GE 5GEB22 User Manual

GE Proprietary and Confidential Information

Transportation

1150 HP AC Drilling Motor, Model 5GEB22

Document No. GEK-91696, Rev. D

GEK-91696D

GE Proprietary and Confidential Information

1150 HP AC Drill

ing Motor, Model 5GEB22

© {2009} Genera General Electric Company and is disclosed in conﬁdence. This publication is intended for use by GE customers solely for purposes of operating and performing routine maintenance of purchased or licensed GE products, and it shall not be reproduced any form, in whole or in part, or used for any other purpose, or disclosed to third parties, without the express written consent of GE.

GE and Customer agree that the information contained herein does not purport to cover all details or variations in GE products or mation be desired or should particular problems arise that are not covered sufﬁciently for the user’s purposes, the matter should be referred to Gene ral Electric Company. Any applicable Federal, State or local regulations or company safety or operating r has no obliga tion to keep the material up to date after the original publication.

GENERAL ELECTRIC COMPANYEXPLICITLY DISCLAIMS ALL WARRANTIES OFACCURACY, MERCHANTABILITY OR FITNESS FOR ANY PURPOSE IN CONNECTION WITH THIS PUBLICATION AND USE THEREOF.

If you are not an authorized recipient of this publication, you are hereby notiﬁed that any perusal, use, distribution, copy- ing or dis following address: GE Transportation, Technical Publications Department, Building 14, 2901 East Lake Rd., Erie, PA 16531.

closure is strictly prohibited. If you have received this publication in error, please immediately return to GE at the

, redistributed, retransmitted, translated, abridged, adapted, condensed, revised or otherwise modiﬁed, in

to provide for ever y possible contingency with installation, operation or maintenance. Should further infor-

ules must take precedence over any information or instructions given in the Technical Documentation. GE

GEK-91696D

GE Proprietary and Confidential Information

1150 HP AC Drilling Motor, Model 5GEB22

CONTENTS

Page

1. GENERAL INFORMATION.......................................................................................................................................................................................... 4

1.1. INTRODUCTION........................................................................................................................................................................................................... 4

1.2. SAFETY INFOR

1.3. ATEX CERTIFICATION.................................................................................................................................................................................................. 4

1.4. INSTALLATION AND OPERATIONAL INSTRUCTIONS..................................................................................................................................... 5

1.5. MODEL DIFFE

2. CONTROLS AND INDICATORS................................................................................................................................................................................ 13

3. FUNCTIONAL DESCRIPTION................................................................................................................................................................................... 13

4. SCHEDULED M

4.1. MONTHLY SCHEDULED MAINTENANCEPROCEDURE..................................................................................................... ............................ 14

4.2. CLEANING THE MOTOR ............................................................................................................................................................................................ 16

5. REMOVAL AN

5.1. MOTORPREPARATION FOR SHIPMENT.............................................................................................................................................................. 16

5.2. DISASSEMBLY PROCEDURES............................................................................................................................................ ...................................... 19

5.3. INSPECTI

5.4. STEAM CLEANING.......................................................................................................................................................................................................28

5.5. STATIC ELECTRICAL TESTING.................................................................................................................................................................................. 29

5.6. ROTOR SUB

5.7. ROTOR INSTALLATION INTO THE STATOR FRAME .........................................................................................................................................35

5.8. MOTORBEARING CHECKS AFTER ASSEMBLY.................................................................................................................................................37

5.9. FINAL AS

5.10.FINAL ASSEMBLY OF ROTOR CONNECTION END (CE) COMPONENTS.................................................................................................. 39

5.11. ELECTRICAL RUNNING TESTS.... .............. .............. .............. .............. .............. .............. ........................................................................................ 39

5.12. HUB INS

6. SUMMARY DATA........................................................................................................................................................................................................... 44

6.1. DRILL MOTOR DATA....................................................................................................................................................................................................44

6.2. DRILL M

6.3. INSPECTIONDATA....................................................................................................................................................................................................... 47

6.4. SPECIAL TOOLS AND MATERIALS......................................................................................................................................................................... 47

MATION..............................................................................................................................................................................................

RENCES ...............................................................................................................................................................................................

AINTENANCE..................................................................................................................................................................................

D REPLACEMENT PROCEDURES ...............................................................................................................................................

ON AND REPAIR PROCEDURES ..........................................................................................................................................................

ASSEMBLY PROCEDURES...................... .............. .............. .............. .............. .............. .............. ......................................................

SEMBLY OF ROTOR DRIVE END (DE) COMPONENTS ................................................................................................................

TALLATION....................................................................................................................................................................................................

OTOR COMPONENT IDENTIFICATION................................................................................................................................................

GEK-91696D

GE Proprietary and Confidential Information

1150 HP AC Drill

ing Motor, Model 5GEB22

1. GENERAL INFORM

1.1. INTRODUCTION

This publication provides basic instructions for inspection, maintenance, and overhaul procedures the drilling motor model 5GEB22. Figure 1 represents the 5GEB22 motor with cooling blower and connection box. Figure 2depictsthe tools and materials required to perform the procedures.

For general

For drilling motor application da ta, refer to Table 8insection

This publication has signiﬁcant changes since the last release. Due to major changes, there are no revision bars.

5GEB22 grounding block and rotor lock for shipment. Also included in this publication are special

drilling motor information, refer to Table 9 in section

ATION

6.1.2. Drill Motor General Data

6.1.1. Drill Motor Application Data

in this publication.

Figure 1. 5GEB22 Drilling Motor with Blower and Connection Box.

1.2. SAFETY INFORMATION

Safety precautions, which must be observed when working on this equipment, appear throughout this publica- tion. WARNINGS indicate the potential for personal injury, and CAUTIONS indicate the potential for equipment damage.

1.3. ATEX CERTIFICATION

ATEX certiﬁcation applies only to those motors with the increased safety nameplate shown in Figure 3 .

NOTE: In order to maintain ATEX approval, only GE Transportation ori ginal parts shall be used as replace- ment parts.

Due to format changes, revision bars are not used.

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ing Motor, Model 5GEB22

Figure 2. 5GEB22 Drilling Motor Without Cooling Blower or Connection Box.

1.4. INSTALLATION AND OPERATIONAL INSTRUCTIONS

ING: Installation shall be in accordance with the instruction as deﬁned in E N 60079–14:2008 “Electrical

WARN apparatus for explosive gas atmospheres,Part14. Electrical installation in hazardous areas(otherthanmines)". Guard for couplings, belts, o r chains should be installed as needed to protect against accidental contact with

ing parts. Machines accessible to the public should be further guarded by screens, guard rails, etc., to

mov prevent the public from coming in contact with the equipment. Failure to observe these precautions may result in injury or death.

1. This machine is suitable for operation in typical oil well drilling industry rig environments including offshore platforms and mobile drilling units. Use the motor in the correct ATEX categor y only as indicated in Figure 3 . For other types of applications and environments, please contact your GE representative to determine suitability.

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1150 HP AC Drill

ing Motor, Model 5GEB22

DRILLING MOTOR MODEL NO. – 5GEB22

.ON LAIRES

COOLING–3000 SCFM AIR SUPPLIED BY BLOWER UNIT

CLOSED COOLING SYSTEM, IP56, TO MAINTAIN MAX. INTERNAL AIR TEMPERATURE OF 45 C

RATINGS S9 CONTINUOUS

PHASE 3 AC VOLTS (L-L) 587 AMPS AC 1380 1120 / 1048

RATER RPM 800 SHAFT HP 1400 1150 / 1075 MAX. FREQUENCY HERTZ 153 MAX OPERATING RPM 3000 CONSTANT HP 800–1800 RPM (600 VOLT L–LINE SUPPLY)

CONSTANT HP 800–2400 RPM (690 VOLT L–LINE SUPPLY)

INSULATING CLASS H

INGRESS PROTECTION

WITH 600 VOLTS MAINTAINED ABOVE 820 RPM

WITH 690 VOLTS MAINTAINED ABOVE 940 RPM

AMBIENT AIR MAX 45 C 45 C / 55 C

N WYEOITCENNOC

IP44 / 6424 LBS (2914 Kg)

IP56 / 7124 LBS (3238 Kg)

Figure 3. Safe Electrical Parameters for the 5GEB22 Motor.

2. It is the end user’s responsibility to ensure that the motor with steel components including shaft, stator frame, stator core, and rotor core, along with the blower and variable speed drive are installed in the correct

gnated area and will not be subjected to existing (or foreseeable) aggressive destructive substances.

desi

3. Periodic lubrication is not required on model 5GEB22 drilling motor between scheduled overhaul intervals

ause the bearings are grease packed and permanently sealed. Motor bearings MUST be replaced after

bec 25,000 hours of operation, which is 90% of calculated bearing life. All maintenance must be carried out in accordance with:

EN 60079–17:2003

— Electrical apparatus for expl osive gas atmospheres, Part 17. Inspection and

maintenance of electrical installations in hazardous areas (other than mines).

E-

50984

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ing Motor, Model 5GEB22

IEC 60079–19:2006

haul for appara

1150HPACDrill

— Electrical apparatus for explosive gas atmospheres, Part 19. Repair and over-

tus used in explosive atmospheres (other than mines or explosive industry).

4. Safe electrical parameters are deﬁned in Figure 3 and Figure 4 deﬁnes the safe environmental parameters for the drilli

ng motor model 5GEB22. The drilling motor may be operated in the presence of typical vibrat ion

levels encountered on land and offshore rigs.

CERTIFIED Ex e II T3 (T IEC 60034–1

SIRA 09ATEX3077X Year of Construction

1180

II 2 G c T3 Motor Model Number: 5GEB22 Maximum Current: 1800 AMPS (RMS) Ratio Max./Nom. (IA / IN) Current: 1.36 Safe Stall Time: 37 Seconds Temperature Protection Devices Must Be Set At 190

C (maximum)

DO NOT OPEN WHEN ENERGIZED

AMB

Figure 4. Safe Environmental Parameters for the 5GEB22 Motor.

1.4.1. Drilling Motor Model 5GEB22 Operational Requirements

The drilling motor requires:

–40 C to +55 C)

E-50985

1. The cable ﬁtted to the equipment must be capable of withstanding maximum temperatures of 230°F (110°C) at the cable entry point. No PVC type insulation is permitted.

2. The equipment must be supplied continuously with at least 3000 Standard Cubic Feet per Minute (SCFM) (84930 SLPM) of cooling air. The cooling arrangements must be suitable for the area in which it is installed. When ﬁtted to the equipment, the cooling arrangements must ensure that the equipment satisﬁes a degree of protection of at least IP44.

3. RTDs suppli ed with the motor are to be connected to intrinsically safe circuits to meet compliance of the Ex certiﬁcation for operation in a hazardous environment. The protective device must be suitably certiﬁed as compliant with the European Directive 94/9/EC as a Safety Relate d Device. These circuits are to be manually reset only and will trip (stop) the motor at 190 °C (374 °F).

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1150 HP AC Drill

1.4.2. 5GEB22MotorEquippedwithClosedLoopCoolingSystem

When the motor is equippe d with a closed loop cooling system, the cooling arrangement must ensure that the equipment satisﬁes a degree of protection of at least IP56. The motor must be used in accordance with the duties deﬁned in this certiﬁcate, with the water cooler supplied with coolant in accordance with Table 2 .

ing Motor, Model 5GEB22

TABLE 2. 5GEB22 CLOSED LOOP COOLING OPTIONS

Duty Minimum Water Flow Rate Max. Coolant Temp. (at cooler inlet)

S1 (continuous) S1 (continuous) S9 (Duty A) S9 (Duty A) 50 US gal/min (189.2 liters/min) 25.0 ºC (77 S9 (Duty B) S9 (Duty B) S9 (Duty B)

Duty Reference Speciﬁcation

1.4.3. Drive Systems Used with the 5GEB22

120 seconds on at 800 rpm, 1400 HP, 9200 lb/ft torque, followed by 90 seconds on at 80 rpm, no load. (S9 duty)

144 se rpm, no load. (S9 duty)

32 seconds on at 800 rpm, 1400 HP, 9200 ft/lb torque, followed by 30 seconds on at 800 rpm, no load. (S9 duty)

100 US gal/min (378.5 liters/min) 50 US gal/min (189. 2 liters/min) 100 US gal/min (378.5 liters/min)

100USgal/ 88 US gal/min (333. 1 liters/min) 50 US gal/min (189. 2 liters/min)

TABLE 3. 5GEB22 DUTY CYCLES

conds on at 669 rpm, 1150 HP, 9025 lb/ft torque, followed by 116 seconds on at 80

min (378.5 liters/min) 37.7 °C (99.86 °F)

33.0 °C (91.4 °F)

25.0 ºC (77 ºF)

33.0 °C (91.4 °F)

36.0º C (96.8 ºF)

28.0 ºC (82.4 ºF)

ºF)

The 5GEB22 motor shall be used w ith one of the drives indicated in Table 4 or as listed in the ATEX certiﬁcation. The drive outputs shall be limited to 1800 amps maximum .

TABLE 4. DRIVE SYSTEM LIST.

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MANUFACTURE MODEL

GE AC2000AW Variable Speed Drive

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GEK-91696D

ing Motor, Model 5GEB22

Cegelec Baut Unico Inc Type 2400 Series (Part #109341) with or w ithout a smoothing inductor

National Oilwell Varco

ABB

Offshore

M&I Type AC1350

Omron

eil

&MarineASA

GD3000E AC Dr

Ross Hill Model 6000

Ross Hill Model ABB ACS800 manufactured by NOV

ABB ACS600 manufactured by ABB

ABB ACS800 manufactured by ABB

Compact AC Dri ve P1030 with or without a smoothing ﬁlter

Compact AC Dri ve P1180 with or without a smoothing ﬁlter

Compact AC Dri ve P1300 with or without a smoothing ﬁlter

Compact AC Dri ve P1500 with or without a smoothing ﬁlter

Type OIDM G5M-5C00

Type OIDM G5M-5900

ive System

Stadt Automasjon Type 875TCX 6G2N0-AFE (limited to 586 Amps)

Stadt/ABB

Alstom MV3000 Converter

Siemens

Converter Type 2000-6-AC-2-00

6SE7241-IFQ20-3AB0-Z PWM Inverter

Sinamics S120 Bluedrive

6SE704 1-**** (see Figure 5 below)

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1150 HP AC Drill

ing Motor, Model 5GEB22

SIEMENS DRIVE IDENTIFICATION 6SE7041 - * * * *

RATED CURRENT INDICATOR: 0 = 1000A (M CHASSIS) 2 = 1200A (L OR M CHASSIS) 5 = 1500A (M CHASSIS)

DC LINK VOLTAGE INDICATOR: V = 930V (690V LINE-LINE) U = 780V (600V LINE-LINE)

CHASSIS INDICATOR: M L

DIGIT 2 OR 6

Figure 5. Siemens Drive Nomenclature.

1.4.4. Grounding Instructions

Ground failure in the machine.

WARNI condition in which serious or fatal injury from electrical shock is possible.

Grounding conductors must be provided between the machine frame a nd th e sup porting structure to avoid hazardous potential voltage difference between the machine frame and the adjacent surface on which a person may be standing while touching the machine

NOTE: This type of ground connection is referred to in electrical standards as “equipment ground" or “en- closure ground" which is not to be confu sed with “system" or “circuit" grounding. Drilling drive systems normally do not have an intentional circuit ground connections, except through high impedance detectors.

Grounding conductors must be provided on drilling units on which the construction on the unit and/or instal- lation of the machines does not inherently ensure positive grounding of the equipment. Examples are those portable (modular) platform rigs and land rigs which do not already have ground cables to all machinery struc- tures. Offshore rigs with equipment fastened to the decks by bolting or welding should not require additional grounding. Reference ABS Rules for Building and Classing Steel Vessels, section 4−8−4/23.3 and IEEE Standard 45−2002, Recommended Practice for El ectrical Installations on Shipboard, section 21.4.

ing motor frames is required to safeguard personnel from electric shock in the event of an insulation

NG: Failure to properly ground electrical equipment may expose personnel to a potentially hazardous

E-50871

1.4.5. Grounding Procedures

GE Proprietary and Confidential Information

The 5GEB22 has a ground blockattached totheframeasshowninFigure2 . The mounting stud is 3/8–16 thread. To attach a ground cable to the ground block:

1. Obtain a 3/8–16 nut and a lockwasher. Also required is a cable lug to ﬁt the ground cable and terminal hole clearance for the 0.375 diameter stud.

2. Prepare a ground conductor (use appropriate size cable per National Electrical Code) long enough to run from the motor frame to an existing ground conductor system or to a suitable equipment ground point as deﬁned by the National Electrical Code Article 250 or other applicable regulation. Check that the system ground detector is a lso connected to the Common ground point for the rig and make connection if neces- sary.

3. Install terminal lugs on cable. Remove paint, rust and oil from all surfaces to which the cables are to be attached and bolt the lugs securely to t hese surfaces. Torque the nut to 25 lb-ft (34 Nm).

4. After installation, protect the ground stud, nut, and cable lug connection from corrosion by applying a rust inhibitor on the exposed components.

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ing Motor, Model 5GEB22

1.4.6. Motor Coupling and Alignment

CAUTION: Be sure to align, or check alignment carefully on either motors or MG sets. Misalignment can cause excessive vibration and damaging forces on shaft and bearings.

Time taken to assure good alignment will be returned in reduced downtime.

.4.6.1.Coupled

On coupled drives, when a motor and adriven unit together have fourormorebearings, ﬂexible couplings should be used

CAUTION: Careful alignment of machines, when using either solid (rigid) or ﬂexible couplings, is essential to

nt excessive vibration, hot bearings, or shaft failures.

preve

Couplings must be properly sized to be capable of driving maximum machine t orque. Interference ﬁts should be used between motor shaft and coupling.

.4.6.2. V-Belt Drives

On V−beltdrives, thedrivinganddriven shafts shouldbelocated so that they areparallelandthe sheaves aligned. If properly aligned, there is minimum wear on the belts and no excessive thrust on the machine bearings. The sheave should be mounted as close as possible to the motor bearings. The following recommendations should be followed concerning the minimum sheave pitch diameter which can be used for the particular motor. The belt manufacturer should be consulted for the maximum speed ratio and belt for the particular application.

Drives

to facilitate alignment. Three−bearing construction requires a rigid coupling.

The following formula and dat a can be used to select the MINIMUM allowable sheave diameter from the stand- point of bearing life and shaft stress. A larger s heave will further reduce the shaft stress and bearing loading. This data is based upon the belts being tightened to a maximum total pull of 1.5 times the required transmission load used in the sheave diameter calculation. Belts should never be tightened more than necessary to transmit this torque.

D = HP/RPM X 189000/W

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1150 HP AC Drill

Where D = Minimum sheave pitch diameter in inches for V-belt application.

HP/RPM = Maximum ratio of hors epower, including overloads, to the speed which that power occurs.

W = Maximum allowable radial load.

Belt−driven machines may be equipped with sliding rails. Proper and constant belt tension is easily maintained and the replacement of belts is simpliﬁed. This reduces the operating cost a nd increases the efﬁciency. Sliding rails are to be used for ﬂoor mounting only.

Belt idlers reduce the life of the belts and should not be used if any other method is available. The belts should never be forced over the sheaves. W hen the drive is started and operating at full speed and full load, the take−up should be adjusted until only a slight bow appears in the slack side. If slippage occu rs after the belt tension has been correctly adjusted, the belts and p ulleys have not been chosen properly for the job.

CAUTION: Over−tightening to avoid this slippage may result in early failures of belts, shafts, and bearings.

Belt tension s hould be checked and adjusted following the belt manufacturer’s recommendations.

ing Motor, Model 5GEB22

There is n belts seat themselves in the sheave grooves and initial stretch is removed. Belt tension should be rechecked after a day or two of operation.

Matched belts run smoother,look better, and last longer. Longer belt life results if the belts and sheaves are kept clean and the belts are prevented from rubbing against the belt guards or other obstructions.

.4.6.3. Grouting

On conc

A rich, non−shrink grout should be used. High− grade grout mixtures are available commercially. If the grout is to be to give a stiff mixture. The clean, but rough surface of the foundation should be wet and the grout rammed or puddled under the base.

.4.6.4. Flexible Coupling Alignment Procedure

Leve should be checked as follows :

1. Remo

2. Check the coupling hub spacing is in accordance with the outline dimensions with the units in the mechan-

ormally a drop in tension during the ﬁrst 24 to 48 hours of operation. During this "run in" period, the

rete foundations, a minim um of one inch (25 mm) should be allowed for grouting.

prepared at the site, a cement−sand ratio of 1:2 is recommended. Just enough water should be used

l all mounting base supports before setting the base in position. Before grouting the base, the alignment

ve all coupling bolts a nd slide the shells back so the hub faces are exposed.

l center of their end play.

ica

3. Start with the coupling next to the largest unit (usually the motor) or near the middle of multiple units. Check radial alignment by using a straightedge across the two hubs at vertical and hori zontal. Or, clamp a dial

the indicator to one hub and use the outside diameter of the other member to give indication of the misalign- ment. Be sure the dial indicator supports do not bend or sag, since this will give inaccurate readings. The

ximum variation should not exceed 0.002 inches (0.05 mm).

4. Insert a feeler gage or use the dia l indicator at hub faces. Measure the gap between hub faces at 0, 90, 180

d 270 degrees and record. Rotate both shafts together 90 degrees and repeat the gap readings. Continue

an rotation in 90 degree inc rem ents until ﬁve sets of readings are taken. The ﬁfth set of readings is a check on

the ﬁrst set of readings to assure that data is reliable. The readings should not vary by more than 0.002

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inches (0.05 mm

5. Correct the horizontal alignment by shifting frames on the base and the vertical alignment by shimming between the ma

6. Repeat Steps 2, 3 and 4 on each coupling, working away from the motor or center unit.

7. Recheck the coupli ngs on long sets after completing the above checks, because shimming when checking subsequent units may affect those already checked. After the set has been aligned within the speciﬁed limits, the

1.5. MODEL DIFFERENCES

coupling shells may be bolted together.

TABLE 5. 5GEB22 MODEL DIFFERENCE INFORMATION

1150HPACDrill

) between the four readings taken at each coupling position.

chines and the base.

GEK-91696D

ing Motor, Model 5GEB22

5GEB22A1 Original d 5GEB22A2 Same as 5GEB22A1 except new rotor shaft material. 5GEB22A3 Same as 5GEB22A2 except new CE bearing.

2D1

B22D4

Same as 5

Same a

Sam

5GEB22A 5GEB22A5 Same as 5GEB22A3 except stator t erminal alignment. 5GEB22C1 Same as 5GEB22A2 except shaft lengthened and CE insulated bearing. 5GEB2 5GEB22D2 Same as 5GEB22D1 except without ABS sha ft certiﬁcation. 5GEB22D3 Same as 5GEB22D1 except stator terminal alignment. 5GE

esign 5GEB22.

GEB22A2 except stator t erminal alignment.

s 5GEB22A3 except rotor shaft diameter increase.

e as 5GEB22D2 except stator terminal alignment.

2. CONTROLS AND INDICATORS

t Appli cable to drill motor model 5GEB22. Refer to drive system instruction publications for controls and indi-

No cators.

3. FU

NCTIONAL DESCRIPTION

The Model 5GEB22 drilling motor is a force–ventilated, three–phase alternating–current induction motor de-

igned for use in the oil and gas industry to power offshore and land based drilling rigs. The normal function of

s the horizontally mounted 5GEB22A motor is to provide power for the mud pumps and drawworks. The 5GEB22D motor has an oversized shaft and is designed for belted horizontal applications such as mud pumps.

Motor speed is controlle d by varying the frequency of the alternating current in the motor stator windings. The direction of rotation of the motor rotor is changed by reversing the phase rotation in the motor stator.

The motor is force ventilated by a blower assembly, meeting IP44. It can also be provided with a closed loop cooling system meeting IP56.

4. SCHEDULED MAINTENANCE

Periodic mainten ance should be performed to ensure successful motor operation. The following procedures de- tail the procedures for Scheduled Ma intenance. The motor bearings do not require lubrication between overhaul intervals due to packed grease and permanently sealed bearings.

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NOTE: In order to maintain ATEX approval, only GE Transportation ori ginal parts shall be used as replace- ment parts.

4.1. MONTHLY SCHEDULED MAINTENANCE PROCEDURE

4.1.1. Covers, Seals, and Latches

WARNING: Hazardous voltages are present in this equipment. Follow shutdown procedures to ensure power is not applied to the machine before performing any maintenance procedures. Failure to do so may result in injury or death.

1. Remove all power from the machine before attempting maintenance procedures.

2. Clean the outside of the mach ine and remove the inspection covers.

ing Motor, Model 5GEB22

WARNING: W to personnel in the immediate area. Personnel should be provided with, and trained in the use of, protective equipment as speciﬁed by applicable federal or state safety regulations. Failure to do so may result in injury or death.

4.1.2. Power Cable Inspection

hen using compressed air for cleaning pu rposes, ﬂying debris and particles may present a hazard

3. Use clean, dry compressed air and blow the dirt and dust from the interior of the machine.

4. Check exterior covers to ensure the felt seals are intact. Replace seals if missing, broken, deformed or hard- ened.

5. Install the covers into position on the machine. Torque the cover bolts to 58 ±2 lb.–ft. (79 ±2,7 Nm).

During inspection of the power cables and associated hardware, replace any components that are damaged. Inspect the power cables for:

1. Inspect the cable terminals for discoloration from heat, arc damage, cracks or fractures. Replace terminals and/or cable if damage is found.

2. Ensure terminal connections are tight and arcing is not present.

3. Inspect cable insulation for cracked, worn, cut, bubbled or burnt insulation. Replace the cable if damage is found.

4. Check cable connection bushings and mounting hardware (such as cable cleats). Replace damaged or miss- ing hardware.

5. Check the ground cable connection to the motor frame. Ensure the connection is tight on the ground stud.

4.1.3. Megohmmeter Test

The insulation condition of the motor and cables can be determined by a megohmmeter test. When the high voltage of the megohmmeter test instrument is applied to the power components of the motor circuit, a high ohm reading i ndicates good insulation quality. Low ohm readings indicate insulation breakdown, moisture/de- bris contamination, or carbon tracking. To test the power circuit insulation with a megohmmeter:

1. Ensure all the components in the power circuit are not affecte d by a megohmmeter test. Check the drive system for megohmmeter test procedures or disconnect power cables from the drive system. If cables are

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disconnected for the megohmmeter, make sure the cables are insulated from touching any surrounding surfaces.

2. Connect a le ad from the megohmmeter instr ument to th e motor TA lead.

3. Connect the second lead of the megohmmeter to a cleaned ground connection.

ing Motor, Model 5GEB22

4. Apply a 500 vo

5. If the reading is above 2 megohms, the power circuit insulation is satisfactory and proceed to Step 7.

6. If the reading is below 2 megohms, the power circuit insulation is degraded or bad. Perform the following procedures to attempt to raise the ohm reading:

a. Check the power cables for cracks, scuffed or open insulation. Repair or replace the cables if dam-

b. Water or dirt/debris contamination may be adversel y affecting the ohm reading. Disconnect the

7. Connect o

8. Connect the second lead of the megohmm eter to one of the RTD leads (red, white, or white).

9. Apply a 500V megohmmeter test to the circuit.

10. If the re the RTD cable for cracked, scuffed, or open insulation. Repair or replace the cable if damage is found. If no cable damage is found, then the RTD is defective and should not be used.

ading is greater than 2 megohms, proceed to Step 11. If the reading is less than 2 megohms, check

lt megohmmeter test to the power circuit.

age is found.

power cables from themotorandretestjustthe stator leads. If the reading is still below 2 megohms, the motor w publication for cleaning instructions.

ne lead of the megohmmeter to the motor lead TA.

ill have to be removedfor cleaning or repair. Refer to

4.2. CLEANING THE MOTOR

in this

4.1

11. Move the ﬁrst lead of the megohm meter from the motor TA lead to a cleaned motor frame ground while leaving the second lead of the megohmmete r connected to one of the RTD leads (red, white, or white).

12. Apply a 500V megohmmeter test to the circuit.

13. If the

14. Repeat Steps 7 through 13 until all the RTD cables have been checked against the stator motor leads and

15. Remove the megohmmeter leads and return all components to operating condition.

.4.

Mot

Check the motor mounting bolts, nuts, and associated hardware. Ensure the hardware is not missing or loose. Rep

reading is greater than 2 megohms, proceed to Step 14. If the reading is less than 2 megohms, check the RTD cable for cracked, scuffed, or open insulation. Repair or replace the cable if damage is found. If no cable damage is found, then the RTD is defective and should not be used.

the motor frame.

or Mounting Hardware

lace missing hardware and tighten loose bolts.

GEK-91696D

GE Proprietary and Confidential Information

1150 HP AC Drill

4.2. CLEANING THE MOTOR

Cleaning the motor is essential to long–term motor life. When the drilling motor is removed from its machinery, accumulated dirt a nd oil buildup can be removed. The external motor surfaces can be cleaned by steam clean- ing. The i nternal motor components should not be sprayed with a steam cleaner. To clean the motor:

1. Clean the motor only when the drilling motor is removed from its machinery and power is removed from the

WARNING: Personnel performing cleaning procedures must wear protective clothing, gloves and eye protec- tion. Follow local practices and procedures for cleaning. Failure to do so may result in injury or death.

ing Motor, Model 5GEB22

motor.

CAUTION: Al due to theadverseaffects on motor insulation. Use of thesesolutionsmaycause motor failure or reducedmotor life.

CAUTION: Do not spray the internal components of the motor with a steam cleaner. Moisture contamination may cause motor failure or reduced motor life.

WARNIN to personnel in the immediate area. Personnel should be provided with, and trained in the use of, protective equipment as speciﬁed by applicable federal or state regulators. Failure to do so may result in injury or death.

kali and chlorinated hydrocarbon cleaning solutions arenot recommended forcleaningdrillmotors

2. Cover the motor air inlet and outlet with heavy plastic and tape. Ensure the interior motor components are protect

3. Steam clean the external surfaces of the motor. Do not direct the spray at mot or openings or the plastic covers.

4. When steam cleaning is complete, let excess ﬂuid drain from the motor.

5. Remove the plastic covers or protecti ve covers and tape from the motor.

G: When using compressed air for cleaning purposes, ﬂying debris and particles may present a hazard

6. Using compressed air, blow out the interior of the motor to remove all dirt, dust and moi sture. If necessary, apply heat to dry the motor thoroughly.

ed from spray during cleaning

Recommended cleaning solutions are: CHEMICAL METHODS, INC., 809 or GE BETZ KLEEN SBC120.

5. REMOVAL AND REPLACEMENT PROCEDURES

The following procedures outl ine the overhaul process. All procedures may not be required even though all are described. Inspection of the components will determine the procedures necessary to return the motor to oper- ation.

Do not order replacement parts from this publication. Refer to the PARTS CATALOG for the motor for the correct replacement part number.

5.1. MOTOR PREPARATION FOR SHIPMENT

The drill motor must be prepared for shipment to prevent damage to components during shipping. The following sections detail rotor locking procedures and packaging for shipment.

5.1.1. Rotor Locking for Shipment

GE Proprietary and Confidential Information

The rotor must be locked in position prior to shipm ent to prevent damage to bearings and othe r components of the motor. Figure 2 depicts the 5GEB22 rotor locking arrangement. To lock the rotor for shipment:

1. Remove two diametrically opposite bearing cap b olts and washers (Item 31, Figure 15 ). Place the rem oved bearing cap bolts and washers into a bag that will be attached to the locking bolt.

2. Thread 0.625–11 x 4.54 in. lock bolts (with jam nuts threaded onto the bolts) into the bearing cap holes as shown in Figure 6 . The lock bolt heads are painted yellow to distinguish the bolts as rotor locking bolts.

3. Torque the rotor locking bolts to 30 lb.–ft. (40,7 Nm). To secure the locking bolts into place, run the jam nuts down to the bearing cap and tighten.

4. Secure the bag containing the two removed bearing cap bolts and washers to the rotor locking bolts as showninFigure2.

5. After motor shipment, the rotor locking bolts m ust be removed prior to the motor going into service. To remove the rotor locking bolts:

1150HPACDrill

GEK-91696D

ing Motor, Model 5GEB22

a. Back the jam nuts away from the bea ring cap.

b. Remove the bearing cap bolts from the attached bag on the rotor locking bolts.

c. Thread the bearing cap bolts and washers into the bearing cap holes.

d. Torque the bearing cap bolts to 115 ±15 lb.–ft. (156 ±20,3 Nm).

e. Place the removed rotor locking bolts and jam nuts into the bag and store for future motor ship-

ment.

gure 6. Rotor Lock Bolts.

GEK-91696D

GE Proprietary and Confidential Information

1150 HP AC Drill

5.1.2. Motor Packaging for Shipment

After locking the rotor for shipment, the motor should be securely packaged to avoid damage during s hipment. To package the motor for shipment:

1. Prepare wood stock of sufﬁcient length to skid the motor as shown in Figure 7 . The yellow pine wood stock

2. Drill 1.62 in. (41,2 mm) clearance holes in the wood stock to ﬁt the holes in the motor mounting feet (four

WARNING: The drill motor weighs approximately 5689 lbs. (2580 kg). Use appropriat e lifting devices when lifting the motor. Failure to do so may result in injury or death.

ing Motor, Model 5GEB22

must be able to support the approximate 5700 lbs. (2585 kg) weight of the motor (not including the blower and connection box).

holes).

3. To avoid da

a. Do not lift the motor by the rotor shaft.

b. Do not allow the motor to impact another object when lifted.

c. Do not wra

be wrapped around the motor frame.

4. Lift the

5. Install four 1.5–6 in. bolts and washers through the motor mounting feet an d wood stock frame. Tighten the bolt int

6. Slush the machined surfaces with a rust inhibitor before enclosing the motor for shipment.

5.1.3. Motor Storage

The mo

1. When preparing the motor for storage:

motor onto the wood frame and align the motor foot holes with the wood frame holes.

o position.

tor should be prepared for storage to prevent damage.

a. Construct a platform to secure the motor as described in section

ment

mage to the motor during handling:

p the rotor with straps or banding for shipment. Any securing straps or banding should

5.1.2. Motor Packaging for Ship-

in this publication.

b. Slush the exposed machined surfaces with a rust inhibitor.

c. Inst

d. Ins

e. Apply power to the anti−condensation heater while motor is stored.

all wire leads to the anti−condensation heater that allow the heater leads to be connected to

an external power source.

tall cover and side panel to crate the motor.

ALLOW CONTAINER

GE Proprietary and Confidential Information

CLEARANCE FROM MOTOR ON BOTH ENDS

1150HPACDrill

GEK-91696D

ing Motor, Model 5GEB22

Figure 7. Shipment Preparation for the 5GEB22 Motor.

2. When removing the motor from storage:

a. Disco

nnect power from the anti−condensation heater.

b. Remove the crating material from the motor.

c. Remove the rust inhibitor from the machined surfaces.

d. Visu

ally inspect the motor for excessive rust or other defects.

e. Megger the stator lea ds as described in section

f. If the motor has been in extended storage, the grease in the bearing should be replaced. Follow the

overhaul instructions in the following sections to disassemble the motor for bearing access.

5.2. DISASSEMBLY PROCEDURES

5.2

.1.

Hub

Removal

1.5-6 BOLTS, NUTS, AND WASHERS, 4 PLACES

APPROXIMATE WEIGHT OF MOTOR 5689 LBS (2580 KG)

4.1.3. Megohmmeter Test

in this publication.

E-50540

When removing a hub, use a suitable puller, similar to Part 41B535703G1, Figure 32 . This is a simple, efﬁcient

draulic puller employing the ﬂoat method of removal. A complete unit consists of a pump kit, a backing pla te,

hy anadapter,afeltringandabolt.

GEK-91696D

GE Proprietary and Confidential Information

1150 HP AC Drill

NOTE: Do not heat the hub before pulling it, and do not use steel wedges between the hub and bearing cap.

1. Remove the set−screw plug from the tapped hole in the end of the shaft.

2. Screw the backing plate, with felt ring in place, to the end of the shaft as tight as possible by hand. Back off the backing plate to line up the slot with the tapped hole in the end of the shaft. This is to provide sufﬁcient clearance for the hub to pop off.

3. Screw the pressure−ﬁtting adapter into the hole in the shaft until it seats at the bottom.

4. Attach the pump by screwing the connector on one end of the pressure tube into the adapter, and the other end into the pump.

5. Close the hand relief valve and work the pump handle to force oil into thegrooveinthearmatureshaftunder the hub. When sufﬁcient pressure has been built up, the hub will pop off the shaft and be stopped by the felt washer and backing plate.

NOTE: Capacity of the pump is 40,000 psi (275800 kPa). It holds sufﬁcient oil to remove eight to ten hubs; check at each use. Periodically, remove the ﬁlling plug and reﬁll with SAE−10 lubricating oil.

ing Motor, Model 5GEB22

6. Open the relief valve, disconnect the pump from adapter, remove the adapter and backin g plate from the shaft, and lift off the hub. Rein sert the plug to prevent clogging the hole.

5.2.2. Rotor Removal

To remove the rotor from the motor assembly:

CAUTION: Special precautions should be taken to avoid damage to the rotor, bearings, or bearing ﬁts when lifting the rotor in the vertical position or turning the rotor to a horizontal position.

NOTE: N COMPONENT IDENTIFICATION of this publication, unless otherwise noted.

1. Place

2. Remove the eight bolts and ﬂat washers (31) securing the connection−end bearing housing to the connec-

3. Screw two long guide studs (.625–11 X 10) through the frame head and into the connection−end bearing

4. Plac

umbers in parenthesis () refer to item numbers in Figure 15 located in section 6.2. DRILL MOTOR

the motor in a horizontal positi on.

end frame head. Remove the connection−end bearing cap

tion−

r cap (35) in opposite holes of the six just emptied. These studs will help to guide the rotor out of the

inne motor frame.

e the motor on a heavy−duty stand with the drive−end up. Level the mot or so that the rotor can be lifted

vertically with a hoist without damaging the bearing or bus rings.

5. Rem

6. Screw a 1 in.−8 steel lifting eyebolt into the threaded hole in the drive−end of the rotor shaft (5).

7. Align the hoist cable with the center line of the rotor and attach the hoist hook to the lifting eye.

NO removed with the rotor as an assembly.

ove the eight bolts (10) and ﬂat washers holding the drive−end frame head to the motor frame.

TE: The connection−end bearing and housing and the drive−end frame head, bearing and housing are

GEK-91696D

GE Proprietary and Confidential Information

1150HPACDrill

CAUTION: Use extreme care when turning the rotor to the horizontal position to avoid damage to the core and the bearing and

8. Carefully lift the rotor assembly out of the motor stator and p lace the rotor in a horizontal position on a

9. With the rotor in t he horizontal position, remove the two long guide studs (.625–11 X 10) from the connec-

frame head ﬁts. Use two hoists when positioning the rotor horizontally.

wooden cradle supporting the core assembly.

tion−end bearing housing.

ing Motor, Model 5GEB22

10. Remove and service the rotor bearings according to instruction in section

Assembly Removal

5.2.3. Connection End (CE) Bearing Assembly Removal

There are two Connection End (CE) bearing assemblies used for the 5GEB22 models. Models of the 5GEB22 man- ufactured prior to October, 2001 use the original design CE bearing assembly as shown in Figure 8 . 5GEB22 models manufactured after September, 2001 ( Figure 9 ) use an enhanced p erformance CE bearing assembly. Refer to section the CE bearing designs. The following sections describe the CE bearing removal for both designs of CE bearings. Select the removal procedure appropriate for the bearing design on the drill motor.

.2.3.1. Connection End Bearing Assembly Removal Procedure for 5GEB22 Models Manufactured Prior to October,

2001

The following procedure details the removal procedure for 5GEB22 drill motor models manufactured prior to October, 2001. To remove the CE bearing assembly:

NOTE: Numbers in parenthesis () refer to item numbers in Figure 15 located in section 6.2. DRILL MOTOR COMPONENT IDENTIFICATION of this publication, unless otherwise noted.

1. Remove the twosetscrews(40) from the rotorbearingnut(33). Attach the spanner wrench (GE Tool9945228) to the rotor beari ng nut. Using a dead blow hammer, tap the wrench handle in a counter clockwise (CCW) direction t o loosen the nut. Remove the spanner wrench, and remove the bearing nut from the rotor.

of this publication.

6.2. DRILL MOTOR COMPONENT IDENTIFICATION

in this publication for details of differences in

5.2.3. Connection End (CE) Bearing

2. Assemble the bearing puller (GE Tool 41D736059G3), and use the hydraulic jack to pull the connection–end bearing housing (35) and bearing (34) from the rotor shaft.

3. Position the bearing housing – with the bearing down – on a ﬂat surface. Reassemble the be aring puller (to GE Tool 41D736059G4), and use the hydraulic jack to push the bearing from the bearing housing.

+ 49 hidden pages

GE 5GEB22 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual