION
: S.KANDPAL/PRATEEK AGRAWAL SO/B SO/E : VIVEK JAIN SME (E) :
FREQUENCY
DATE
CREW
SUPERVISOR - 1 TECHNICIAN - 2
TOOLS/EQUIP
: SPANNER SET, ALLEN KEY SET, SCREW DRIVER, MALLET, PULLER : MARKENE CLOTH, LUBRICATION GREASE
DURATION JOB
OF
2 HOUR
MATERIAL
A) 1) 2) 3) 4) 5)
PRE-REQUISITE: Work permit is available. Drawings are available. Proper tools and instruments are available. Consumables are available. Before starting the job ensure isolation is been given. Description Cleanliness of ventilation fan Check for corrosion Tightness of fan blade on hub (No. __________ Dt. _______________) : __________________________________ : __________________________________ : __________________________________
:___________________________________ Expected value As found As left Remarks
S.No 1 2 3
Clean No corrosion on the blade Blade tight on the hub
- 34 -
RAJASTHAN ATOMIC POWER STATION-3&4 ELECTRICAL MAINTENANCE UNIT PREVENTIVE MAINTENANCE CHECK LIST FOR VENTILATION FAN
R-3&4-EMP-50100-01
Sheet 2 of 2 UNIT NO. EMP/50100/01/PM/05 S.No 4 : R-3/R-4 CHECK LIST NO. :
Description Tightness of hub and fan blade assembly on shaft Check for axial and radial play
Expected value Fan blade assembly is tight No play axially (ensured by key in key way) No play radially (ensured by circlip or tightening screw) Clearance ensured for free rotation of blade
As found
As left
Remarks
When mounting in duct check fan blade for clearance with duct.
(PM carried out by) SIGNATURE (Date & Time) Name & Desgn. : :
(Checked by)
Feed Back Session
S. No. 1. 2. 3. 4. 5. 6. 7.
Description Consumable used Spares used Duration of job Man power used Entry done in Area cleaned Other abnormality : :
Write the actual duration Write the name of man power History file/CMMS file Area should be cleaned
Signature Name Checking Authority
Signature Name Reviewing officer
: :
- 35 -

Electrical Motor

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Electrical Motor

Uploaded by

Copyright:

Available Formats

MAINTENANCE PROCEDURE

NUCLEAR POWER CORPORATION

RAJASTHAN ATOMIC POWER STATION 3&4

MAINTENANCE PROCEDURE FOR ELECTRICAL MOTORS

Prepared by : (C.P. Sharma) SO/E (EM)

(Vivek Jain) SME (E)

Rev. No. 0 Feb. 2002

Rev. No. 0 Feb. 2002

No. of motors (both Unit) 8 6 4 6 3 6 4 2 2 8 10 4 4

Rev. No. 0 Feb. 2002

Volt 415 415 415 415 415 415

No. of motors (both Unit) 8 4 6 2 8 3

CATEGORY OF EQUIPMENT / MAINTENANCE CRITERIA:

GENERAL DESCRIPTION : GENERAL

viii) ix) x) xi) xii) xiii)

Rev. No. 0 Feb. 2002

vii) viii) ix) x) xi)

ROTOR & BEARINGS

ii) iii) iv)

Rev. No. 0 Feb. 2002

Rev. No. 0 Feb. 2002

Rev. No. 0 Feb. 2002

FAN & FAN GUARD

TECHNICAL DETAILS : APPLICABLE STANDARDS

Rev. No. 0 Feb. 2002

To be injected after running hours 2 pole 4 pole 6 & 8 pole

LIST OF EQUIPMENT SUB-ASSEMBLIES:

Rev. No. 0 Feb. 2002

LIST OF REFERENCES AND DRAWINGS:

2.1 2.2 2.2.1

PREVENTIVE MAINTENANCE: Frequency of Preventive Maintenance:

Tools & Special Instruments:

Rev. No. 0 Feb. 2002

Expected Time of Completion:

Initial Observation Before Starting the Job:

Safety Instruction and Precaution:

Rev. No. 0 Feb. 2002

9) 10) 11) 12) 13)

2.2.10 Test on Equipment:

2.2.11 Return to Service: 2.2.11.1 Re-assembly

Rev. No. 0 Feb. 2002

BREAK DOWN MAINTENANCE :

Rev. No. 0 Feb. 2002

Tools & Special Instrument:

Expected Time of Completion:

Consumables & Spare Requirement:

Initial Observation Before Starting the Job:

Safety Instruction & Precautions:

Rev. No. 0 Feb. 2002

Hot Bearings Ball or Roller

Motor runs and then dies down

Motor starts sluggishly speed falls when load is put on

Rev. No. 0 Feb. 2002

Motor Vibrates connections are made

11. 12. 13.

Rev. No. 0 Feb. 2002

Rev. No. 0 Feb. 2002

Tight No damage & Clean Earth at both side

Rev. No. 0 Feb. 2002

Sl. No. 2.0

CB end (Relay) Check corresponding relay(s) is/are calibrated (By RT lab)

Rev. No. 0 Feb. 2002

Rev. No. 0 Feb. 2002