SONY 29FX66E Service Manual

IEEE

Recommended Practice

for the Repair

and

Rewinding of Motors for the Petroleum and Chemical Industry

Standards Coordinating Committees

Sponsored IEEE Industry Applications Society Electric Machinery Committee

PuMshed

June22.

by

1990

by

the Petroleum and Chemical Industry Committee

and

the

of

the IEEE Power Engineering Society

the

Institute

of

Electrical and Electronics Engineers, Inc.,

345

East

47th

Street,

New

York,

of

the

NY

1001Z

w13391

USA.

THIS

BLANK IN

PAGE WAS

THE

ORIGINAL

IEEE

Recommended Practice for the

Repair and Rewinding of Motors for the

Petroleum and Chemical Industry

Sponsor

Petroleum and

IJ3EE

and the

Abstract:

Motors for the Petroleum and Chemical Industry,

that need repair vices. The use of this recommended practice effective, and timely repairs. It also provides guidelines

Reswords:

IEEE Std

Motors. reDair and rewindine

1068-1990,

as

well

as

for owners and operators of establishments that offer motor repair ser-

The

Institute

345 East 47th Street,

No

part of this publication may be reproduced in any form,

without the prior written permission of the publisher.

Chemical

Industry

ElectricMachinery

IEEE

Power

Approved May

IEEE Recommended Practice for the Repair and Rewinding

of

Electrical

in an electronic retrieval system

Industry

Applications

Eqhenng

Committee

31

,

is a reference document for owners of motors

is

expected

of:

horizontal motors: vertical motors.

ISBN

1-55937-038-6

Copyright

Q

1990

and

Electronics Engineers,

New

York,

Committee

Society

of

the

society

1990

to

result in higher-quality, more

for

evaluating repairs and facilities.

by

Inc.

NY

10017-2394,

or

otherwise,

USA

o{

cost-

IEEE

Standards

Committees of the IEEE Societies and the Standards Coordinating Committees serve voluntarily and without compensation. They are not necessarily members of the Institute. The standards developed within IEEE represent a consensus of the broad expertise on the subject within the Institute as well as those activities outside of IEEE which have expressed an interest in participating in the development of the standard.

Use of an IEEE Standard is wholly voluntary. The existence of an IEEE Standard does not imply that there are no other ways to produce, test, measure, purchase, market, or provide other goods and services related

expressed change brought about through developments in the comments received from users of the standard. Every IEEE Standard is subjected reaffirmation. When a document not been reaffirmed, it is reasonable though still art. Users are cautioned edition of any IEEE Standard.

Comments for revision of IEEE Standards are welcome from any interested party, regardless of membership affiliation with IEEE. Suggestions for changes in documents should be in the form of a proposed change of text, together with appropriate supporting comments.

Interpretations: Occasionally questions may arise regarding the meaning of portions of standards tions. When the need for interpretations

IEEE, the Institute will initiate action sponses. Since IEEE Standards represent cerned interests, it is important also received the concurrence of a balance of interests. IEEE and the members of its technical committees are riot able to provide an instant response cases where the matter has previously received formal consideration.

Comments on standards and requests for interpretations should be

addressed

of

to

the scope of the IEEE Standard. Furthermore, the viewpoint

at

the time a standard

to

of

to:

documents are developed within the Technical

the IEEE Standards Board. Members of the committees

is

approved and issued is subject

state

of the art and

review

some value, do not wholly reflect the present

at

least once every five years for revision

is

more than five years old, and has

to

conclude that its contents, al-

to

check

to

determine that they have the latest

as

they relate to specific applica-

is

brought

to

ensure that any interpretation has

to

interpretation requests except in those

Secretary, IEEE Standards Board

445

Hoes Lane

P.O.

Box

Rscataway,

1331

NJ

08855-1331

to

prepare appropriate re-

a

consensus of all con-

state

of the

the attention of

For

this reason

to

or

USA

IEEE Standards documents are adopted by the Institute of Electrical

to

and Electronics Engineers without regard may involve patents on articles, materials, or processes. Such adoption does not assume any liability assume any obligation whatever to parties adopting the standards documents.

to

whether their adoption

any patent owner, nor does it

Fomrd

(This Foreword

for

the Petroleum and Chemical Industry.)

This recommended practice was conceived held in September Project Authorization Request was submitted September Standards Board on December

is

not a part of

1984

IEEE

Std

1068-1990,

IEEE

Recommended

at

the Petroleum and Chemical Industry Conference

Practice

for the Repair and Rewinding of Motors

in San Francisco, following a panel discussion on motor repair. The

26,

1984,

and approved by the IEEE

13, 1984.

The project was sponsored jointly by the Petroleum and Chemical Industry Committee (PCIC) of the Industry Applications Society and the Electric Machinery Committee (EMC)* of the Power Engineering Society. The first ballot was mailed out

1989.

in June solved, it was felt that

Although the required affirmative votes were received and negative ballots were re-

a

reballot was in order, and the second ballot was mailed in November

1989.

The IEEE Motor Repair and Rewind Working Group, which had members from both the PCIC

and the EMC, had the following membership:

Milton

Kirk Armintor Rich Buschart Jim Cunningham Gary Donner

The committee that balloted and approved this recommended practice for submission

H.

Ramsey,

Glen Griffith Dick Nailen Bill Newman

Chairman

Jim Oliver Charles Rowe Virgil Wheaton

Les

Zupon

to

the IEEE Standards Board consisted of members of the PCIC and the EMC, and had the following membership:

K.

Armintor

S.

P.

Axe

D. C. Azbill

D.

G. Broussard

R. Buschart

J.

Cunningham

J.

M. Daly

J. J.

Demos

G.

Donner

J.

S.

Dudor

M.

0.

Durham

J.

B. Dyer

H.

B. Dygert

C.

J.

Erickson

E.

J.

Fagan R. L. Fields D. C. Grant G.

Griffith

When the IEEE Standards Board approved this recommended practice on May

S.

W. Hagemoen

F.

P.

Hogan

R.

H.

Hulett R. M. Jackson B. C. Johnson

J.

H. Kassebaum

J.

W. Kilgore

P.

M. Kinney

J.

C. LaCour W. H. Levers C.

R.

Lockerd B. W. McCarty B. McDaniel

P.

Myers

R. L. Nailen

J.

P.

Nelson

W. G. Newman

J.

A.

Oliver

T.

P.

Pearson

B. M. Polkinghorn

M.

Ramsey

Q.

Reynolds

C.

M. Rowe

S.

W.

Shannon

P.

Skobel A. W. Smith T. B. Smith

H.

Sorokin

H.

R. Stewart E. B. Turner

D.

Vardeman V. N. Wheaton A.

E.

Whiteside

B.

Wiseman

B.

Wood

J.

R.

Zahn

L. Zupn

31,1990,

it had the

following membership:

Marco

W.

Migliaro,

Chairman

Andrew

Dennis Bodson Paul L. Borrill Fletcher

J.

Buckley

L.

Clapp

Allen Stephen R. Dillon Donald C. Fleckenstein Jay Forstert Thomas L. Hannan

*Formerly the Rotating Machinery Committee tMember Emeritus

Kenneth John W. Horch Joseph Irving Kolodny Michael Donald John

G.

D.

L.

Koepfingeri

A.

J.

Loughry

E.

May,

Salem,

Hendrix

Lawler

Jr.

James

Secretary

M.

Daly,

Vice Chairman

Lawrence L. Bruce McClung

Donald T. Michaelt Stig Nilsson Roy T. Oishi Gary S. Robinson Terrance R. Whitternore Donald W. Zipse

V.

McCall

THIS

BLANK IN

PAGE WAS

THE

ORIGINAL

SECTION

1

.

Introduction

1.1

1.2 Scope

1.3

1.4 Other Insulation Systems

1.5

..............................................................................................

Purpose

.............................................................................................

................................................................................................

References Definitions

.........................................................................................

........................................................................................

PAGE

......................................................................

7

7 7

8

2 . Prerepair Activity and Responsibility

2.1 User Responsibility

2.2 Repair Facility Responsibility

2.3 Damage Appraisal

.

3

Recondition without Damage Repair

.

Repair Period

4

4.1 Repair Facility

4.2 Field Repairs

5

.

Postrepair

5.1

Repair Facility

5.2 Postrepair User

6

.

Bibliography

TABLE

Table

1

Maximum Amplitude. Inch. Peak.to.Peak. Measured on Bearing Housing in any Direction (with Half Key)

APPENDIXES

Appendix A Appendix B

...........................................................................................

................................................................................................

............................................................................................

Motor Repair Report Form Motor Data Insulation Resistance Record

..............................................................................

..................................................................................

....................................................................................

..................................................................................

................................................................

...............................................................

..............................................................

.............................................................

.................................................................

...............................................

9

10 12

15

20

21

19

22

23

THIS

BLANK IN

PAGE WAS

THE

ORIGINAL

IEEE

Recommended Practice

Repair and Rewinding

Petroleum and Chemical Industry

1,

Introduction

1.1

Purpose.

intended that can be utilized and referenced by owners of

motors that need repair as well as by owners an'd operators of establishments that offer motor repair services. It has been developed primarily for the needs of the Petroleum and Chemical Industry but can applications.

The use of this recommended practice by users and repair facilities in higher-quality, more cost-effective, and timely repairs. It also provides

evaluating repairs and facilities.

1.2

Scope.

general recommendations

electric motors and includes recommendations for both the user and the repair facility. It is not intended

tions contained in the manufacturer's instruction book between a manufacturer and a purchaser of a

given machine.

These recommendations apply

horizontal and vertical motors, NEMA frame

140

size

15

kV

or

only to the repair of motors and are not

intended

Excluded from the scope of this

recommended practice are the following:

1.2.1

and inspection required for listed

explosionproof and dust-ignition-proof

machines.

1.2.2

requirements

cooled machines, submersible motors,

Class

1E

This recommended practice

to

be a basic

This recommended practice covers

to

or

in any contractual agreement

and above, having a voltage rating of

less. These recommendations apply

to

cover major modifications.

Specific requirements, certification,

Any specific

for

nuclear service motors.

or

primary document

be

adapted

is

expected

a

means of

for

the repair of

supplant specific instruc-

or

additional

hermetic motors, hydrogen-

to

is

other

result

to

or

for

the

of

Motors

1.3

References

1.3.1

General.

and test methods not specifically covered in this

recommended practice should comply

with the following publications and standards

as

insofar revisions of reference standards are issued, the revision shall apply.

111

for Temperature Limits in the Rating of

Electric Equipment and for the Evaluation of Electrical Insulation (ANSI).'

[21

IEEE

for

Electrical Machinery hp) (ANSI).

131

Generators (Revision

141

Induction Motors

15.2

the construction, tests should be made in accordance with the following IEEE test procedures:

[51

Recommended Practice

'IEEE publications can

Electrical and Electronics Engineers, Service Center, 445

Hoes

2ANSI/NEMA

Department, American National Standards Institute, 1430 Broadway, New Electrical Manufacturers Association, 2101 L Street Washington, DC 20037.

3API

Petroleum Institute, 1220 L Street

20037.

they are applicable. When approved

IEEE

Std

1-1986,

Std

432-1976

Insulation Maintenance for Rotating

ANSUNEMA

API

541-1987,

Insulation

IEEE Std

Lane,

P.O.

Box

publications are available from the Sales

York,

publications are available from the American

for

the

Definitions, construction,

IEEE Standard Principles

(Reaff

19821,

IEEE Guide

(5

hp to less than

MG1-1986,

7).2

Form-Wound Squirrel-Cage

250

hp and Larger, 2nd ed.3

Tests.

Where appropriate

43-1974

1331, Piscataway, NJ 08855-1331.

(Reaff

for

be

obtained from the Institute of

NY

10018,

or

from the National

NW,

Washington, D.C.

10

Motors and

1984),

Testing

000

to

IEEE

NW,

I

7

l

IEEE

std1068-1990

IEEE RECOMMENDED PRACTICE FOR

Insulation Resistance of Rotating Machinery (ANSI).

[61

IEEE Std

117-1974

(Reaff

19841,

IEEE Standard Test Procedure for Evaluation of Systems of Insulating Materials for RandomWound AC Electric Machinery (ANSI).

171

IEEE Std

275-1981,

IEEE Recommended Practice for Thermal Evaluation of Insulation Systems for AC Electric Machinery Employing Form-Wound Pre-Insulated Stator Coils.

[81

IEEE Std

429-1972,

IEEE Standard Test Procedure for the Evaluation of Sealed Insulation Systems for AC Electric Machinery Employing Form-Wound Stator Coils

1.4

Other Insulation Systems.

(ANSI).4

For other insulation systems that do not have established test procedures, similar procedures may be used if

is

shown that they properly discriminate

it between service-proven systems known

to

be

different.

When being evaluated by an established test, a new should be compared

or

modified insulation system

to

an

insulation system on

which there have been two years of service

a

experience. If

comparison is made on system of the same temperature class, the new system should have equal

or

longer thermal endurance under the same test conditions; if the comparison is made with

a

system of a

lower temperature class, it should have equal

or

longer thermal endurance at an appropriately higher temperature. When comparing systems of different classes, an appropriate higher temperature should be

to

be

25

"C

considered

per class higher than the temperature for the base insulation system class.

1.5

Definitions.

Definitions in this document

are in accordance with the definitions in IEEE

100-1988,

Std

IEEE Standard Dictionary

of

Electrical and Electronics Terms (ANSI).

to

Definitions that are unique

this document

are as follows:

41EEE Std 429-1972 has been withdrawn and is included for information only. However, it is currently being revised, and when the revision and published, the revision will apply.

is

completed, approved,

THE

accepted test.

REPAIR

A

test on a system

AND

tem that simulates the electrical, thermal, and mechanical stresses occurring in service.

experience.

Successful operation for a long time under actual operating conditions machines designed with temperature rise at near the temperature rating limit.

insulation system.

An

assembly of insulating materials in association with the conductors and the supporting structural parts. All of the components described below that are associated with the stationary winding constitute one insulation system, and all of the components that are associated with the rotating winding

constitute another insulation system.

coil insulation with its accessories.

Comprises all of

the

insulating materials that envelop and separate the current-carrying conductors and their component turns and strands and form the insulation between them and the machine structure; includes wire coatings, varnish, encapsulants, slot insulation, slot fillers, tapes, phase insulation, pole-body insulation, and retaining ring insulation when present.

COMWtiOn

a

Includes all of the insulation materials that

and

*ding

Support

envelop the connections that carry current from coil tating coil terminals

to

coil, and from stationary

to

the points of external circuit attachment; and the insulation of any metallic supports for the winding.

associated structural parts (insulation system).

space blocks and ties used

Includes items such as slot wedges,

to

position the coil

ends and connections, any nonmetallic

supports for the winding, and field-coil

flanges.

insulation class.

cording

to

the thermal endurance of the

Divided into classes ac-

system for temperature rating purposes. NEMA classes of insulation systems used in motors include Classes A, These classes have been established in ac-

cordance with IEEE Std

1-1986

classes of insulation are constantly being

developed for such use.

Insulation systems shall be classified as

w

s:

follo

5The numbers in brackets correspond to those of the

references listed

in

1.3.1-1.3.2.

REWINDING

or

model sys-

insulation.

or

B,

F, and

Other

of

or

ro-

H.

8

OF

MOTORS

major modification.

from one type of machine to another type of machine, conversion from one type of enclosure from one rating

motor.

electrical energy into mechanical energy. As used in this document, the term can also be used

repair.

damage appraisal, cleaning, replacement or fixing of damaged part($ postrepair inspection and test, and refinishing.

FOR

THE

PETROLEUM

(1)

NEMA Class A.

(105

tem ing by experience shown to have suitable thermal endurance when operating ing Class the temperature rise standard for the machine under consideration.

(2)

NEMA Class

(130 40

perience

to

when operating at the limiting Class

B

perature rise standard for the ma-

chine under consideration.

(3)

NEMA Class

(155

40

experience or accepted test can be shown endurance when operating at the limiting Class specified in the temperature rise standard for the machine under consideration.

(4)

NEMA Class

tem ing

by experience

shown to have suitable thermal endurance when operating at the limiting Class the temperature rise standard for the machine under consideration.

to

another type of enclosure, or conversion

A

to

mean a generator.

Includes incoming inspection and test,

"C temperature limit includ-

a

40

"C ambient or

or

A

temperature specified in

B.

"C temperature limit including

"C ambient

have suitable thermal endurance

temperature specified in the tem-

or

accepted test can be shown

F.

"C temperature limit including

"C ambient

(180

a

40

or

to

have suitable thermal

H.

"C temperature limit includ-

"C ambient or

or

H

temperature specified in

to

another rating or both.

rotating machine that converts

AND

CHEMICAL.

An insulation sys-

65

"C rise) that

accepted test can be

at

the limit-

An

insulation system

90

"C rise) that by ex-

An

insulation system

115

"C rise) that by

F

temperature

An

insulation sys-

140

"C rise) that

accepted test can be

Includes conversion

or

both, assembly,

INDUSTRY

repair facility.

repairs; includes the "on-site" repair(s) made by employees of that entity in addition to repaids) made the supervision of that entity.

user.

The owner of the motor

agent of the owner.

a

2

Frerepair

Several items should be considered and

documented prior to repairs. Indeed, some

prequalification activities should be finished

to

prior

Some of the user, while others are assigned

pair facility.

failure

of

these activities are the responsibility

The entity contracted

at

a

shop operated by or under

or

Activityand

or

shipment

Responsibility

to

a

repair facility.

a

2.1

User Responsibility.

operation to be of high quality and costeffective, the user should make advance

preparation.

2.1.1

Records.

tion the owner can furnish the better the repair will times the nameplate will not be readily readable after several years in service, and pertinent data must be obtained largely by measurements. It would be ideal if the owner would keep a record of the nameplate and other motor information in

2.1.2

to

Facility.

to

data as ment, and other problems and repairs This record would then pair facility.

time facilities. The following are possible check items:

2.1.2.1

capacity and condition of lifting equipment

should be adequate safely and smoothly.

2.1.2.2

clean and orderly, and tools and equipment in good repair. The area, containers, and equipment used should be checked.

2.1.2.3

facility should have the necessary equipment to

adequately install and test the integrity of

the insulation system.

Obviously, the more informa-

failure history, bearing replace-

prequalify several local repair

Crane Equipment Capacity.

Cleanliness.

to

apply the insulation system

Insulation Requirements.

In order for the repair

to

the repair shop,

be.

For

a

file along with any

be

furnished

The owner should take the

to

handle large motors

Facilities should be

Ern

stdl0681990

to

make

an authorized

to

the re-

example,

or

to

at

both.

the re-

The

9

IEEE

stdl0681990

2.1.2.4

Instrumentation.

have adequate instrumentation brated yearly Records are necessary on instruments are recommended for data verification.

2.1.2.5

costs, inspection, rewinding, ing motors should be established in advance.

2.1.2.6

and conditions should be in writing and

clearly understood by both parties before re-

pairs are begun.

2.1.2.7

safely and without damaging machine iron should be available.

2.1.2.8

analysis equipment should be available.

2.2

Repair Facility Responsibility

2.2.1

unloading the machine, the shipment should

be inspected with the shipper representative for

obvious damage that may have occurred during shipment.

2.2.1.1

broken

problem(s1.

2.2.1.2

that cannot be adequately described, pictures should be taken

2.2.1.3

information available. The following data should be obtained:

(1)

Type of apparatus

(2)

Manufacturer

(3)

Style

(4)

Serial number

(5) HPfkVAJkWipower factor

(6)

RPM

(7)

Phase

(8)

Frequency

(9) Volts

(10) Full-load amps

(11)

Temperature risehsulation class/ ambient base

(12) Type of bearing and manufacturer

(13)

Code (14) Service factor (15) Enclosure

2.2.2

performed, the following should be recorded:

2.2.2.1

bearing damage.

to

properly perform all tests.

all

Pricing Structure.

Warranty.

Facilities for removing windings

Rotor balancing and vibration

All warranty items

Incoming Inspection.

A Damage Report should include

or

missing parts and/or any unusual

For

unusual damage

to

identifjr the condition.

Record all motor nameplate

or

locked

rotor

amps

If incoming running tests are

Make sure that there is no shaft

IEEE RECOMMENDED PRACTICE

The shop should

that

is

cali-

testing. Back-up

Agreement as

or

recondition-

or

conditions

Prior

to

or

FOR

THE

REPAIR

AND

REWINDING

2.2.2.2

lubricated.

2.2.2.3

be performed. See 2.3.4.1.9 through 2.3.4.1.12

for minimum insulation resistance values, temperature compensation requirements, and

test

voltages. See Appendix B for a motor data

insulation resistance record form.

2.2.2.4

IEEE

Std

to

the winding being tested.

2.2.2.5

energizing the motor are

(1)

Continuity of field coils and stator

win dings.

(2) Condition and installation of brushes.

(3)

Single-phase, low-voltage (approximately on ac squirrel-cage rotor to find defective rotor bars. Maximum accepted line-current variation shaft is rotated with full-load current

applied. (4) Core-loss test. (5) Polarization index.

2.2.2.5.1

permit, the motor should be run at reduced voltage initially (25% to

If the

test

in Appendixes A and

at

full voltage, if possible.

2.2.3

Verify that bearings are

Insulation resistance

Hipot

to

ground in accordance with

432-1 976

(Re&

1982)[21

Other tests required before

as

10%

to

20% of rated voltage) test

Running Tests.

50%

is

successful, complete the data sheets

B,

and then run the motor

tests

should

as

appropriate

follows:

<

3%,

as

If conditions

of rated voltage).

the

Disassembly Procedures and

Instructions

2.2.3.1

parts should be marked (i.e., brackets, frame, covers, and brush holders).

2.2.3.2

identified as pairs.

2.2.3.3

identified and recorded.

2.2.3.4

sketched, and marked before disconnecting.

2.2.3.5

other shaft-mounted components, measure and record their position with respect of the shaft (flush, past flush, Critical components may need marked for reassembly.

2.2.3.6

cracks using

2.2.3.7

noted damage

2.2.3.8

pliance with original motor specifications. If

Before any disassembly is begun,

Brackets and bearings should be

Frame-mounted devices should be

Wiring should be recorded,

Before removing the coupling

to

or

from flush).

to

be match-

Check fan blades for damage and

a

penetrating dye system.

As parts are removed, record all

or

special markings.

Check shaft extension runout com-

or

the end

I

10

--

-1

OF

MOTORS

other information lowing:

(1)

(2)

rubbing

end rings, armature iron, etc.). the core on its shaft. Visually inspect for

of axial and radial movement.

components. condition of commutator, core iron, windings,

connections, bands, keyway, support rings, wedges, ties, threaded fits, etc.

tion of bar joints, end rings, windings, slip rings, key ways, threaded fits, synchronous pole pieces, etc.

of the following:

(1)

(2)

(3)

(4)

(5)

(6)

nonrotating components (brackets, baffles, shrouds, brush holders, brushes, gasket, spacers, shims, threaded fits, machine fits, etc.).

for housings, cartridges, and bearings. ball- or roller-bearing housing or cartridges

(wear, grooving, seal fits, fretting, grease fitting, insulation, oil gages, etc.).

sleeve bearings while still in brackets (wear,

oil grooves,

etc.).

poles, iron, mounting blocks, welds, machined fits, brush rigging, space heaters, etc.

2.2.4

FOR

THE

PETROLEUM

is

not available, use the fol-

ACmotorrunout

indicator reading DCmotormout indicator reading

2.2.3.9

2.2.3.10

2.2.3.11

2.2.3.12

2.2.3.13

2.2.3.14

2.2.3.15

2.2.3.16

2.2.3.17

Visually check for evidence of

at

outside diameters (fan, shrouds,

If possible, check for tightness of

Visually check rotating

2.2.3.11.1

2.2.3.11.2

Shaft extension

Journal and bearing

Shaft extension runout Shaft seal Commutator diameter Commutator riser and brush surface length

Removal

DC

AC

Machines.

Measure and record dimensions

fits

Visually inspect the condition of

Measure and record bracket Visually inspect the condition

Visually inspect the condition

oil

rings, seals, dowels, parts,

Visually inspect field-frame

of

Field Coils-Synchronous

AND

=

0.001

=

0.002

Machines.

Inspect condi-

fits

CHEMICAL

inch inch total

total

signs

Check

fits

Roton3

2.2.4.1

tion orientation and wiring connections should be made before attempting poles.

A

diagram showing field pole loca-

to

remove

INDUSTRY

2.2.4.2

according

2.2.4.3

field poles should be measured and recorded before removal to ensure that they are rein-

stalled

2.2.5

2.2.5.1

of field-pole connections should be made facing connection end. Show main poles and interpoles with relation frame-mounted device such etc. Clearly identify connecting lead from interpole

order when reconnecting.

2.2.5.2

identifying shunt pole leads by Fl-F2, series pole leads with leads

2.2.6

2.2.6.1

make an accurate drawing showing the loca-

of

tion ciated hardware. Shaft keyway can be used as a reference indicating relationship of collector

rings, brush exciter, leads, and wiring

cleats.

2.2.6.2

marked with respect

sure that they are reassembled cation and in the same orientation. General practice is sequence while facing the collector ring or exciter end.

2.2.6.3

location of the pole pieces with respect

rotor

of

accomplished by identifying Pole ing a center punch mark at this midpoint, and measuring the distance from the center

of

punch mark using this dimension and shaft reference, place the remaining poles. Locating the poles in this manner will allow the

to

its

method is to measure the distance between

each pole piece dovetail and slot edge.)

2.2.6.4

the rings must be removed in order

dismantle the poles, all orientations for the

rings should be recorded on a drawing.

Field poles should be marked

to

FrameRotor location.

The axial position for rotating

at

correct electrical center.

Field Pole/Removal

A

diagram (wiring around frame)

to

some permanent

as

to

brush holders (dc machines) in

to

ensure correct commutating polarity

Follow standard practice

Sl-S2,

and interpole/armature

Al-A2.

RotordRotating

Prior

all poles, wiring, fan blades, and asso-

Each pole piece should be match-

to

number the poles in a clockwise

Measure and record the axial

core and shaft. (Generally, this is best

to

a

center punch mark on each of

correct magnetic center.

When inspecting collector rings, if

Poles

Inspection

to

disconnecting the wiring,

to

the

rotor

to

the shaft reference.) 'Then

rotor

its

IEEE

stdl0681990

conduit box,

spider

to

the same lo-

to

#1,

plac-

to

be returned

(An

alternate

outside rotor

of

en-

the

to

11

IEEE

Std106al990

2.2.6.5

rotor

bars and their connecting end rings should be inspected for cracks, arcing in slots, and for

cage migration. arcing should be recorded and, if possible, pictures taken showing the location of damaged bars. the defective bar location and all connecting parts between poles and end rings should be identified and recorded on the drawing.

2.2.7

2.2.7.1

for presence of cracks, signs of wear, rubbing.

2.2.7.2

wear.

2.2.7.3

tolerances should meet the motor manufacturer’s cations.

2.2.7.4

housing, cartridge, and bearings should be measured and recorded.

2.3

Damage

2.3.1

condition, the repair facility, purposes:

2.3.1.1

are needed. The motor may have been sent the repair center with limited external evidence What seems wrong may be correctable in several ways.

2.3.1.2

perhaps unrelated

2.3.1.3

help prevent

2.3.2

complete review of the following conditions of each part of the motor:

2.3.2.1

2.3.2.2

cas ti ngs

2.3.2.3

2.3.2.4

fretting.

2.3.2.5

evidence of overheating.

2.3.2.6

2.3.2.7

the machine.

When inspecting squirrel-cage

bars (synchronous and induction), rotor

All

cracks and evidence of

A

drawing should be made showing

Other

Mechanical

Motor parts should be inspected

The keyway should be inspected for

Ball-, roller-, and sleeve-bearing

or

bearing manufacturer’s specifi-

Dimensions of bracket

Inspection

Appraisal

A

thorough appraisal of the motor’s

as

the machine is received in

is

essential for three

To determine what specific repairs

as

to the nature and location of trouble.

To find unsuspected trouble,

to

the obvious defect.

To diagnose cause and effect to

a

recurrence.

This appraisal should include

General cleanliness.

Cracked

or

broken welds

.

Missing hardware.

Wear

or

rub marks, including

Discoloration, charring,

Looseness at mating

Corrosion, moisture,

IEEE RECOMMENDED

or

fits

for

or

other

fits.

or

oil inside

PRACTICE

2.3.3

tions found are strongly recommended as part of the appraisal process and inspection report. In the absence of clear photographs, any drawings, diagrams, no uncertainty tions described. If references are made to “clock position” (e.g., “inboard”

tory

note

tion being described. The terms “drive end”

and “opposite drive end” are recommended for horizontal-shaft machines; “top” and “bottom” for vertical-shaft units.

2.3.4

is

nents

2.3.4.1

first.

comes

2.3.4.1.1

are loose, damaged,

position.

2.3.4.1.2

or

broken.

2.3.4.1.3

on coil surfaces.

2.3.4.1.4

burning, tracking,

or

cracked tape, coils that have moved within

the

slot,

insulation pitted

abrasive particles. If severe arcing

has taken place, inspect the entire unit interior

to

carefully for globules

copper that may have been projected from the

failed winding.

2.3.4.1.5

for cracked, overheated,

and loose

2.3.4.1.6

evidence of destructive arcing

observe and record carefully the location and

nature of the damage. If

equally overheated, ventilation failure, un-

dervoltage, stalling, or prolonged overload are

likely causes. If coils within one phase are

largely undamaged,

single-phase operation balance. If only certain coils adjacent to line leads have been damaged, especially with relatively little heating, the likely cause is a transient surge voltage on the feeder circuit. These and many other failure modes, with the probable contributing factors, are reviewed in the bibliography (Section

FOR

THE

REPAIR

Photographs of any abnormal condi-

or

descriptions should allow

as

to

the location of the condi-

or

to

or

“outboard”), some explana-

or

sketch should make clear the

Damage appraisal of motor compodivided into two categories.

Electrical.

Look for the following:

Slot wedges (“top sticks”) that

Ties

or

Dirt, oil,

Coil damage. Besides obvious

or

charring, look for loose

deposits of dirt or chemicals, and

or

worn away by airborne

or

On lead cables

or

burned terminal lugs.

When a winding shows clear

AND

ends of the machine

The stator winding

or

have shifted in

lashings that are loose

or

moisture deposited

fragments of molten

or

frayed insulation;

or

all

the

likely causes are

or

serious voltage un-

6).

REWINDING

loca-

or

burning

straps, look

overheating,

coils appear

OF

MOTORS

FOR

2.3.4.1.7

THE

PETROLEUM

AND

CHEMICAL

Be alert also for evidence of in-

sulation damage caused by flying objects such

as

broken fan blades within the motor. The

to

impact will typically gouge down

bare copper without any burning unless adjacent turns become short-circuited and failure progresses.

2.3.4.1.8

not winding damage is apparent,

Pay close attention, whether

to

all stator

or

ventilating passages. These can be blocked by

or

varnish

contaminants even when

winding looks fairly clean on the surface.

2.3.4.1.9

If no stator winding damage is

apparent, test the insulation resistance for

a

windings using dance with IEEE Std

megohmmeter in accor-

43-1974

(Reaff

1984)

[51.

Record the value of insulation resistance (IR)

between the winding (all leads connected

to-

gether) and the stator core. Test voltage, ap-

1

plied for

5200throughl3800

sistance corrected

at

least equal

nameplate rating plus

min, should be as follows:

Rated

Motor Megohmmeter Test

Voltage Voltage,

240throUgh2400

3o0OthIuugh4800

2.3.4.1.10

If the measured insulation re-

to

a reference of

to 1 Mi2

per

1

WO

2500

25Ooor5OOO

1000

MQ,

dc

40

“C

is not

V

of motor

the winding should be thoroughly dried and the test then repeated. Drying-out temperature of the winding

‘should not exceed

80

“C

as measured by ther-

mome ter.

2.3.4.1.11

To correct IR readings

to

the

reference temperature, use the formula found

in

IEEE Std

43-1974 (Reaff1984)

[51.

R,=K,XR,

where

R,

=

insulation resistance (in megohms) corrected

R,

=

measured insulation resistance (in megohms) at temperature

I?

=

insulation resistance temperature efficient at temperature

Obtain K from Fig

1974

(Reaff

2.3.4.1.12

to

40

“C

t

1,

1984)

page 9 in IEEE Std

[51.

Windings in apparently good

t

co-

43-

condition should receive a dc overpotential

1

fiipot) test for

min at a voltage T calculated

as follows:

INDUSTRY

T

= 0.65

(2E,

+

lo00

W(1.7).

Volts

where

E,

=

rated motor nameplate voltage

2.3.4.1.13

If these tests are not passed,

the repair center should discuss the results

to

amve

at

a

with the owner

or

to

attempt further reconditioning and retest-

ing (for example, by reimpregnating the

a

winding).

2.3.4.1.14

Inspect the

decision

stator

ture itself carefully for evidence of severe rosion, local overheating of laminations,

or

loose

spacers,

broken slot teeth, loose

or

rub marks from contact by the rotor

or material caught in the

be

test should

performed

or

air

gap. A core-loss

to

evaluate the condi-

tion of the laminations.

2.3.4.1.15

electrical component

The rotor

to

be appraised. Cleanli-

is

the second major

ness; lamination, vent-spacer, condition; and rub marks are checked as in the stator.

2.3.4.1.16

A

squirrel-cage rotor will be the type most often encountered. It may use cage-bar and end-ring structure that is cast in place using aluminum alloy;

or

aluminum bar

ring assembly; cated copper alloy cage. Whichever the type, using a dental mirror if necessary, inspect all accessible surfaces of bars and end rings, looking for “blued” (overheated) areas; cracks; missing pieces; bar movement in the

or

slots; porous

deteriorated brazed joints; and bars that have “lifted” outwards in the slots under centrifugal force. Record the location and nature of all defects found.

2.3.4.1.17

When overheated bars are present, the most severe overheating will typically be at the ends of the rotor, outside the core stack, when starting duty is the source of trouble. ventilation is the problem, more likely

or

burning along the edges of bars adjacent

to

slots. This generally indicates bar

If running overload

to

be within the core stack itself.

2.3.4.1.18

Look for evidence of arcing

rotor

overheating is

looseness.

2.3.4.1.19

One

or

more cracked

ken cage bars normally dictates replacement

rotor

of the entire cage. If the placement, aluminum

cage requires re-

or

aluminum-alloy

cages should be of low copper content

EEE

stdl0681990

to

rewind

core struc-

shifted vent

or

slot-tooth

a

fabricated

or

a fabri-

or

welded

or

melted

or

blocked

or

(0.2%

cor-

a

bro-

or

13

IEEE

Std1068-1990

IEEE RECOMMENDED PRACTICE FOR

less). Copper or copper-alloy cages should use metal-joining material that is phosphorusfree. If bars are loose but undamaged, swaging (with near each end of the core stack and one

a

properly radiused

tool)

of the bars

or

more locations along the stack length may expand the bar material sufficiently to tighten the fit. However, this will not work if the bars are of the T-shape (narrow top, wide bottom)

a

loose

fit

designed for Varnish treatment of

of the upper portion.

a

rotor containing

loose cage, even if vacuum-pressure impreg-

is

nation loose bars in position and should not be used

used, will not permanently lock

to

repair a loose cage. Unless the bars can be mechanically tightened, they should be replaced.

2.3.4.1.20

tested in one of two ways

The entire

to

rotor

should be

locate broken cage

bars that are not otherwise apparent. If the

stator and bearings are in usable condition, a single-phase test may be performed (applying

typically

the

10%

rated voltage

stator

winding, turn the rotor slowly by

to

only two leads of

hand and observe for current variations

indicating the possible presence of cage

2.2.2.5

(3).

defects; see

Otherwise, the removed

rotor can be similarly tested on a “growler.”

is

Neither test, unfortunately,

or

procedurally standardized.

difficulty is that the halves of

either infallible

A

typical

a

broken bar

may separate only when the rotor is hot, the gap

rotor

cools

off.

to

the ends

Oven-

to

closing again when the

rotor

heating the growler

or

test

2.3.4.1.21

“shrink rings” (usually attached

of high-speed

for a short time prior

may be helpful.

Examine steel retention caps

rotor

cages

to

restrain centrifu-

gal expansion) for signs of distortion, loose-

or

ness,

such panded outward into

fretting. End rings themselves in

rotors

may sometimes fail by being ex-

a

somewhat conical shape

by high centrifugal forces-a condition that

must be corrected by replacement rather than remachining.

2.3.4.2

Mechanical. The mechanical

condition appraisal should give particular

to

attention Condition of lubricant; dirt, rust,

the following:

2.3.4.2.1

Antifriction bearings.

or

moisture;

fretting corrosion; thermal discoloration; pit-

or

ting

spalling of balls, rollers,

or

races; bro-

ken or missing retainers.

2.3.4.2.2

Sleeve bearings.

Scoring

or

wiping of babbitt; integrity of any insulation

THE

REPAIR

AND

furnished to block passage of bearing current

(50

MR

minimum IR is recommended; no temperature correction needed; use megohmmeter with less than

50 V output); oil leakage; oil ring wear. Check forced-oil lubrication systems for blockage inside piping; presence of proper metering orifices in the system;

proper pump operation.

a

2.3.4.2.3

(ANSUNEM

4.06);

cracks, corrosion; scoring

2.3.4.2.4

Shafts.

MG1-1986

Seals.

Rubbing or wear; leak-

Straightness

131,

Sections

age; glazing or hardening of felt tomeric materials.

2.3.4.2.5

Gaskets.

Hardened, broken, or

shifted parts; missing gaskets; evidence of

or

lubricant

contaminant leakage past

gasket.

2.3.4.2.6

missing,

2.3.4.2.7

Fasteners and dowels.

or

broken parts.

Frame

or

housing.

structural weld integrity; blocked drains, breathers,

2.3.4.2.8

ventilating

Condition of accessories.

air

passages.

or

heaters, thermostats, etc.

2.3.4.2.9

Many users and repair facilities consider it good practice to replace antifriction bearings on any unit sent in for overhaul regardless of what other repair work is done. When large and expensive components are involved, such as spherical roller thrust bearings, financial constraints dictate

a

keeping existing bearings in service if

possible. That requires careful appraisal of

bearing condition. To do that, the repair facil-

ity should use illustrated guidelines published

by most bearing manufacturers and readily

available through suppliers of power transmission equipment. The symptoms of shaftcurrent flow, improper thrust loading, fatigue,

or

lubrication failure,

other defects are well

defined in such literature.

2.3.4.3

Stator

and

Rotor

Repair

2.3.4.3.1

mechanical

Eliminate laminations with

or

electrical damage. The follow-

ing three methods of repairing iaminations in

or

a motor stator

rotor are dependent on the de-

gree of damage. Selection of a method is based

on the inspector’s experience and judgment

to which repair method will eliminate core hot

spots.

2.3.4.3.2

Method One.

(Stator is slightly

rubbed by the rotor fusing the edges of the

REWINDING

4.05

and

or

galling.

or

elas-

Loose,

Corrosion;

Space

at

all

Lamination

as

a

14

I

OF

MOTORS

laminations together.) The effectiveness this method depends on the depth of the the extent

I

FOR

PETROLEUM

to

which the winding

AND

CKEMICAL

of

slot

and

fills

the

slot. The fused laminations may be vib-

rated apart with an air-driven hammer placed

against the end of the core section. Vibrations of the lamination fingers will break the metal fusion. While vibrating the damaged

a

section, spray varnish in the damaged area.

high-quality insulation

As

the fingers vibrate, the varnish will penetrate the air

gapa caused by the vibration and

reinsulate the fingers. This method assumes

is

the damage section and the damage

near the end of the stator core

is

on the tips of the

fingers. Alternately, the laminations can be

separated and the interlaminar insulation

iestored by the insertion of varnished mica

splittings followed by an overall varnish

treatment.

2.3.4.3.3

Method

Two.

(Coil has failed

in the slot melting the laminations or the sta-

rotor.)

tor is moderately rubbed by the

With

pencil metal grinder, grind away fused metal

until a definition of

seen. Small, high-speed

core

laminations can be

(25

000

rpm) hand grinders equipped with carbide-tipped, coneshaped rotary files work best. Grind with light, intermittent pressure rather than continuously with movement in the same plane as

is

the laminations until the fused metal

re-

moved. Repaint the ground area and test the

Do

core for hot spot in the damaged area.

not grind an area that will damage the mechanical integrity of the slot. If the damaged area is

10%

more than core, then go

2.3.4.3.4

greater than

of the total surface area of the

to

Method Three.

iO%

of

core-surface area or can-

(Damage is

not eliminate hot spot by Method Two.) If the damaged area cannot be repaired by one of the

or

first two methods, then a partial restacking of the stator

or

rotor core must be

considered. The laminations will need

or

disassembled and replaced

repaired by

total

to

be

hammering and sanding away the damaged metal. The laminations must then be reinsulated by dipping in an organic insulating material

at least

300

"C

temperature rat-

With

ing and air drying before reassembly. Inorganic insulation with higher temperature ratings is preferred, if available. The damaged area can be redistributed in the core by rotation of each damaged lamination by one

INDUSTRY

slot. This may require rekeying the lamination in the frame.

3.

Readition

without

Damaw

There are occasions when motors will be in

a condition that requires only that the ventila-

or

tion passages be cleared

the exterior be cleaned and painted, sometimes even reusing the same bearings, although this mally recommended for antifriction bearings. Perhaps the insulation is in good enough

a

condition that

varnish and rebake (dip and bake) may restore the serviceability motor. When the motor is only to and revarnished or possibly have the bearings

changed, the repair facility must ensure that

any method and solvents used for cleaning must be compatible with both the winding insulation (including slot liners and caps) and the

enamel on the iron and any paint on the surfaces of the motor. Similarly, if motors are

a

be dried out, care must

be

exercised to avoid any possibility of overheating windings sulation. It peratures

is

recommended that drying tem-

be

kept below

4.

Repair

80

"C.

Period

4.1 Repair Facility

4.1.1 Receiving.

In most cases, the repair

facility will have already received the unit

and been involved with the decision On some occasions, the initial damage evaluation will have been made at another location. In any case, there are steps covered in that need to be performed and should be reviewed before damage repair or reconditioning is started.

4.1.2 Stripping and Cleaning.

most potentially damaging procedures in the rewinding operation is the removal of the old, failed, electrical windings. There are several ways to remove these. Three of the ways addressed in this recommended practice.

4.1.2.1 Oven

Burnoff.

Some types of interlaminar insulation are severely damaged by exposure of laminations to temperatures above

650

OF

during this process of "burning out" a

winding preparatory

to

rewinding. Tests show that this may result in increased core (with resulting reduction in efficiency) or

IEm

stdl0681990

Repair

is

not nor-

of

the

be

cleaned

or

to

rewind.

One of the

will

loss

to

in-

2.3

be

15

IEEE

stdl0681990

overheating of the new winding after

IEEE

RECOMMENDED PRACTICE

it

has

been installed, or both.

Holding the oven chamber temperature be-

650

OF

low damage. Lamination temperature

will not necessarily eliminate the

is

not nec-

essarily the same. Conventional oven tem-

too

perature controls are often

to

maintain the safe limit. Furthermore,

slow in response

shutting down the oven heat source does not

to

a

necessarily limit the core temperature

safe value. Some epoxy insulations, for example, will release large amounts of heat (even in the

as

absence of oxygen) the oven burners have been shut

they break down, even if

off.

It has been demonstrated that even with

at

650

OF,

ovens set

800

exceed couple

OF.

or

resistance-temperature detector (RTD) is recommended iron temperature.

is

corder

preferred for recording both oven and

the iron temperature can

The use

of

an

imbedded thermo-

to

monitor the actual

A

properly calibrated re-

motor temperatures. The oven temperature

must

be capable of being automatically

controlled.

is

Therefore, oven burnoff

only

recommended if core temperature does not

650

OF

exceed

through use of a water- or steam-

injection system in the oven for rapid

suppression of “flaming” from burning

insulation.

NOTE:

The

use

of

recommen de d.

4.1.2.2

blasting

is

hand-held torches

Water Blasting.

the procedure used for insulation

or

direct

flame

When water

is

not

removal, the following should be observed:

Extra care should be exercised when direct-

ing the cutting stream around the laminations

so

that moisture is not forced between the laminations. In conjunction with that, the motors should not be allowed to set overnight immediately after water blasting without removal of the windings and commencement some form of artificial drying

500

temperature (less than

to

solutions added

the high-pressure water

OF).

at

Any cleaning

of

a low

must be compatible with the materials used in the motor construction. User and repair facility should be aware that there are significant safety hazards in using this method, and proper precautions should be taken.

4.1.2.3

Mechanical.

When using me-

chanical removal techniques, extra care

FOR

THE

should be exercised

REPAIR

so

AND

REWINDING

as

to not cause sepa-

ration of the laminations while pulling the

is

used

to

windings. When heat lation

(as

opposed

to

the flame must not

burning out in an oven),

be

allowed to impinge on

soften insu-

the motor.

4.1.3

Replacement

of

Coils.

The designations “random-wound” and “mush-wound” are interchangeable and, for replacement coils, refer to windings that are wound on a

that

winding lathe and inserted into slots

are

usually semiclosed. Form-wound coils are

a

wound with rectangular wire, also on

winding lathe, and are usually used in slots that are “open.” These windings rely on sheet ma-

to

terial for insulation

ground and between coils. Conductor and turn insulation is usually enamel for random-wound coils. Formwound coils utilize enamel, glass, or mica tape for conductor and turn insulation. hermetic motors with randomcoils, the insulation material must

OF

form-wound

be

For

compat-

ible with the refrigerant.

4.1.3.1

prior

After removal

to

replacement of the coils, the iron

of

the old coils, but

should be cleaned, inspected, repaired if necessary, and repainted.

all

4.1.3.2

motors.

4.1.3.3

Slot

liners are recommended for

Coils should be formed from continuous lengths of properly sized and insulated magnet wire (to match nameplate criteria). Splices are not recommended in in-

dividual coils under normal circumstances.

4.1.3.4

done with care insulation

the slots should be held

Insertion of coils in slots should be

to

avoid damage to the

or

magnet wire.

4.1.3.5

Crossings of magnet wire within

to

a minimum on

random-wound coils.

4.1.3.6

RTDs or thermocouples should be placed within the windings if they were part of the original design.

4.1.3.7

placed between phases and between wedge and coil and as fillers

fit

snug

Insulating material should be

as

extra protection

to

obtain

against slot teeth. Form-wound coils should be insulated with a turn insulation of a minimum of one 1A-lapped layer of at least mil

(0.005

in> mica paper, mica flake,

or

mica

splitting supported by glass cloth, polyester

floc,

or

a

mat, polyester

combination of these

in either tape or wrapper form. Turn insula-

tion should be used on all

stators

that have

5

a

16

OF

MOTORS

core length greater than

FOR

TKE

PETROLEUM

AND

0.64

m (25 in). Also,

CHEMICAL

turn-to-turn insulation should be used accord-

to

ing

the following turn-to-turn voltage

schedule:

>

50 V peak-one 1/2-lapped layer

>

80

V

>

NOTE: Designs with

strand and turn insulation

peak-two 112-lapped layers

120 V peak-three 1/2-lapped layers

one

strand

per

turn should have both

as

required

in

this

4.1.3.8

Shape and secure end turns with

section.

proper bracing as required for particular coil design.

4.1.4

Replacement

Restoration

4.1.4.1

Removal

of

Fits

and

of

Bearings and

Seals

Bearings.

Roller and

ball bearings should be removed by using

or

hydraulic presses

screw-drive bearing pulling equipment. Removal by hammering is not acceptable. If heat removal, precautions are

must

be applied for

to

be used

to

ensure that heating is concentric and that the shaft will not be heated unevenly, and the bearing should not be reinstalled.

4.1.4.2

Reassembly

4.1.4.2.1

ings that are either new replacements been rebuilt should be fitted

Bearings.

Split sleeve bear-

or

have

to

journals by “bluing and scraping” as in the following sections.

4.1.4.2.2

Using a bearing scraping tool

(typically a triangular file with the teeth

off),

ground

to

the clearances and contours recommended by the motor manufacturer. Apply amount of nondrying bluing compound shaft journal, spreading it out form coating

scrape any side reliefs and lands

a

small

to

form a uni-

1

to

2 in wide the full length of the

the

bottom of the journal. Lift the shaft slightly, roll the lower bearing half into place, then lower the shaft onto it, ensuring that the nor-

rotor

mal

weight is applied

Turn shaft 112

to 1 revolution. Lift the shaft

to

the bearing.

again, and roll the lower bearing half out. pattern of very light blue and dark blue areas will be seen on the bearing surface. These cor-

to

respond

“high” and “low” portions of the

bearing surface, respectively. Scrape the high

to

spots

make the lightldark pattern uniform;

the fitting process should be repeated with blu-

80%

ing as required until at least

contact has been achieved. When this is complete, leave the lower bearing half in place with the rotor weight resting on it.

INDUSTRY

wire

4.1.4.2.3

or

Lay two

or

three pieces of lead

other calibrated deformable gage

material on the journal, perpendicular

shaft centerline; their ends within horizontal split line. Make sure the upper and lower bearing halves are clean. If shims are

used between the halves, make sure they are

clean also. Place the upper bearing half over

or

the journal on the wires

upper bearing cap

bolts

to

specification. Then unbolt and remove

or

gage. Install the

housing and tighten its

the upper bearing housing and upper bearing

half carefully. Measure the thickness of the

or

lead wire

material

the clearance of the deformed

as

instructed on the package. If the

clearance is within limits, remove the wires

or

gage and proceed with reassembly. If it is

not within limits, both bearing halves must be

too

loose,

or

rebabbitted if

must be scraped if

4.1.4.2.4

too

Reassembly of horizontal or

vertical tilting-pad

top half of bearing

tight.

or

shoe bearings should follow whatever procedures the manufacturer prescribes. Unless supplied by the owner, details of that procedure should

be

owner as part of the final repair report (see 5.1

and Appendix

4.1.4.2.5

be fitted

A).

Ball

or

roller bearings should

to

shafts by heat-expanding the inner bearing race in accordance with the bearing manufacturer’s recommendations, using an

or

oil-bath heater ings must not be allowed

in

a

cocked position

ed up

to

the locating shaft shoulder

an induction heater. Bear-

to

seize onto the shaft

or

before being fully seat-

ing ring. For those motors in which the outer bearing race is the “tight-fitted” member (e.g., vibrating screen drives), the bearing chamber

to

be heat-expanded: the inner bearing race

is will be used

a

slip fit on the shaft.

to

seat a tight-fitting bearing race shall be

Any

equally applied all around the race.

A

4.1.4.2.6

secure a bearing race against rotation. If the metal-to-metal

or

bearing housing is not within design lim-

Sealants should not be used

fit

between races and the shaft

its, parts should be either bushed, sleeved, remachined, metal sprayed and machined size,

or

otherwise restored

to

acceptable di-

mensions.

4.1.4.2.7

housings

or

more than one-third full, using

to

the motor’s operating environment.

Grease-lubricated bearing

chambers should be packed no

a

Em

stdl0681990

to

the

1/2

in

of

the

given

to

the

or

retain-

pressure

to

grease suited

17

IEEE

M1068-1990

4.1.4.2.8

Either sleeve

IEEE

or

antifriction

RECOMMENDED

bearings may be electrically insulated in

to

some way

block the passage of damaging shaft currents originating within the machine's electromagnetic dissymmetries. The integrity

this insulation, as applied

to

the

of

bearings themselves, should be tested during the reassembly process. (See

4.1.4.2.9

All accessories fitted

ing assemblies shall be replaced

is

ing insulation

not short-circuited and

2.3.4.2.2.)

to

so

that bear-

bear-

so

that no protective system sensitivity is lost. Such accessories include lubrication system piping and fittings

as

well as temperature

or

vibration sensing devices.

4.1.4.2.10

adjusted

Bearing assemblies should be

to

provide total shaft end play in

ac-

cordance with the machine's design limits.

For

horizontal-shaft antifriction bearing mo-

tors, the end play must allow for thermal

to

expansion of the shaft without damage

bearings. For vertical motors, locknut adjustments, spacer rings, and installation of thrust bearing, support springs must be in

dance with manufacturer's instructions

accor-

(or

owner specifications). Sleeve-bearing machines must be assembled-by adjustment of

or

bearing

ing assembly will "float"

rotor positions-such that the rotat-

at

its magnetic center position within the normal end-play limits. This natural rest position will be indicated by any "magnetic center indicator" sup-

on

plied checked

the motor, which should be carefully

at

reassembly. Any change in the

magnetic center position, although it may be

so

acceptable, must be marked on the shaft not

to

mislead the installer into positioning the

as

coupling inappropriately.

4.1.4.2.11

blies for oil leaks

Check sleeve-bearing assem-

as

follows: With all piping,

seals, probes, etc., in place, coat the exterior

or

surfaces of all joints, splits, fittings with whiting and allow it the bearing chamber

to

its normal oil level.

threaded-in

to

dry. Fill

Observe the whiting for any signs of darkening indicating an oil leak, and seal any leaks that may appear with original sealing gasket

or

material. Repeat this process following

final running tests.

4.1.5

&tor

4.1.5.1

lifted and handled carefully transmit any lifting part of the rotor cage

Rotohhaft assemblies should be

so

as not

or

other stresses

or

other motor windings.

to

any

PRACTICE

Lifting equipment must not cause abrasion other physical damage seal

fits.

FOR

THE

Do

not allow the rotor

REPAIR

AND

to

journal surfaces

to

drag against

REWINDING

or

the inner diameter of the stator when inserting the rotor into the stator.

4.1.5.2

Centering of the

rotor

within the

stator should be checked, whenever permitted by the machine construction, by both "stationary gap" and "rotating gap" feeler

at

gage readings

Readings should

90"

points

apart around the

both ends of the motor.

be

taken

at

not less than three

rotor

periphery. In the "stationary" check, feeler gages are inserted successively at the separate points and the values recorded. In the "rotating" check, the gages are left is turned in

90"

one location and the

steps, noting the reading

rotor

at

each step. This test can reveal an eccentric

rotor

that may go undetected by the

"stationary" test. Readings should fall with-

a

+lo%

in end except for two-pole

deviation from the average

(3600

rpm) induction

machines, which should be limited

deviation. (See API

541-1987 [41,

at

each

to

+5%

Section

2.4.8.13.)

4.1.5.3

should be dynamically balanced

Balancing.

Rotodshafi assemblies

at

the largest

fraction of maximum operating speed possible

on the repair center balancing machine. Balancing should be done with the rotor supported on its shaft-bearing journals. The amount of unbalance should be measured in

ounce-inches. The amount and location of balance weights added in the process, including their relative phase angle, should be

recorded. Available manufacturer's recom-

be

mendations should

followed concerning the

acceptable limit of residual unbalance, but in

be

of

what-

these

ro-

any event, the degree of balance must

to

ever is required

as given in Table

CAUTION:

two-pole machines may require special balance tech-

niques, sometimes at rated speed. The balance

tors

instructions or approval.

Induction two-pole machines or synchronous

should not

be

meet final vibration limits

1.

changed without express written owner

After complete motor reassembly, final

balancing at maximum operating speed

to

should be carried out

dard vibration limits, as shown in Table

4.1.6

Electrical

4.1.6.1

Connections

Where any cables pass across

achieve NEMA stan-

1.

or

against metal edges of motor structural parts

in the assembled machine, cable should

be

T

18

-1

I

OF MOTORS FOR

I

THE

PETROLEUM

AND

Maximum

CHEMICAL

Amplitude,

INDUSTRY

Table

1

Inch,

Peak-to-Peak,

MeasuredonBearingHousinginanyDirection

(with

KalfKey)

~ ~ ~ ~ ~~~~

Machine

3000

and above 0.001

1500-2999, incl.

Above 445 T Frame 0.002 0.0005 To 446 T Frame 0.0015 0.0005

1000-1499, incl. 015

Above 445 T Frame 0.0025 0.001

Below

999

and

Above 445 T Frame 0.003 0.0012

*Special requirement is

RPM

445 T Frame 0.002 0.001

below

for

NEMA

important

Standard Special* InchedSecond

O.OOO25

motors

as designated by the owner.

Velocity

0-Peak

0.1

015

IEm

Std1068-1990

appropriately sleeved

or

taped for mechanical

protection of the insulation against abrasion.

4.1.6.2

manent markings adjacent

All leads should be given per-

to

the terminal

lugs in the form of indented metal bands

(unless permanently die-stamped into the

ca-

ble insulation). Lead identification should be in accordance with ANSUNEMA MG

131,

Part 2.

4.1.6.3

Lead cables should not be brazed

welded

to

terminal lugs. The preferred method of attachment is by crimping indenting the lug barrel, using a lug sized

or

pressure-

1-1986

or

to

suit the particular cable stranding provided, in accordance with recommendations of the lug manufacturer.

split barrel lugs are

to

No

be used. The crimping tool used should have ratchet pressure control such that the tool cannot be opened and released from the lug until the minimum recommended crimping

No

force has been applied. should be crimped within the barrel

more than one cable

of

any one lug. In no case shall any strands of cable be cut

or

bent back out of the lug barrel more easily strands must be fully attached

4.1.6.4

fit

the cable into the barrel.

to

Any bolted joints in the lead connections, such as where two are permanently joined together

the lug.

or

more lugs

or

where bus

so

as

to

All

bars are interconnected in some large

to

machines, should be tightened

the following

minimum torque values (based on heat-

5.0

treated, Grade

steel bolts having un-

lubricated threads):

Minimum Dry

Bolt Size Tightening Torque

Inch lb-ft

1

11

21

38

85

75

4.1.7

4.1.7.1

114

5A

6

318

112

5/8

Fits

All parts containing machined

fits-bearing brackets, frame structures,

or

bearing capsules handled in such

scarring any of the machined surfaces.

holders, etc.-should be

a

way

as

to

avoid distorting

or

Any

such fits should be thoroughly cleaned before

to

a

being reassembled

to

avoid getting a fit "cocked," and be sure

mating part. Take care

parts are fully seated against any locating shoulders.

4.1.7.2

materials appropriate

Gaskets should be replaced with

to

the motor's in-service

environment. Sealing compounds used in lieu

of

gasketing should be applied in adequate

to

thicknesses

be

should

fully seal the opening and

of a consistency such as

to

remain in

place after assembly.

4.1.7.3

mating parts are Tightness of mounting bolts, sealing compound, is not

Any dowel pins supplied between

to

be properly replaced.

or

any sort of

to

be relied upon

to

maintain part alignment.

-1

1

19

IEEE

Std106El990

shims

gap

4.1.7.4

or

Some large motors may require

to

adjust

stator

position for correct air

to

control bearing pedestal position. Shims used for that purpose must be free from burrs, and either stepped

as

necessary to accommodate surfaces

IEEE RECOMMENDED PRACTICE FOR

flat,

clean,

or

tapered

that

may not be parallel.

4.1.8

Painting

4.1.8.1

All accessible bare metal surfaces (including weld beads applied during repair) should be thoroughly cleaned and prime painted. Unless the owner specifies otherwise,

finish paint can be chosen by the repair facility.

4.1.8.2

as

shaft extensions) should be coated with

rust-preventive coating unless the machine

to

be returned

4.1.9

4.1.9.1

Exposed machined surfaces (such

to

Shipping

service immediately.

Precautions

For

either railcar or highway truck

is

transportation, rotodshaft assemblies of sleeve-bearing motors should be blocked for shipment. The shaft should be restrained against either endwise, sidewise,

or

up-and-

down movement caused by impact. Screws,

or

clamps, plates,

other blocking means should be clearly identified for removal before the motor is started.

4.1.9.2

Vertical-shaft motors, or motors having antifriction bearings, need not be blocked for shipment provided one bearing is

as

"locked"

4.2

mended practice is intended that are accomplished in

part of the normal assembly.

Field

Repairs.

Although this recom-

to

apply

a

repair facility, it

to

repairs

is

recognized that repairs can and will be made

For

at the installation location.

those cases, not all of the sections of this document will apply. Others, however, should still be required.

a

These can be handled on

job-by-job basis through communication between the owner and repair facility.

5.

Postrepair

5.1

Repair

Facility.

Upon completion of motor repairs, the repair facility should submit written report including the following:

Condition of the motor upon receipt

(1)

THE

REPAIR

(2)

A detailed description of the work

AND

performed

(3)

Condition of the motor (both electrical and mechanical) when returned

(4)

Sufficient test data demonstrating that the motor was appropriately repaired

(5)

Photographs

as

deemed necessary for

clarity The Motor Repair Report (Appendix A) intended should be supplied

to

demonstrate

the

information that

as

a

minimum. This report should be protected by a water-resistant envelope, attached

to

the motor when it is

returned.

5.2

a

Postrepair

User. After repairs have been completed and the motor is returned to the owner,

few precautions need

to

a

ensure that the repairs will have the desired result-a motor restored to a condition that will perform with the same or better characteristics as the original motor.

to

If the motor is stored in such a manner tegrity of the repairs. If it

be put in stock,

as

to

preserve the in-

is

left outdoors, some method of low-level heating should be employed to avoid moisture condensation within

the enclosure and deterioration of unpainted surfaces.

is

When the motor

reinstalled, the mechani-

cal placement and alignment should be care-

fully checked to ensure that the motor

securely fastened

to

the foundation and that the shaft is properly lined up with the shaft of the driven equipment. Proper shaft alignment critical whether the shafts are parallel line.

The electrical connections should be carefully made to ensure that they are tight and properly insulated. When the motor is first

energized, a check should be made of the ning currents and these compared with both the nameplate and historical data. It is helpful if the motor is run uncoupled until bearing temperature stabilizes to rule out any major

to

problems and

locate the magnetic center for proper coupling installation. After the motor is coupled to the load but before energizing, the

shaft should be rotated by hand, if possible,

a

be sure that no problems have occurred in the driven load or the coupling installation.

REWINDING

be taken

it

should be

or

run-

is

to

is

in

to

OF MOTORS FOR

Armintor,

W.

G., “Repair, Restoration, and Revital-

THE

PETROLEUM

K.,

Mills, R. W., and Stiffler,

AND

CHEMICAL

ization of Large Induction Motors,” IEEE-

PCIC-80-26, New York. Bonnett, Austin

H.

and Soukup, George C., “Analysis of Rotor Failures in Squirrel Cage Induction Motors,” IEEE-PCIC-87-2, New

York.

H.,

Bonnett, Austin

“Safety Considerations for the Application, Installation, Operation, and Maintenance of Industrial AC Induction Motors,” IEEE-PCIC-88-9, New York.

Campbell, and Wakeley,

K.,

E., McShane,

“Strains

on

I.

E.,

Motor

J.

J.,

Clark,

P.

Endwindings,” IEEE-PCIC-82-6, New York.

INDUSTRY

Hamer, Paul

S.,

“Acceptance Testing tric Motors and Generators,” IEEE-PCIC-87-5, New York.

B.

H.

Maru,

and Wennerstrom, C.

H.,

of Modifications on Efficiency of AC

Induction Motors,” IEEE-PCIC-81-20, New

York.

Montgomery, David C., “The Motor Rewind

-A

Issue

New Look,” IEEE-PCIC-83-73, New

York.

L.,

Nailen, R.

“A User’s View of Motor Repair Standards and Specifications,” IEEE-PCIC87-16, New York.

Soukup, George C., ”Determining Motor Quality Through Routine Electrical Tests,” IEEE-PCIC-88-24, New York.

IEEE

std1068-1990

of

Elec-

“Effect

IEEE

stdl0681990

IEEE RECOMMENDED PRACTICE FOR

Appendixes

THE

REPAIR

AND

REWINDING

(These appendixes are not a part of IEEE Std

Motors

for the Petroleum

and

Chemical Industry, but are included for information

1068-1990,

IEEE Recommended Practice for

AppendixA

Motor

Repair

Motor Number Date Serial Number Service

MFG

I

P.F.

Frame

Type

I

KPlkW

I

Exciter

I

Voltage

I I

I

Insulation Class

Style

A

I

Exciter

V Secondary

Amps

Report

I

Design

1

Work

Performed:

STATOR: Rewind Retreat Clean and Paint STATOR SHORTED IRON: Yes No

If found shorted, action taken:

Circle the appropriate items below

the

only.)

Repair and Rewinding of

Form

Hz

I

Phase

Fordandom Wound

A

I

I I

I

Secondary V Rise Temperature

Code

RPM

I

Temperature Ambient

I

OT

fill in

as

necessary.

I

Enclosure

I

Model

ServiceFador

I

1

ROTOR SINGLE-PHASE TEST: If bad, action taken:

ROTOR: Rebuild Rewind Retreat Clean and Paint ARMATURE OR FIELDS: Rewind Retreat Clean and Paint LEADS: Repair Replace Seal BRUSH HOLDERS: Reinsulate Repair Replace Clean COMMUTATOR: Repair Rebuild Replace Turn METAL WORK: Housing Journal Other: ANTTFRICTION BEARINGS: (Indicate type: SLEEVE BEARINGS: Rebuild Replace Scrape Reinsulate BEARING SEAL: Rebuild Replace Remachine Reset

FLAME

SEAL: Rebuild Replace Remachine Reset

Good

22

Bad

)

Sealed Shielded Open

Undercut

OF MOTORS FOR

THE

PETROLEUM

AND

CHEMICAL

INDUSTRY

IEEE

std1068-1990

Motor

Data

Insulation

Resistance

ReUd

Temperature Humidity Surge test passed failed

Drive-End Bearing

&Pe*B

Found Bearing Size Shaft Size

Before

Fan End Drive End Vertical Horizontal Diagonal

Left

Fan-End Bearing

Found

After

Fan End Drive End

Left

Cause

of

FailMotes/Comments

Vibration

23

Analysis

THIS

BLANK IN

PAGE WAS

THE

ORIGINAL

THIS

BLANK IN

PAGE WAS

THE

ORIGINAL

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SONY 29FX66E Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

References

Repair Facility Responsibility

4.1 Repair Facility

Postrepair