abcd alstom (switzerland) ltd. nhon trach 1 …eam.pv-power.vn/attachments/0000676280.pdfoperation...

Owner’s Consultants

ESB International

Owner PETRO VIETNAM

GPPMB

PECC2

EPC Contractor

LILAMA – CC1 CONSORTIUM

Issued by

LILAMA CORPORATION – HYUNDAI ENGINEERING

Subcontractor

abcd

ALSTOM (Switzerland) Ltd.

Project

NHON TRACH 1 CCPP PROJECT

Owner’s Identification No. EPC Contractor Identification No.

ALSTOM Document Code NHT/01/M/-------B20/MM/001

Revision History

Rev. Revision Date Created by Checked by Approved by Description

A 10.04.2008 D.E.YANG J.W.SHIN K.R.KIM First issue

Description latest Revision:

OPERATION AND MAINTENANCE MANUAL FOR CONDENSATE EXTRACTION PUMPS

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OPERATION AND MAINTENANCE MANUAL

FOR CONDENSATE EXTRACTION PUMPS

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TABLE OF CONTENT CHAPTER DESCRIPTION PAGE

1.0 OPERATION ---------------------------------------------------------------------- 1

1.1 Environment, Health and Safety Instruction ------------------------------------ 1

1.2 Description of Equipment ---------------------------------------------------------- 4

1.3 Operation ----------------------------------------------------------------------------- 7

2.0 MAINTENANCE ------------------------------------------------------------------ 12

2.1 Environment, Health and Safety Instruction for Maintenance ----------------- 12

2.2 General and Preventive Maintenance --------------------------------------------- 15

2.3 Corrective Maintenance ------------------------------------------------------------- 25

2.4 Decommissioning -------------------------------------------------------------------- 28

2.5 Packing, Transport and Disposal --------------------------------------------------- 35

2.6 Component Documentation --------------------------------------------------------- 38

- SECTION 1 : MOTOR

- SECTION 2 : MECHANICAL SEAL

- SECTION 3 : GEAR COUPLING

3.0 TECHNICAL DOCUMENTATION

- Data sheet NHT/01/M/-------B20/DS/001

- Performance curves

- Outline drawing

NHT/01/M/-------B20/MD/002

NHT/01/M/-------B20/MD/002

- Sectional drawing NHT/01/M/-------B20/DD/001

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2.7 Lubrication Schedule............................................................................................................... 39

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- P & I diagram NHT/01/M/-------B20/DD/002

- Installation drawing NHT/01/M/-------B20/DD/003

- Aux. piping drawing NHT/01/M/-------B20/PS/001

- Nameplate drawing NHT/01/M/-------B20/DD/006

- Mechanical seal detail drawing & data NHT/01/M/-------B20/DD/004

- Coupling detail drawing & data NHT/01/M/-------B20/DD/005

- Spare and wear part list NHT/01/M/-------B20/LS/001

- Special tool list NHT/01/M/-------B20/LS/002

- Inspection & Test Plan NHT/01/M/-------B20/MP/001

- Inspection & Test Procedure NHT/01/M/-------B20/MP/002

- Painting specification NHT/01/M/-------B20/MP/003

- Erection Instructions NHT/01/M/-------B20/EI/005

- Erection follow up list NHT/01/M/-------B20/MA/001

- Erection document list NHT/01/M/-------B20/DL/006

- KKS number list NHT/01/M/-------B20/LE/001

- Measurement list NHT/01/M/-------B20/LI/001

- Signal exchange list NHT/01/M/-------B20/LM/001

- Electrical terminal list NHT/01/M/-------B20/TC/001

- Electrical consumer list NHT/01/M/-------B20/EL/002

- Electric connection diagram NHT/01/M/-------B20/WD/001

- Instrument data sheet NHT/01/M/-------B20/DS/003

- Tech. specification for Induction Motor NHT/01/M/-------B20/MD/101

- Motor data sheet NHT/01/M/-------B20/DS/101

- Motor outline drawing NHT/01/M/-------B20/DD/101

- Motor general assembly drawing NHT/01/M/-------B20/DD/102

- Motor main terminal box ass’y NHT/01/M/-------B20/DD/103

- Motor acc’y terminal box ass’y NHT/01/M/-------B20/DD/104

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- Motor heater terminal box ass’y NHT/01/M/-------B20/DD/105

- Motor speed torque & current curve NHT/01/M/-------B20/DD/106

- Motor thermal limit & time current curve NHT/01/M/-------B20/DD/107

- Motor painting procedure NHT/01/M/-------B20/DD/108

- Motor wiring diagram NHT/01/M/-------B20/TC/101

- Motor instrument list NHT/01/M/-------B20/LI/101

- Motor test plan & test procedure NHT/01/M/-------B20/MP/001

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1.0 OPERATION 1.1 Environment, Health and Safety Instruction

SAFETY STANDARDS Persons responsible for the equipment covered in this manual must ensure that it is properly and safely installed and maintained, operated at the specified conditions. Only appropriately qualified staff, applying acceptable standards of engineering practice and the recommendations contained in this manual, must be employed in these activities. Any similar instructions for the overall plant in which the equipment is to be incorporated, which have an influence on the equipment application, must be strictly followed. Statutory and local requirements concerning work practices, safety and/or health precautions must be observed. Where appropriate, warnings, cautions and notes are included in the manual, and are defined as follows ;

WARNINGS : A warning calls attention to instructions which must be followed to avoid danger to personnel.

CAUTION : A caution calls attention to instruction to instructions which must be followed to avoid damaging the equipment or its surroundings. NOTE : A note gives supplementary information where considered necessary. OPERATING CONDITIONS If the equipment application or operating conditions differ from the equipment was supplied, the equipment was supplied, the equipment and the operating recommendations contained in this manual may be inappropriate. In such circumstances verification of the suitability of the equipment and of the operating and maintenance manual must be obtained in writing from HHI. The contents given below should always be followed since any of them covers important notes on safety. 1. General

1) Never allow any persons other than service engineers to engage in disassembly or repair, or remodeling work.

2) Never work alone and be sure to put on helmet, safety goggles, ear plugs, safety shoes, etc. in

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conformity with the Labor Safety and Health Law, etc.

3) Prior to carrying out any sparking work such as welding, etc., make sure that there are no dangers of fire and explosion hazards.

4) Check the place where emission of toxic gas and deficiency of oxygen are conceivable, such as pit, manhole, etc. before starting on work and make sure of safety.

5) When carrying out the work for centering check, disassembly, etc., be sure to turn OFF the motor switch and affix a tag indicating “NO POWER ON” or the like to the switch so that the switch will not be turned ON by mistake.

6) Before starting on work, be sure to conduct checking of slinging outfits such as crane, wire rope, etc. unfailingly.

7) Install safety fences around the working area and secure an emergency passageway.

8) Since any split oil on the floor, passageway etc, may lead to a cause of slippage etc., wipe it off forthwith.

9) Shaft seal parts will not function to stop the pumped-liquid completely. When handling such a liquid which may cause serious troubles to the human body, therefore, do not touch the splashing liquid from shaft seal parts.

10) Keep away from the casing of the pump that is handling such a hot liquid as may lead to a danger of scalds if coming in contact with the human body.

11) Do not gain access to rotating parts recklessly since there is a possibility of scattering caused by breakage of rotating parts.

12) Take precautions against the possible breakage and scattering which may be caused if leaning against or stopping on the guard.

13) Do not open the thermal cover of electrical devices including motors as there is a danger of electrification while they are being energized.

2. Handling Where both pump and motor are assembled on the common bed, never hang a wire rope on the eyebolt of the motor. Furthermore, do not gain access to the underside of the suspended pump. 3. Direct-coupling For the type of coupling applied with safety cover (coupling cover), fix the safety cover securely to

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the predetermined position with clamping bolts. 4. Disassembly and Reassemble

1) Before carrying out the disassembly work, be sure to turn OFF the motor switch and affix a tag indicating NO POWER ON” or the like to the switch so that the switch will not be turned ON by mistake.

2) Shut off the valves on the suction side and discharge side totally and, in the case of hot liquid, discharge the pump interior liquid from drain valve at the point when the casing temperature has come down to the room temperature or so.

3) Where the pumped-up liquid is a chemical solution, it may lead to a danger of causing injuries such as inflammation and the like if adhering to the human body.

To prevent this, make sure that the casing interior liquid has been discharged thoroughly.

4) When removing parts and partly-assembled components, hang wire ropes to the positions as shown in the instruction manual and use a chain block, etc.

5) When handling hot components such as ball bearing, coupling, etc., be sure to put on protective gloves.

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1.2 DESCRIPTION OF EQUIPMENT

1.2.1 GENERAL DESCRIPTION

This pump has been manufactured with strict quality control and has been designed to demonstrate maximum efficiency during operation. In particular, the impeller which is the most critical part, has been designed based on the three dimensional blade theory to obtain a high efficiency with a minimum of loss. The sliding parts of the rotating body which are subjected to wear are replaceable, and interchangeability of all parts with other pumps of the same type has been taken into consideration. There are no difficulties with operation however, care must be taken to insure that the pump itself and the pipeline are always filled with water. The driver is a motor. For a full understanding of the motor, please carefully read the motor's instruction manual and become thoroughly familiar with it. After careful reading of this pump instruction manual, be sure to operate the pump unit always keeping in mind the operation of the entire plant rather than only operation of the pump alone. 1.2.2 CONSTRUCTION

The condensate extraction pump is a vertical, multi-stage type. Refer to the Pump Sectional Assembly and Outline Drawing provided for the shape, dimensions and structure of this pump. The pump is supported in the vertical position by the mounting flange which is an integral part of the can (1180). The pump driver is mounted on the motor pedestal (1131) and is coupled to the upper shaft (1310B) by means of a flexible coupling (1850). The pump thrust bearing (1440) supports the weight of the pump rotor plus any up or down thrust that is created within the pump. The mechanical seal is used to seal the liquid within the pump at the point where the upper shaft passes through the stuffing box (1610).

1.2.2.1 PUMP CASING The pump casing is composed of the suction cover, volute casing, volute discharge casing, discharge bowl, column pipe and discharge head.

1) Discharge head (1130) The discharge head consists of four parts. Suction/discharge nozzles which are flanged for

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connection to system piping.

Stuffing box (1610) containing mechanical seal that

control liquid leakage to the atmosphere at the pump

shaft where it protrudes through the pressure boundary.

The stuffing box to discharge head joint is sealed by gasket. Radial and thrust bearing case for pump are also mounted on the supporting flange which is bolted to the motor pedestal.

Flanges which are bolted to the can (1180) and column pipe.

The can to discharge head (1130) joint is sealed by a rubber ring.

2) Discharge bowl (1120) The bowl act in directing the flow of liquid through diffuser passage while helping to increase pressure through each successive stage. Bowl contains the bearing fit for a sleeve bearing (1540), plus the casing rings (1230). All bolts are mechanically locked to prevent loosening.

3) Column pipe (1140) The column pipe is fabricated from carbon steel plate and has sufficient strength to withstand the weight and internal pressure of pump.

4) Suction cover (1150A/B) The suction bell consists of a hub which contains sleeve bearing (1540), plus supporting ribs which serve as liquid flow guides. It also contains the suction cover casing rings (1230A) for the first stage impeller (1210A). The suction cover bolts to volute casing (1151), housing the first stage impeller. The suction cover to volute casing joint is sealed by rubber-ring.

5) Volute casing (1151), Discharge volute casing (1152) The casing (1151,1152) consist of hydraulic diffuser passage which convert fluid velocity to pressure. The volute casing contains the bearing fit for sleeve bearing (1540) which prevents the lower shaft from any radial gyrations. The discharge volute casing also houses the casing ring (1230A) for the second stage impeller (1210B). All casing to casing joint are sealed by use of rubber rings. 1.2.2.2 ROTATING PARTS

1) Impeller (1210A/B/C/D) The double suction first stage impeller (1210A) is keyed and held in position on lower shaft (1310A)

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by impeller nut (1212). The remaining impeller is also keyed to the lower shaft (1310A). The impeller has held in position on its respective pump shaft by use of split ring (1883). All impellers are of the enclosed type, one piece construction and are dynamically balanced.

2) Shaft (1310A/B) All shafts are special quality stainless steel and used to transmit the driving force from the motor to the pump impeller (1210).

3) Muff coupling (1840) Keyed and sleeve type coupling provide ease of assembly and disassemble. The coupling slides over the shaft and is keyed to both shafts to transmit the pump torque.

4) Flexible coupling (Gear coupling, 1850) Concentricity of bores and parallelism of machined faces are checked prior to final assemble to insure proper alignment of pump and motor shaft. 1.2.2.3 OTHER PARTS

1) Can (1180) The can encloses the pumping element and provides for immediate containment of the liquid being pumped.

2) Shaft sleeve (1320A/B) The shaft sleeves are of the replaceable type and held in position on the pump shafts(1310A/B) by use of key.

3) Sleeve bearing (1540A/B/C) Sleeve bearing for pump is composed of carbon and nickel. Spiral groove inside of this bearing help the lubrication and prevent from clogging. They are mounted within suction cover, discharge volute casing, discharge bowl, column pipe and stuffing box. The sleeve bearings are renewable and lubricated by the liquid being pumped.

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1.3 OPERATION

During the initial trial operation after installation and operation after disassembly, carefully follow paragraphs.

1.3.1 PIPING CHECK BEFORE START UP

1) Discharge

a) Ensure that discharge supports are located as specified on the construction drawing. b) Check the supports are properly installed. c) Discharge supports should be adequate to support and/or dampen excessive piping vibration. d) Ensure that the valves in the discharge piping are supported. e) Check valve and discharge vent are located below the static water elevation of the system. f) Ensure that all high points in minimum flow by-pass system are adequately vented.

2) Suction

a) Ensure that supports are located as specified on the construction drawing. b) Check that the suction valve is supported. c) If expansion joints are employed with the rods, ensure that they are uniformly tightened. d) The system has to be checked for water leaks. e) All high points in suction piping have to be vented. f) Provision for continuous venting have to be made for the point where air pockets cannot be avoided. g) Check provisions to monitor suction strainer head losses (blockage) are available.

1.3.2 PREPARATIONS AND CHECKS FOR PRE-START 1) Ensure that the control panel system is correctly connected to the pump set and all functions are satisfactory. 2) Check the quantity of lubricant oil for the thrust bearing. 3) Check the cooling water line for pump thrust bearing.

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4) Check the mechanical seal according to "Mechanical seal drawing" and "Manual for mechanical seal". CAUTION : Ensure that centering tabs shall be removed before running pump according to seal drawing. 5) Turn only the motor shaft by hand. 6) Confirm the motor rotating direction by starting it just for a moment. It should be clockwise viewed from the motor top. 7) Connect the coupling. Ensure that the reamer bolts are inserted to the coupling and all nuts are fastened. Also the coupling guard is installed in the windows of the discharge head. 8) Check the auxiliary piping. It is especially necessary to confirm the opening or closing of valves at the piping. 9) No protection relay should be actuated, if any. 1.3.3 STARTING STEP Correct starting of the pump will assure maximum service life, whereas, incorrect starting can cause premature wear. 1) Close discharge valve 2) Check that the sealing liquid is injected to the mechanical seal during the following: a) During pump running b) During "stand-by" condition if pump is operating under vacuum. 3) Open the suction valve slowly. Make sure the pump is completely filled with the liquid to be pumped.

WARNING : Before starting any centrifugal pump, the pump and suction piping must be completely filled with liquid. Damage can be caused if the pump is operated dry.

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4) Open the discharge and suction vent valves. 5) Start the pump. As soon as it is up to speed, open the discharge valve slowly to prevent any abrupt change in capacity. If the pump is to be used to fill or flush the system, the discharge valve must be regulated so that discharge pressure is at design pressure or above. 1.3.4 CAUTIONS FOR START-UP AND OPERATION Check to make sure that start-up requirements are completely satisfied. 1) Ensure that the seal water valves are opened. Before starting or while operating the pump, casing and suction line must be filled with the liquid being pumped. The rotating parts depend on this liquid for lubrication and the pump may seize if operated without water. 2) Discharge line to check valve should be fully primed to avoid water hammer damage. If this is not physically possible provisions should be made for slow motor starts, flywheel addition, or by-pass. 3) When operating for some time at reduced capacity, much of the pump horse power will go into the liquid in the form of heat. A by-pass must be provided under these conditions to prevent the liquid in the pump from becoming hot enough to vaporize. 4) Do not attempt any maintenance, inspection, repair or cleaning in the vicinity of rotating equipment. Such action could result in personnel injury. 5) Be careful not to start the pump under reverse flow condition, and not to operate at shut-off condition over than one (1) minute. We do not recommend that the pump be operated under prolonged or severe cavitating conditions. Avoid sustained pump operation below Min. flow. 6) For the first operation after pump installation or re-assembly, start the pump for a short time period. During this time, check that the equipment operates satisfactorily without detrimental surges, vibration, noise, etc. If operation is satisfactory, operate the pump continuously. 7) The unit must not be operated unless the coupling guard is placed at proper position. Failure to observe this could result in injury to operation personnel. 1.3.5 OPERATING CHECK

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1) Pay attention to abnormal noise and abnormal vibration. If air or foreign matter enters the pump, or if there is a change in the operation point or mis-operation and defect of valves in the discharge lines, abnormal noise and vibration will occur and pump discharge pressure will vary greatly or the current meter of the motor will vary suddenly during operation. In such cases, immediately check these problems and find the cause. 2) Check the motor temperature detector. After starting operation, pay attention to the temperature rise of the motor bearing. Even after the temperature reaches a steady value, occasionally check it. If an abnormal rise is noted in the temperature, immediately shut down the pump and investigate the cause. 3) Check the pump bearing temperature detector. After starting operation, pay attention to the temperature rise of the pump thrust bearing. Even after the temperature reaches a steady value, occasionally check it. 4) Emergency stopping. If following happens, it is preferred to interlock to stop the pump automatically.

a) Motor overload b) Starting delay c) Motor winding temp. rise : over 140 d) Motor bearing temp. rise : over 100 e) Pump thrust bearing temp. rise : over 90

1.3.6 SECURING THE PUMP 1) Close the discharge valve. 2) When discharge valve is completely closed, immediately trip the motor circuit to stop the pump. If pump stops abruptly when motor is shut down, investigate for pump binding. Take necessary remedial action before restarting pump. 3) Close the vent and drain valves in accordance with established plant procedures. 4) Turn off sealing liquid to stuffing box.

CAUTION : Do not close the suction valve before stopping the pump; this would cause the pump to run dry and may cause the pump to seize.

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1.3.7 FREEZING 1) When the pump is exposed to freezing temperatures while not in operation, care should be taken to prevent the liquid from freezing within the pump (seal flushing line, cooling water line, inside pump). If necessary, the pump should be drained. 2) Take adequate measures to protect motor from freezing temperatures while not in operation (i.e., cooling coils, when used, must be drained, etc.). See motor manufacturer's instructions.

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2.0 MAINTENANCE

2.1 Environment, Health and Safety Instruction for Maintenance

SAFETY STANDARDS

Persons responsible for the equipment covered in this manual must ensure that it is properly and

safely installed and maintained, operated at the specified conditions.

Only appropriately qualified staff, applying acceptable standards of engineering practice and the

recommendations contained in this manual, must be employed in these activities.

Any similar instructions for the overall plant in which the equipment is to be incorporated, which

have an influence on the equipment application, must be strictly followed.

Statutory and local requirements concerning work practices, safety and/or health precautions must be

observed.

Where appropriate, warnings, cautions and notes are included in the manual, and are defined as

follows ;

WARNINGS : A warning calls attention to instructions which must be followed to avoid danger to personnel.

CAUTION : A caution calls attention to instruction to instructions which must be followed to avoid damaging the equipment or its surroundings.

NOTE : A note gives supplementary information where considered necessary.

OPERATING CONDITIONS

If the equipment application or operating conditions differ from the equipment was supplied, the

equipment was supplied, the equipment and the operating recommendations contained in this manual

may be inappropriate. In such circumstances verification of the suitability of the equipment and of

the operating and maintenance manual must be obtained in writing from HHI.

The contents given below should always be followed since any of them covers important notes on

safety.

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1. General

1) Never allow any persons other than service engineers to engage in disassembly or repair, or

remodeling work.

2) Never work alone and be sure to put on helmet, safety goggles, ear plugs, safety shoes, etc. in

conformity with the Labor Safety and Health Law, etc.

3) Prior to carrying out any sparking work such as welding, etc., make sure that there are no dangers

of fire and explosion hazards.

4) Check the place where emission of toxic gas and deficiency of oxygen are conceivable, such as pit,

manhole, etc. before starting on work and make sure of safety.

5) When carrying out the work for centering check, disassembly, etc., be sure to turn OFF the motor

switch and affix a tag indicating “NO POWER ON” or the like to the switch so that the switch will

not be turned ON by mistake.

6) Before starting on work, be sure to conduct checking of slinging outfits such as crane, wire rope,

etc. unfailingly.

7) Install safety fences around the working area and secure an emergency passageway.

8) Since any split oil on the floor, passageway etc, may lead to a cause of slippage etc., wipe it off

forthwith.

9) Shaft seal parts will not function to stop the pumped-liquid completely. When handling such a

liquid which may cause serious troubles to the human body, therefore, do not touch the splashing

liquid from shaft seal parts.

10) Keep away from the casing of the pump that is handling such a hot liquid as may lead to a

danger of scalds if coming in contact with the human body.

11) Do not gain access to rotating parts recklessly since there is a possibility of scattering caused by

breakage of rotating parts.

12) Take precautions against the possible breakage and scattering which may be caused if leaning

against or stopping on the guard.

13) Do not open the thermal cover of electrical devices including motors as there is a danger of

electrification while they are being energized.

2. Handling

Where both pump and motor are assembled on the common bed, never hang a wire rope on the

eyebolt of the motor. Furthermore, do not gain access to the underside of the suspended pump.

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3. Direct-coupling

For the type of coupling applied with safety cover (coupling cover), fix the safety cover securely to

the predetermined position with clamping bolts.

4. Maintenance

When carrying out the work for replacement of gland packing or mechanical seal, be sure to turn

OFF the motor switch and affix a tag indicating “NO POWER ON” or the like to the switch so that

the switch will not be turned ON by mistake.

5. Disassembly and Reassemble

1) Before carrying out the disassembly work, be sure to turn OFF the motor switch and affix a tag

indicating NO POWER ON” or the like to the switch so that the switch will not be turned ON by

mistake.

2) Shut off the valves on the suction side and discharge side totally and, in the case of hot liquid,

discharge the pump interior liquid from drain valve at the point when the casing temperature has

come down to the room temperature or so.

3) Where the pumped-up liquid is a chemical solution, it may lead to a danger of causing injuries

such as inflammation and the like if adhering to the human body.

To prevent this, make sure that the casing interior liquid has been discharged thoroughly.

4) When removing parts and partly-assembled components, hang wire ropes to the positions as

shown in the instruction manual and use a chain block, etc.

5) When handling hot components such as ball bearing, coupling, etc., be sure to put on protective

gloves.

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2.2 GENERAL AND PREVENTIVE MAINTENANCE

2.2.1 ROUTINE MAINTENANCE

1) Daily Check

Performing daily inspections and keeping records of pump operation help in finding abnormalities

and preventing trouble in advance and record daily the followings.

Record daily the following ;

a) Discharge pressure

b) Water level of suction pit

c) Electric current

d) Electric voltage

e) Motor power

f) Temperature of motor bearings

g) Temperature of pump thrust bearings

h) Ambient temperature

i) Operation time

j) Flow at seal water line

k) Cooling water flow at pump thrust bearing line.

l) Lubrication oil level or grease quantity for bearing

2) Overhaul Check

a) Pumps should be overhauled once a year.

When overhauling a pump, check every part for wear, erosion, corrosion.

Also, measure and record the outside and inside diameter of sliding parts and their clearance. The

designed dimensions of these sliding parts are as shown in Table 2.1. If wear exceeds the allowable

value or nearly reaches it, replace any wear part with a new one.

b) Coupling and Keys

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Examine all keys for wear and damage. Make sure that they are flat, parallel and free from burrs,

and have a good fit in the key slot. Replace, if necessary.

c) Check the function of small valve in auxiliary piping

Table 2.1

2.2.2 DISASSEMBLY

Disassembly procedure shall be performed in the following order. Before starting disassembly, read

and study paragraph 2.2.3 CAUTIONS FOR DISASSEMBLY. Confirm that the working area is

sufficiently large and that the ground is flat enough for a crane to be used conveniently.

Prepare tools, lifting wire, temporary rust preventive, etc. Remove water from the pump and related

piping.

1) Break and tag motor circuit breaker. Disconnect electric leads and water cooling service lines.

Remove the coupling guard from discharge head.

2) Remove the coupling bolting.

3) Remove the motor to motor pedestal (1131) bolting

4) Rig the motor to an overhead hoist. Lift motor from the motor pedestal and place motor on

blocking on the floor.

Running Clearance (mm) Max. Allowable Clearance At Dry condition

1st Impeller wearing 0.45 ~ 0.553 0.83 Series Impeller wearing 0.50 ~ 0.622 0.93 Sleeve bearing (Lower) 0.13 ~ 0.16 0.24 Sleeve bearing (Inter, upper) 0.26 ~ 0.31 0.46

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5) Disconnect suction/discharge piping from discharge head (1130), plus auxiliary piping which will

interface with dismantling.

6) Remove flexible coupling with key from upper shaft (1310B).

7) Remove journal nut (1489), bearing cover (1443), radial bearing case (1441), radial bearing

(1430), journal (1488), thrust bearing (1440), thrust bearing case (1442) in sequence.

CAUTION : Do not disassembly the cooling water coil inside bearing box from thrust bearing case body.

8) Remove mechanical seal. (1893)

9) Remove the stuffing box(1610) from discharge head(1130).

CAUTION : Take care not to damage the mechanical seal(1893) in the process of removing the stuffing box (1610).

10) Rig sling at lifting rug hole of discharge head.

Remove bolt which secure discharge head flange to can (1180) flange.

Using overhead hoist, lift the pump proper from the can.

11) Position blocking under the volute casing, the discharge bowl, column pipe (1140) and discharge

head (1130) as shown in Fig. 1

Fig. 1

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12) Remove the discharge head to column pipe bolting.

13) Slide the discharge head and column pipe from the upper shaft and place them in a vertical

position on blocking on the floor. Remove rubber ring and discard. Soon after dismantling the

column pipe, support the shaft by wooden block in order to protect shaft from permanent bending.

14) Pull muff coupling toward discharge upper side and remove the upper shaft, muff coupling and

coupling collar. Place shaft on horses and block to prevent rolling.

15) Remove lower column pipe, intermediate shaft, muff coupling and coupling collar with the same

procedure as described in 13) and 14).

16) Remove bolting holding suction cover lower (1150A) to volute casing (1151).

17) Withdraw the suction cover lower and casing wear ring (1230A). This will expose the lower

shaft sleeve and first stage impeller. Remove exposed rubber ring from fit in flange of suction cover

and discard rubber ring.

18) Remove the snap ring in order to dismantle lower shaft sleeve (1320A) and key for sleeve from

the lower shaft.

19) Remove the impeller nut (1212), first stage impeller (1210A) and distance piece (1211).

20) Remove bolt holding volute casing (1151) to volute discharge casing (1152).

21) Remove volute casing (1151). After that upper suction cover (1150B) can be dismantled.

22) Remove bolt holding volute discharge casing (1152) to discharge bowl (1120A).

23) Remove volute discharge casing (1152).

24) Remove snap ring in order to dismantle inter shaft sleeve (1320B) and key for sleeve from the

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lower shaft (1310A).

25) Remove the split ring (1883) and the second stage impeller (1210B)

26) Remove second stage discharge bowl (1120A).

27) Remove snap ring in order to dismantle inter shaft sleeve (1320B) and key for sleeve from the

lower shaft (1310A).

28) Remove second stage split ring, impeller, discharge bowl, snap ring and inter shaft sleeve with

the same procedure as described in 25) ~ 27)

29) Remove the last stage discharge bowl (1120C).

30) Remove the split ring (1883) and the last stage impeller (1210D).

31) Remove the snap ring in order to dismantle inter shaft sleeve (1320B) and key for sleeve from

the lower shaft (1310A). Tag and record all items for reassembly purposes.

2.2.3 CAUTIONS FOR DISASSEMBLY

1) Cautions for unloading products

a) In hoisting heavy parts such as the pump proper, pay careful attention to attaching the wire rope so

that the load will be centered and the wire rope will not slip.

b) When lifting heavy parts, use soft padding under the wire to protect the coated and machined

surface from the wire. Do not raise or lower the parts too rapidly with the crane.

c) When mounting the parts on the ground, use protecting blocks between the parts and the

ground. Also, when assembling the pump parts horizontally, use protecting blocks under the pump

casing as shown in Fig. 2 to protect the coated surface and prevent rolling.

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d) When lifting the pump proper, be careful not to bump the wire on the coupling.

Fig. 2

2) Do not damage the surfaces of mating flanges.

3) Tape the shaft threads for protection after disassembly.

4) After disassembly, apply temporary rust prevention to the machined surfaces of the motor

pedestal, discharge elbow and outside surfaces of coupling.

5) When laying the shafts on the floor, support them more than three points per shaft (ends and

center of shaft), as horizontally as possible, to do not cause bending.

6) To prevent missing parts and confusion of parts with those from another machine, provide cases

for disassembled parts and put parts into the cases.

7) Put bolts into bags as a set, if necessary.

8) During and after disassembly, do not step on the auxiliary piping or drop anything on them,

because the auxiliary piping will be damaged.

9) Before attempting any inspection or repair on the pump the driver controls must be in the "off"

position, locked and tagged to prevent injury to personnel performing service on the pump.

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2.2.4 REASSEMBLY

The reassembly procedure should be performed in the opposite order of the disassembly. Before

starting the reassembly, read and study paragraph 2.2.3 CAUTIONS FOR REASSEMBLY.

For the centering of pump and motor, be careful of followings.

1) Check the level of the upper surface of the pump base. Tolerance of lever should be less than

0.05mm.

2) Mount the pump on the pump base.

3) Check the lubricant for the motor bearings and turn the motor shaft several times by hand.

4) Attach a dial gauge to the hub of motor coupling and turn the motor by hand.

To perform this centering, the motor can be moved horizontally with the push bolts, provided at the

top of motor pedestal.

a) The parallel misalignment shall be adjusted by moving the motor horizontally with the push

bolts which are fitted on the top of the motor pedestal. The parallel misalignment is the half of the

total indication reading on the dial indicator.

b) The angular misalignment shall be adjusted by inserting or removing the shim plate between

bottom side of motor flange and upper surface of motor pedestal, be sure not to touch the shaft or

coupling when taking the dial indicator reading.

The shaft centering should be less than 0.05mm as shown in Fig. 3

Between motor & pump shaft A(mm) B(mm) Below 0.05 Below 0.05

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Fig. 3

5) Adjust the impeller clearance.

a) First loosen the journal nut (1489) sufficiently in order to lower the pump rotor fully.

Be careful that the journal nut have left-hand thread.

b) Turn the journal nut until pump rotor is lift up to 5mm in order to adjust impeller clearance (axial

clearance between casing ring and impeller shall be 10mm) as shown in Fig.4.

Fig. 4 Adjusting of impeller clearance

6) Finally fasten the bolts between the motor and the discharge head.

7) Check the rotating direction of motor.

8) Connect the coupling of pump and motor side with the reamer bolts.

2.2.5 CAUTIONS FOR REASSEMBLY

1) Refer to paragraph 2.2.4, item 1) for unloading.

2) Clean and flush the interior of auxiliary piping just before reassembling.

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3) When reassembling each part, remove foreign material in the tap holes with compressed air and

check that there is no protuberancy or dust on the flange and fitting surfaces.

4) Be careful not to drop tools and small parts into the suction can. If these are sucked into the pump,

the rotating element, casing and impeller will be damaged.

5) Before reassembling, clean the temporary rust preventive from the machined surfaces of motor

base, discharge head and outside surfaces of the coupling. After completion of centering of the pump

and motor, and motor pre-commissioning, re-coat some rust preventive to the outside surfaces of the

coupling.

6) If wear of sliding parts exceeds the allowable value or nearly reaches the value, replace any worn

part with a new one. Refer to paragraph 2.2.1 2).

7) Generally, replace the consumables (such as O-rings, rubber rings, gland packing, etc.) with new

parts.

8) All reassembly must be done according to joint marks, which have been put on each part at shop

(for example, on the flange rim)

9) When assembling the impeller and coupling to the shaft and tightening the fixing bolts, spray or

coat anti-galling compound (Never Seez or equivalent) on the fitting surface, thread and reamer

surface to prevent seizing.

10) Details of "NEVER SEEZ" are shown in Table 2.2.

Table 2.2 Brand Name & Type Material Maker Prevention

NEVER SEEZ (AEROSOL AND STANDARD TYPE)

HYDRO CARBON COMPOUND, ETC.

NEVER SEEZ COMPOUND CORP.

SEIZING

11) Fastening direction of the impeller nuts : Clockwise (C.W)

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12) To prevent uneven tightening, tighten flange bolts in a cross-cross pattern as shown in Fig. 5

Fig. 5

13) After reassembly, repeatedly check to make sure that all bolts of each flanges and other parts are

completely and evenly tightened.

14) Touch up the coated surface with paint which has been damaged during reassembling. After

completion of centering of the pump and motor, and motor pre-commissioning, re-coat some rust

preventive to the outside surfaces of the coupling.

15) During and after reassembly, do not step on the auxiliary piping or drop anything on them,

because the auxiliary piping will be damaged.

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2.3 CORRECTIVE MAINTENANCE

2.3.1 TROUBLE SHOOTING

Please refer to "TROUBLE SHOOTING CHART".

This covers common troubles and measures to be taken.

It must be noted that two or more of the following causes can take place at the same time.

In case of trouble, details of the trouble should be clarified and referred to pump maker Hyundai

Heavy Ind. Co., Ltd.

TROUBLE SHOOTING CHART

TROUBLE

CAUSE REMEDY

Speed too low Check power supply to motor for correct voltage.

Incorrect direction of rotation Switch motor leads.

Foreign material in impeller Dismantle pump and remove any foreign material.

Foreign material in suction line

Check suction pit and remove foreign material.

Insufficient capacity and/or pressure

Mechanical Defects -Impeller damaged -Sheared impeller key(s)

Dismantle pump and correct.

Electric circuit problem Check the electric circuit Pump is not starting

Motor problem Check the motor

Loose mounting or coupling bolts. Tighten bolts.

Broken or damaged coupling Inspect and replace.

Motor problem Check the motor

Pump vibrates

Misalignments Check alignment and correct. See paragraph 4.5

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Foreign material in impeller causing unbalance

Dismantle pump and remove any foreign material.

Mechanical Defects ; - Shaft bent. - Bearings worn.

Dismantle pump and replace parts causing vibration. See paragraph 4.1-(3)

Cavitation Check the pressure of suction and discharge. And check the difference pressure of strainer

Speed too high. Check power supply for correct frequency.

Over-tighten the gland packing

Check the gland packing and loose the gland bolt.

Motor overload

Pump bearings seize or Rotating element binds

Dismantle and replace parts causing seizure, or binding.

Cavitation Check water level and keep operation range.

Loose parts Tighten or replace defective part. Pump is noisy

Noise in driver Check motor with stethoscope.

2.3.2 WORN PARTS EXCHANGE

If wear of sliding parts exceeds the allowable value or nearly reaches the value, replace any worn

part with a new one. In this chapter, the detail procedures for exchange of the worn parts are shown.

1) Wire brush and clean all pump parts thoroughly. Examine the parts for wearing corrosion and

erosion.

2) Indicate each section of shaft on "V" blocks or rollers for run-out. Maximum allowable run-out on

pump shaft (1310A/B) is 0.05 mm TIR. Run-out should be measured with the rollers or V-blocks

located at the bearing journal areas.

3) Casing rings (1230A/B/C) are locked in position by headless setscrews. With the casing ring in

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place, a small hole is drilled so that half of the holes is in the ring and half is in the suction bell, bowl.

The hole is then tapped, and the pin is installed. The hole should be deep enough to permit the pin to

go beyond the top thread or two. The top threads are lightly stacked. Stacking is done by use of a

thin center punch and a lightweight hammer. The depth of the stake should not exceed the top thread

or two: as its intent is to prevent the pin from ever coming out of its own accord, but not to jam the

pin tight at very bottom of its hole.

To remove the setscrew, it will be necessary to insert a thin bladed screwdriver in the hole and

carefully remove the pin. Remove the setscrew and press the casing out of its fit. If pressing is not

easy to remove the ring, drill one or more holes in the face of the worn casing ring split apart. Install

the new ring by using a pieces of steel plate and mallet to tap the ring into position.

For installing new casing ring, drill and tap holes for headless setscrews spaced half the circular

distance from the used holes. Install the setscrews and stake. Check the dimension of casing ring

I.D. versus impeller wear area diameter plus ring clearance. Original running clearance must be

reestablished.

4) The bearings can be removed by the use of a cape chisel or hammering.

5) Check the shaft sleeves and renew if worn. To replace shaft sleeve which are fixed by snap ring

and key, remove snap ring from shaft and slide shaft sleeve from shaft.

6) Inspect suction cover (1150A/B), volute casing, volute discharge casing (1151,1152), discharge

bowl(1120A/B/C) and nozzles of discharge head for cracks.

7) Renew all gasket and rubber-rings during reassembly procedures.

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2.4 DECOMMISSIONING

Before storage pumps and motors, read carefully this manual and examine all related drawings until

they are fully understood. If you have any question, please contact HHI/EMD immediately.

2.4.1 CAUTIONS DURING TRANSPORTATION

Please observe the following items during marine and inland transportation.

2.4.1.1 Care Marks

The care marks are printed on the packages.

Please pay attention to these marks when you are handling the packages.

2.4.1.2 Pay attention to the following items when unloading and hoisting the packages.

1) Tie up the lifting wires securely so that the packages do not slip and become damaged.

2) Tie securely the lifting wires at the position for slings shown on the packages and adjust the wires

so that the load is balanced.

3) Do not raise and set down the packages too rapidly in order to avoid damage.

NOTE : The pump and motor shall be lifted by using 4-lifting lugs.

2.4.1.3 The package shall be fixed with bolts or a suitable manner to avoid damage due to shocks,

impacts and vibration during transportation.

2.4.2 CAUTIONS DURING RECEPTION AND STORAGE

2.4.2.1 Receiving checks

When the pumps are arrived at the site, carefully unpack and immediately check the followings.

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1) Packing contents and quantity of the delivered goods should be checked in accordance with

Packing List.

2) Check the nameplate and confirm that it is the ordered pump.

3) Check the shipping mark, care marks, packing condition and painting condition.

4) Check that the equipment is not damaged and the fixing bolts / nuts have not been loosened during

transportation.

2.4.2.2 Cautions during storage

When the equipment is stored during the period from its delivery to the start of installation

(including transportation), the following treatment is necessary to minimize damage of equipment

during long periods of storage.

The guarantee of the equipment will remain valid for the entire guarantee period only as long as the

equipment is stored faithfully according to the following storage instruction. However, replacement

of parts which become defective due to failure to follow these instructions will be made at some

charge.

1) All packages shall be stored as packed and shall not be unpacked unless a complete repacking

shall be conducted after unpacking.

2) Storage conditions

If possible, all crates and cases shall be stored in a warehouse with a floor. If all crates are not kept in

a warehouse, please store them outdoors according to 2.4.2.2.2) ④ “Storage method”. The maximum

period of storage for equipment in the crating is 6 months after arrival at the site.

If the period is over the above specified term, please consult with the supplier and originate a better

method of storing.

※ Note : During the storage, turn the pump rotor 1 and 1/4 revolution once a week.

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① Environment of storage place

a. Clean, low humidity, good ventilation and temperature lower than 50

b. No dust and no generation of corrosive or harmful gas

c. No damage by small animals and insects

d. Good drainage and few weeds in case of outdoor storage

e. Storage floor or ground shall be level horizontally.

② Storage of mechanical equipment

Many of the machines are furnished with finished painting.

These should not be exposed to direct sunshine and humidity.

Ferrous materials should be protected from humidity for the purpose of anti-corrosion.

③ Storage of electrical equipment

Keep indoors and strictly observe the environment of 2.4.2.2.2) ① above.

④ Storage method

a. For cases

Indoor storage is required.

b. For crates

Indoor storage is desirable. If indoor storage is not practicable and the storage period is more than 20

days, all surfaces of packages shall be covered by vinyl sheets to prevent entrance of water and direct

exposure to the sun.

3) Care marks

For packing which must be handled carefully during transportation and storage, care marks shall be

written where clearly visible on the outside of the packing.

4) A pallet or similar material shall be put under the package to prevent direct contact with the

ground.

5) A vinyl sheet covers each package from the top to the ground level.

6) Pay attention to the weight limitation for stacking of the packages.

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Sleepers shall be put between each case in order to make the weight distribution as even as possible.

7) Inspection and maintenance during storage

① Visual inspection of packages

Each package shall be checked for damage or distortion every three months, and it shall be repaired

if there is anything wrong.

② Inspection for equipment

Twelve months after shipment and every six months after that, each package shall be unpacked and

the exposed machined surfaces including screw threads must be inspected visually.

③ During the above stated operation (Items 1) & 2)), the equipment shall be handled carefully and

care taken not to cause deformation of the equipment or damage to the paint. When repacking, the

package shall have the same structure or manner as before, and all the necessary care marks shall be

printed on the package.

2.4.3 MOTOR MAINTENANCE WORK DURING RELATIVELY LONG STORAGE

PERIODS BEFORE FIRST OPERATION OR WHILE SHUTDOWN FOR SERVICING

If a machine has been out of service for more than three months, the following procedures should be

followed.

The intervals depend on the operating and site conditions.

The following works are recommended under normal conditions.

Table 1. Package Conditions

Machine with export packing. Without packing or machine with domestic packing. Package

Conditions Machine should be stored in a correct mounting position. Machine should be covered with suitable water-proof canvases.

Storage locations

Machine with packing should preferably not be stored in outdoors. where possible, motors should be stored indoors in a clean, dry area. If indoor storage is impossible for machine with packing, it is recommended that the storing it under a

Machine should not be stored in outdoors. Where possible, motors should be stored indoors in a clean, dry area. If indoor storage is impossible for totally-enclosed, outdoor application machine, it is recommended that

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weather-proof roof or alternatively cover it with canvases.

covering it with canvases.

Works for packing

1. In the case of condition before installation. (1) Stacking of heavy machine atop one another should be avoided. Machine should be stored in such in a way that no base frame will suffer distortion. (2) Attention should be paid to the loading capacity of floor. Care should be taken the floor, on which machine is stored, is not subjected to vibration and free from moisture.

(3) Storing of machine for longer than one year is not recommended. If the storing is continued, following procedures described in Table 2 should be done in year : Seal the silica-gel within packing and replace at regular intervals. 2. Fully seal the packing.

(3) The store room should be well ventilated and selected for possible protection against moisture and dirt. 2. Cover the air intake and discharge openings of open-enclosure machine by canvases to be prevent the dust deposits inside the machine. 3. If the other works are still in progress even after completed installation of machine, machine should be protected to ingress of foreign matters by a temporary protection covering.

Table 2. Maintenance work preparatory on machine parts

During long storage Prior to operation

External, unpainted metal surfaces.

Apply the following rust-preventive materials or equal: RUST VETO 244.342. (E.F. Houghton), P101 (Nippon Sekiyu), TECTYL 506 (Valvoline Oil).

Remove the rust-preventives with suitable solvents.

Bearings

Rotate the shaft slowly at least 10 revolutions by hand (*) or for several minutes by temporarily operate (**) the machine once every three months. Exception: In machine with export packing.

Check to see that shaft locking-provisions and temporary-covers have been removed, when provided. Check for irregular noise by shaft rotation by hand. If possible, check that bearings are free from rust.

Regreasable anti-friction bearings

Supply the following amount of grease to the bearing while rotating the shaft by hand. Regreasing amount is indicated on

Remove the old grease from the grease outlet opening before beginning operation. Supply new lubricant of the amount

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the rating plate. Supply the grease once a year. Prior to grease supply, Open the grease outlet. Remove the original grease to avoid excessive filling the bearing cavity and to avoid grease leaks from shaft seals.

indicated on rating plate while rotating the shaft by hand or while the machine is running. Remove old grease by running the machine for a few hours with the grease outlet open.

Oil lubricated bearings

1. Check the reservoir filled with lubricant up to the proper line on the oil level gauge. 2. If a machine is out of service for more than one month, the following procedures should preferably be followed monthly : (1) Lubricate a machine with combined angular-contact ball (72 or 73 series) bearings by operating it for about 10 minutes. Lubricate a bearing of large output machine, provided with oil inlet plug on the top of oil reservoir, by pouring oil through the oil inlet. Then immediately rotate its shaft at least 10 revolutions by hand. After that, drain off excess oil. (2) For a machine with a spherical-roller thrust (293 or 294 series) bearings. A machine should be run for about 10 minutes or the shaft rotated at least 10 revolutions by hand. (3) In a machine with sleeve bearings, a machine should be run for about 10 minutes or the shaft rotated at least 10 revolutions by hand. When rotate the shaft, supply about 50 to 100cm3 of the lubricating oil through the screw plug (or sight-glass) of bearing housing. 3. Replace with new oil once per year.

1. Open the drain plug and remove the original oil. Fill the reservoir with the new lubricant up to the proper line on the oil level gauge. 2. In the forced-feed, oil-lubricated bearing. (1) Clean the inside of the oil piping and refresh them, when required. (2) Fill the bearings connected to a feed-oil system with specified oil, check the system for satisfactory operation.

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Insulated windings

Insulation resistance between winding and earth be measured every six months (Every one year in machine with export and before the machine is started). If the lower insulation resistance values is measured, open the terminal-box cover and, if the value does not increase, winding should be dried. Where surge protection system is provided in main terminal box, these accessories should be electrically disconnected during measuring for insulation resistance of winding.

Anti-condensation heater, when provided.

Heater should be energized, in machine without packing, when power-supply cables and heater leads are connected. To prevent moisture accumulation, some form of heating must be utilized to prevent condensation. This heating should maintain the winding temperature at a minimum of 5 above ambient.

Heater should be disconnected before machine is started up.

Drain water by opening the drain plug in the enclosure. Water drain plug, when provided.

At regular intervals of not longer than six months. One year in machine with export packing.

-

Openings Any unused cable entry into terminal box(s) should be closed.

Remove the temporary protection covers, when provided

Painted external surfaces

Repaint at regular intervals, when necessary.

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2.5 PACKING, TRASPORT AND DISPOSAL

2.5.1 GENERAL

2.5.1.1 Purpose of Packing

The purpose of packing is to safeguard materials during transport, handling and storage against

mechanical damage and environmental encroachment such as rain, humidity, temperature variations,

frost, salt atmospheres, dust, sand, etc.

2.5.1.2 Detail of Nozzle Plugging for Transport Overseas

2.5.1.3 Markings

Each package must be marked at least 3 sides in indelible paint, resistant to weather effects and light.

(One for the top side, the others for on side surfaces)

To avoid the plates becoming detached, the nails can be bent over before the case is closed.

Galvanized steel nails and wires must be used for fastening the plates.

Care must be taken not to damage any sealed bags etc. that may have been used.

The following international standard symbols shall be used:

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1.

2.

3.

4.

5.

6.

7.

A.

B.

Symbols Description Remarks

THIS WAY UP All Top Corners

FRAGILE HANDLE WITH CARE All Top Corners

KEEP DRY All Top Corners

KEEP AWAY FROM HEAT All Top Corners

USE NO HOOKS All Top Corners

CENTER OF GRAVITY All Sides

SLING HERE All Top Corners

STORAGE RECOMMENDATIONS Storage in heated/ventilated warehouse and with precautions (air conditioned)

All Top Corners

STORAGE RECOMMENDATIONS Storage in closed warehouse All Top Corners

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C.

D.

Symbols Description Remarks

STORAGE RECOMMENDATIONS Storage in open shed All Top Corners

STORAGE RECOMMENDATIONS Storage in open air (covered by tarpaulins)

All Top Corners

2.5.2 DETAIL PACKING INSTRUCTION

1) The type of packing should be a wooden case for overseas shipment and land transportation.

Equipments should be enclosed in a protective bag with containing a protective lining moisture

absorptive agent.

2) Equipments should be inspected for cleanness immediately before packing. Dirt, oil residue, metal

chips, or other forms of contamination should be removed by suitable cleaning methods. Any

entrapped water must be removed.

3) Equipments should be completely drained and thoroughly dried prior to shipment.

4) All openings and machined surface should be provided with protection to prevent damage,

corrosion and entrance of foreign matter during shipment. Exposed connections must be cleaned and

coated with a preservative.

5) All flanged openings should be provided with substantial plywood (or plastic) covers and rubber

gaskets (minimum thickness 5mm) bolted with to the connections. At least four bolts shall be used.

6) Threaded or socket weld connections should be protected by metal capping or plugging. All

tapped openings normally plugged during service should be fitted with solid steel plugs.

7) Equipments which can be damaged by condensation trapped within the package should be

packaged with desiccant inside the sealed water-vapor proof barrier or an equivalent method.

8) Equipments should be packaged with a waterproof enclosure so that water, salt spray, dust, dirt,

and other forms of contamination do not penetrate to the equipment.

9) The base of the equipment should be firmly secured to the bottom of the case by means of nuts

and bolts and battens.

10) Any moving parts should be firmly secured on the equipment so that they cannot move.

11) Unless otherwise stipulated, drive motors should normally be dispatched with their own

separated case because of heavy weight.

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2.6 COMPONENT DOCUMENTATION

- SECTION 1 : MOTOR

- SECTION 2 : MECHANICAL SEAL

- SECTION 3 : GEAR COUPLING

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SECTION 1. MOTOR

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The information contained in this book is intended toassist operating personnel by providing information onthe general characteristics of the purchased equipment.IT DOES NOT relieve the user of the responsibility of usingaccepted engineering practices in the installation,operation and maintenance of this equipment.

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2 << INSTRUCTIONS FOR THREE-PHASE INDUCTION MOTORS

This equipment contains hazardous voltages. Death,

serious personal injury or property damage can result if

safety instructions are not followed.

The successful and safe operation of motors is dependent

upon proper handling, installation, operation and

maintenance, as well as upon proper design and

manufacture. Failure to follow certain fundamental

installation and maintenance requirements may lead to

personal injury and the failure or loss of the motor as well

as damage to other property.

Only qualified personnel should work on or around this

equipment after becoming thoroughly familiar with all

warnings, safety notices and maintenance procedures

contained herein. Only qualified personnel should be

involved in inspection, maintenance and repair

procedures and all plant safety procedures must be

observed.

Qualified Person: For the purpose of this manual and

product labels, a Qualified Person is one who is familiar

with the installation, construction and operation of the

equipment, and the hazards involved. In addition, he or

she:

a. is trained and authorized to energize, de-energize,

clear, ground and tag circuits and equipment in

accordance with established safety procedures.

b. is trained in the proper care and use of protective

equipment, such as rubber gloves, hard hat, safety

glasses, face shields, flash clothing, etc., in accordance

with established safety procedures.

c. is trained in rendering first aid.

Motors should be installed and grounded per local and

national codes.

Do not operate this equipment in excess of the values

given on nameplate or contrary to the instructions

contained in this manual. The equipment (or a prototype)

has been factory tested and found satisfactory for the

conditions on which it was sold. Operation in excess of

these conditions can cause stresses and strains beyond

design limitations. Failure to heed this warning may

result in equipment damage and possible personal

injury.

Safety Procedures

Hazardous voltage.Will cause death, serious injury,electrocution or property damage.Disconnect all power before working onthis equipment.

For the purpose of this manual andproduct labels, Danger indicates animminently hazardous situation which,if not avoided, will result in death orserious injury.

For the purpose of this manual andproduct label, Warning indicates apotentially hazardous situation which,if not avoided, could result in death orserious injury.

For the purpose of this manual andproduct label, Caution indicates apotentially hazardous situation which,if not avoided, may result in propertydamage or minor or moderate injury. Itis also used to alert against unsafepractices.

NOTE: Many squirrel cage induction machines are drivenby various types of prime movers as induction generators.This instruction manual applies to both motors andinduction generators. However, for reasons of clarification,the machine will be referred to as a "motor."

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Safety Procedures 2

1. Foreword 4

2. Receiving, Handling and Storage 5

2.1 Receiving 5

2.2 Handling 5

2.3 Storage 5

3. Inspection and Test for Initial Start-up on Site 7

3.1 Installation 8

3.2 Inspection of Installation 9

3.3 Measurement of Insulation Resistance 9

3.4 Inspection of Lubrication Oil 10

3.5 Manual Rotation 10

3.6 Connection to Power and Grounding 10

3.7 Solo Run Test 10

3.8 Alignment 11

3.9 Test Run of Motor 13

4. Inspection and Maintenance Schedule 14

5. Maintenance of Windings 17

5.1 General 17

5.2 Cleaning of Coils 17

5.3 Use of Space Heaters 18

5.4 Drying Insulation 18

6. Maintenance of Slip Rings, Brushes and

Brush Holders 20

6.1 Slip Rings 20

6.2 Brushes and Brush Holders 21

7. Terminal Box for High-voltage Supply 22

7.1 General 22

7.2 Description 22

7.3 Installation 22

7.4 Operation 23

7.5 Maintenance 23

8. Terminal Box for Auxiliary Circuits 24

8.1 General 24

8.2 Description 24

8.3 Installation 24

9. Anti-condensation Heating with Heating Tube 25

9.1 Description 25

9.2 Installation 26

9.3 Maintenance 26

10. Maintenance of Bearings 27

10.1 Flange-type Sleeve Bearings 27

(Ring Lubrication System)

10.2 Flange-type Sleeve Bearings 29

(Forced Lubrication System)

10.3 Rolling-contact Bearings 31

10.4 Insulation to Prevent Shaft Current 32

(High-voltage and Large Machines)

11. Air Filter and Cooler 35

11.1 Air Filter 35

11.2 Cooler 35

12. Protection 37

13. Induction Motor Troubleshooting 38

14. Appendix 43

14.1 HLA7 Horizontal-type Motor Construction 43

14.2 HLS7 Horizontal-type Motor Construction 44

14.3 HRA7 Horizontal-type Motor Construction 45

14.4 HRP7(4P~) Horizontal-type Motor Construction 46

14.5 HRP7(2P) Horizontal-type Motor Construction 47

14.6 HRQ7 Horizontal-type Motor Construction 48

14.7 HRP7(2P) Horizontal-type Motor Construction 49

14.8 HRS7 Horizontal-type Motor Construction 50

14.9 HLB5 Horizontal-type Motor Construction 51

14.10 HRQ7 Horizontal-type Motor Construction 52

14.11 HRQ7(Sleeve Bearing) Horizontal-type Motor

Construction 53

15. Memo 54

Instruction Manual >> 3

THREE-PHASE INDUCTION MOTORS

Contents

(47)

01


This instruction manual describes and provides instructions for

installation, operation and maintenance of induction motors.

These instructions do not purport to cover all details or

variations in equipment nor to provide for every possible

contingency to be met in connection with installation,

operation or maintenance. Should further information be

desired or should particular problems arise which are not

covered sufficiently, the matter should be referred to the

nearest HYUNDAI HEAVY INDUSTRIES business office.

Foreword

NOTE

For service shop requirements, refer to

ROTATING MACHINERY MANUFACTURE DEPT.

ELECTRO & ELECTRIC SYSTEMS DIVISION

HYUNDAI HEAVY INDUSTRIES CO., LTD.

Address: 1 JEONHA-DONG, DONG-GU, ULSAN, KOREA

Telephone: 82-52-230-6671, 6672

Fax: 82-52-230-6996

(48)

2.1 Receiving

Each shipment should be carefully examined upon arrival.

If the packing is damaged, unpacking should be made

immediately to check whether or not the motor and its

fitting are in good condition, and any damage to contents

should be photographed and reported to the carrier and

to the nearest HYUNDAI HEAVY INDUSTRIES business

office.

All large motors are equipped with a locking device, which

protects the bearing from damage due to the movement

of the rotor in transit. Do not remove this device until

transport is complete and coupling is ready to be fitted.

2.2 Handling

To ensure proper handling after unpacking, the motors

require the chain hoist, wire ropes and other handling

equipment. When hoisting the motor, wire ropes should

be attached to the lifting holes on the side of the motor

frame, and should be put in hard rubber, thick cloth, etc.

between the external covers for protective purposes.

Then the motor is slowly and carefully raised and moved

to the intended position.

2.3 Storage

If the motors are not put into service at the time of

delivery, they should be stored according to the following

conditions.

Outdoor Storage Is Not Recommended.

Variations in temperature and humidity can cause

condensation, resulting in corrosion of metal parts and

possibly in insulation failure. Therefore, the following

cover the minimum acceptable storage arrangements in

an unheated but protected environment:

It is preferable to use a heated facility, which would

simplify meeting these conditions.

When outdoor storage cannot be avoided, contact

HHI for specific instructions on minimizing damage, giving

full particulars of the circumstance.

Storage Facility Requirements

The storage facility must provide protection from contact

with rain, hail, snow, blowing sand or dirt, accumulations

of groundwater, corrosive fumes and infestation by

vermin or insects.

There should be no continuous or severe intermittent

floor vibration. Power for the space heaters and

illumination should be available. There should be fire

detection and a fire-fighting plan. The motors must not be

stored where it is liable to be accidentally damaged or

exposed to weld spatter, exhaust fumes or dirt and stones

kicked up by passing vehicles.

If necessary, use guards or separating walls to provide

adequate protection. Avoid storage in an atmosphere

containing corrosive gases, particularly chlorine, sulfur

dioxide and nitrous oxides.


THREE-PHASE INDUCTION MOTORS02 Receiving, Handling and Storage

Heavy EquipmentImproper lifting can cause death, severeinjury, or damage. Check eyebolts,lifting lug and eyenuts before lifting. Useproper slings and spreaders.

Damp Location.Can cause property damage ifequipment is operated intermittently.Use space heaters to prevent dampness.Grease machine fits when unit isreassembled to prevent corrosion.

When unpacking and handling themotor, attention should be given to thefollowing points: - Anticorrosive agent which is applied to

the coupling shaft ends should beremoved right before starting themotor. The coupling or shaft endsshould be checked to ascertainwhether or not they are in abnormalcondition.

Top Heavy.Can cause severe injury or propertydamage.When lifting motor,1. Lift only at designated locations.2. Use spreader for lifting.3. Apply tension gradually to cables.4. Do not jerk or attempt to move unit

suddenly.5. Do not use cover lugs when lifting.

(49)

02


Temperature Control.

Whenever the motor temperature is equal to and below

room temperature, water vapor can condense on and

within it, promoting rapid deterioration.

Prevent this by energizing the space heaters to keep the

motor temperature above room temperature by at least

3 However, during periods of extreme cold or rapid

temperature drops, the space heaters may not be

adequate to maintain this differential and supplementary

heating may be required.

Receiving, Handling and Storage

Fig. 1 Insulation Resistance Temperature Correction

Hazardous Voltage.Will cause death, serious injury,electrocution or property damage.Disconnect all power before working onthis equipment.

If the motor is boxed or covered in anyway when the space heaters areenergized, there should be thermostaticcontrol and sufficient surveillance todetect an over-temperature conditionquickly. Ensure that temporary packagingdoes not contact the space heaters. When windings of motor are uninjuredand their insulation resistance to groundis well above the minimum of ratedvoltage (kV) plus 1 megohm whencorrected to 40 according to IEEE 43 oras below in Fig. 1, low temperature is nota problem. However, if the resistance drops, thewindings can be permanently damagedby freezing. Therefore, the motortemperature should be kept abovefreezing point.

(50)

Generally, inspection and text of motors are performed as

in the following chart for initial start-up on site.


THREE-PHASE INDUCTION MOTORS03 Inspection and Test for Initial Start-up on Site

Inspection of installation

Confirmation of starting panel

Load running test

Inching operation

Solo running test

Measurement of insulation resistance

Inspection of connection cables

High-voltage test with outgoing cables(If necessary)

Inspection of lub. oil

Hand turning (If possible)

Inching operation

Connection withoutgoing cables

Connection withoutgoing cables

END

(51)

03


3.1 Installation

General

Ensure that the motor enclosure is suitable for its

environment, that the ambient temperature is less than

specifications for operating the motor at all times and that

all bearings are lubricated before operating the motor.

Foundation

Motors should be mounted on solid and rigid foundations

to ensure proper vibration and free operation. The

desirable foundation and anchor bolt design will

--- accommodate at least the maximum static and dynamic

foundation loads indicated on the motor outline

dimension drawings.

--- have sufficient rigidity to maintain acceptable alignment

after the application of load.

--- be free of natural frequencies, which are likely to be

excited during normal operation (this could result in

vibration problems on the motor).

In some cases where precision is required, a study of

these factors should be conducted to determine the

natural frequencies of the motor support.

Foundation Bolt

There are some different methods of installing the

foundation bolt as shown in Fig. 2. The methods depend

on the capacity and construction of the motor.

Mounting

After removing the packaging from the skidding of the

motor, remove the polyethylene shroud. Remove the

motor from the skidding. The motors should be mounted

on a flat surface and packed about with shims (shim

allowance is generally 2-3 mm thick).

The shims should support the maximum length of each

motor foot. It is preferable to use corrosion-resistant

shims such as brass or stainless steel; otherwise “shim

swell“ due to corrosion resistance may be detrimental to

good alignment. Care should be taken not to distort the

frame during “bolting down”.

Remove the Locking Device of Large Motors

All large motors are equipped with a device for preventing

the shaft from movement in order to protect the rolling

face of bearing from damages due to vibration in transit.

This locking device is fitted on the drive side or on the

non-drive side. Before connecting a motor to a machine,

the fitting bolts should be loosened, and the fitting device

should be taken off.

Inspection and Test for Initial Start-up on Site

NOTE: If normal vibration or noise will be objectionable (asin office buildings), it may be advisable to use vibrationdampeners between the machine or driven/drive unit andthe foundation.

Fig. 2 Type of Foundation Bolt

Fig. 2 Type of Foundation Bolt

NOTE: Experience has shown that any base-mountedassemblies of motor and driven units temporarily aligned atthe factory, no matter how rugged or deep, may twistduring shipment. Therefore, alignment must be checkedafter mounting.

A basic rule is to not have more than 5shims in a shim pack under any onemachine foot. Thick shim packsconsisting of many thin shims will causea soft foot and cause vibration or twistedframe (machine foot out of plane).

< J-Type >

< Plate-Type >

(52)



Hazardous voltage.Will cause death, serious injury,electrocution or property damage.Disconnect all power before working onthis equipment.

3.2 Inspection of InstallationAfter installation, check for looseness of bolts and nuts on

the terminal boxes, cooler boxes and so on. Then, the

foundation and centering of the motors should be

checked. These items are normally checked and reviewed

on the erection records.

Checklist for inspection of installation

3.3 Measurement of Insulation Resistance

3.3.1 One-Minute Test

If the motors were stored in very damp surroundings for a

prolonged period, the insulation resistance of windings to

frame should be measured at DC power for 1 minute with

a low energy source device (for example, megger).

In case a high-voltage circuit, that is 600 V and above, is

measured by a 1000-V megger, and low-voltage circuit,

less than 600 V, is measured by a 500-V megger.

Insulation resistance of winding for the high voltage motor

will be converted to 40°C-based values by IEEE 43.

The criteria of its value are (kV + 1) megaohm at 40°C for

winding, and 1 megaohm for space heater in accordance

with international standards ( IEEE 43, JEC 37, etc.). If the

insulation resistance has been reduced as a result of

extreme conditions (for example, penetration of water)

and has a value less than the criteria value, the windings

must be dried before connection to supply voltage and

operation.

3.3.2 Polarization Index.

In case the high-voltage circuit, that is 600 V and above,

provided for insulation resistance is within the acceptable

limits, then a polarization index can be performed.

Windings are applied to DC power in accordance with IEEE

43 between windings and ground when the stator coil is

tested. The rotor coil and R.T.D leads are to be earthed.

The insulation resistance at one (1) minute should be

recorded and the insulation resistance at ten (10) minutes

should be recorded.

The polarization index is the insulation resistance index at

10 minutes divided by the insulation resistance index at 1

minute. This index should be greater than 1.

If the polarization index is less than 1, contact HHI’s

service center. The windings may need to be dried before

operation.

3.3.3 High Voltage Test

1. Outside view of machine- No rusted portions.- No damaged portions/parts.- Confirmation of caution, nameplate.

2. Removal of rotor locking device(If necessary)

3. Check for no looseness- End covers.- Terminal boxes.- Cooler boxes.

4. Check around foundation- Motor leveling.- Tightness of foundation bolts.

5. Inspection of accessories- Thermometers

(indication checks at amb. temp.).- Temperature detectors

(indication checks at amb. temp.).

6. Confirmation of centering Do not operate equipment beyonddesign limitations.Can cause personal injury or damage toequipment.Operate in accordance with instructionsin the manual and nameplate ratings.

(53)

03


This test is intended for detecting the weak points of

winding for high-voltage machines. The dielectric test is

carried out before operating the motor, on windings

applied to specified voltage for one (1) minute between

the windings and ground.

Supply voltage: 2E+1000 for the line for

above 1000 V

E means rated voltage or secondary induction voltage in

case of the wound rotor; AC power condition.

If AC power is not supplied, apply DC power instead of the

power frequency voltage specified above. The DC voltage

level is at least 1.7 times of AC high-voltage test voltage.

3.4 Inspection of Lubrication Oil

Before the initial running test, inspection of lubrication oil

is very important, that is, confirmation of no oil leakage

and proper oil level.

Refer to bearing maintenance manual.

3.5 Manual Rotation

If possible, rotate the rotor manually to ensure that it is

free to move without rubbing or scraping and to lubricate

the bearing surfaces. A minimum of 10 revolutions is

recommended.

3.6 Connection to Power and Grounding

Examine the nameplate data to know the correct power

supply. Also check heater power where applicable. Check

all connections to ensure that they have not come loose

during transport. Make certain that the correct cable size

has been selected and connected to phase rotation as

shown in motor terminal box. The motor and control

wiring, overload protection and grounding should be done

in accordance with the National Electrical Code and local

requirements.

In case of the wound rotor, check to see that brushes are

“free“ in the holder and the pressure of the brushes is

applied correctly. Ensure that the slip ring surface is clean

and free from contamination. Avoid “fingerprint” marks on

ring surface. To maintain the proper degree of protection,

make sure all gaskets and cover plates are properly fixed

and sealed. Any unused entry holes should be plugged.

3.7 Solo Run Test

Before coupling with the load machine, the motor is

normally run through a solo running test.

At the initial start, the motor is inching operated for

approx. 1-2 sec.

At that time, inspection of rotation, abnormal noises, and

lubrication conditions are checked during the idling. If

these items have any problems, the supplied power shall

be taken off, checked and reported in detail.

The motor is then restarted. The motor is run during 1-2

hrs. and vibration amplitude on the bearing housing and

bearing temperature are measured and recorded.


Before starting the machine, fill thebearing chamber to the center of the oilgauge. Always fill through the pipe orplug at the side of the motor. Do notoverfill, as the oil may then escape alongthe shaft and enter the unit.Avoid adding oil while unit is running.

Do not exceed number of HYUNDAI-specified hot and cold starts perhour.Will cause overheating.Allow time between starts to permitstator windings and rotor cage to cool.

Observe caution in testing as follows- In case of the wound rotor type, the

slip ring and brush support part of themotor are to be thoroughly cleaned;and dust and moisture are to becompletely removed before the highvoltage test is started.

- When the stator coil is tested, the rotorcoil and RTD leads are to be earthed.

- Electricity is to be discharged withoutfail after the high-voltage test has beenfinished.

- Ensure that the motor starter (suppliedby others) is open.

- Make the connections as in therequired rotation.

- Drill the cable entry plate (at bottom ofbox) to suit your power cable and itsfitting.

- Connect the station ground to one ofthe ground pads provided on thestator frame.

(54)

3.8 Alignment

The correct alignment of machinery is very important for

reducing the stress and vibration of the shaft and the

wear of the bearing and coupling. In case a coupling

maker gives those instructions, it is recommended that

the instructions be followed.

Flexible Coupling

The flexible coupling set forth herein means the one

driven through the rubber brush or the leather brush

including the gear coupling. In aligning the motor

equipped with the sleeve bearing, attention is to be paid

to the endplay of the motor bearing and to the position of

the coupling. The center of the motor bearing endplay is

indicated by the endplay indicator.

The bearing endplay can be equally divided by

setting the endplay indicator to the standard line of the

shaft as shown in Fig. 3.

Rigid Coupling

In case of the sleeve bearing, when both flanges are

connected to each other, the endplay indicator is referred

to install the flexible coupling in order to determine the

position of the motor.

Alignment

Alignment is made to bring the shaft centers of the motor

and machine combined with it into the same line; the

parallel and eccentricity are measured through the

coupling. Generally a thickness gauge or a taper gauge is

used in measuring the parallel, and in measuring the

eccentricity, a dial gauge is to be fitted to the coupling on

one side; the both shafts are to be turned by 0 deg, 90 deg,

180 deg and 270 deg; and the dial gauge reading is to be

taken at the four points as shown in Fig. 4. The alignment

accuracy is to be generally 0.025 mm or less (both plate

and circle).

Measurement of Eccentricity

The both shafts are to be simultaneously turned; the

values shall be obtained from the measurement made at

four points by means of a dial gauge and are to be

recorded; and the corrected value is to be obtained in the

following manners.



Do not operate equipment beyonddesign limitations.Can cause personal injury or damage toequipment.Operate in accordance with instructionsin the manual and nameplate ratings.

NOTE: The foot plane is of concern for each unit of rotatingequipment. Check driven equipment if necessary.

Fig. 3 Endplay Indicator

Fig. 4 Procedure for Alignment

(Measured Value)

Circle

270 deg

90 deg

180 deg 0 deg

In case the coupling is used, it may beconsidered that the rotor can be easilymoved in the axial direction. In fact,however, it hardly slides in the axialdirection at the coupling as the torquegrows greater. When by some reasonthe rotor has undergone some axialmovement, and the coupling does notprovide enough slip to allow the rotor toreturn to the magnetic center of themotor, it will continue to operate withthe bearing end in contact with theshoulder of the journal.

(55)

03


Measurement of parallelism

The values at the four points of E1, F1, G1 and H1 are to

be corrected after measurement made by means of a

thickness gauge at the position where both shafts were

connected to each other at the time of eccentricity

measurement; and measurements are to be made again

at the points of E2,F2, G2 and H2 after turning both shafts.

Belt Connection

If it is intended that the motor will be directly coupled

through a flexible coupling to a machine, no check for the

minimum sprocket diameter will be necessary. However,

if a chain, gear, V-belt, or flat belt drive is used on the

output shaft a check should be made.

Direction of Belt Tension

In the case of the motor with roller bearing, belt tension

may be applied in the horizontal or the vertical direction.

In case of the motor with the sleeve bearing, the belt

tension should be applied in the horizontal direction only.

Alignment of Belted Drives

Aligning a belted drive is much simpler than aligning a

direct coupling drive. To check alignment, place a straight

edge across the faces of the drive and driven sheaves. If

properly aligned, the straight edge will contact both

sheave faces squarely.


(Measured Value)

(Corrected Value)

Circle

D

A

C A

(Measured Value)

Circle

H2

F2

G2 E2

(Measured Value)

Circle

H1

F1

G1 E1

Corrected value of left and right = A - C

2

Corrected value of left and right = A - C

2

(Corrected Value)

Corrected value of left and right

= ( F1 + F2 ) - ( H1 + H2 )

2

Corrected value of left and right

= ( E1 + E2 ) - ( G1 + G2 )

2

The difference between the total of themeasured values at the left and rightpoints (A-C) and the total of themeasured values at the top and bottompoints (B- D) should not exceed 0.03 mm.The improper fitting of the dial gauge andthe erection of the fitting arm, if any, maycause greater difference.

(56)

Belt Tension

The V-belt is to be stretched in the following way.

There is calculated deflection force to be applied

perpendicular to the belt at the center of the belt span as

shown in Fig. 6.

The drive is properly tensioned when the deflection of the

belt caused by the deflection force is equal to 1.6 mm for

span length of 100 mm. If the deflection force is higher

than normal values, this will result in reduced belt life,

reduced bearing life and could cause shaft failure.

Coupling Balance

The coupling should be dynamically balanced to G2.5 or

better. The motor is dynamically balanced with a half key

fitted; therefore, the proposed coupling should be

balanced accordingly, and the correct key profile fitted.

Frame Distortion Test

In addition to ensure the proper alignment of the coupling,

care should be taken to ensure that the motor frame is

not distorted during alignment.

To confirm that distortion has not occurred, we

recommend the following procedure be adopted:

1) Align the motor within tolerances as required by

section “alignment.”

2) Apply a dial gauge between the motor frame adjacent

to one mounting foot and the foundation and set

indicator to zero.

3) Loosen hold down bolt and record movement of dial

gauge measurement.

4) Re-torque hold down bolt.

5) Repeat steps 1- 4 for all hold down bolts, one at a time.

3.9 Test Run of Motor

After coupling with the load machine, the motor is inching

operated at first.

When both motor and load machine show no abnormality,

the motor is restarted with a minimum load. At that time,

the current, supplied voltage is checked and recorded.

While the motor is running continuously, the motor

vibrations on the bearing housing are controlled by the

curve of Fig. 8.



Fig. 5 Alignment of Belt Drive

Fig. 6 Belt Tension

Fig. 7 Coupling Balance

Do not exceed number of HYUNDAI-specified hot and cold starts per hour.Will cause overheating.Allow time between starts to permitstator windings and rotor cage to cool.

Carry out the initial operation inaccordance with contractual agreements.The initial operation may only be carriedout by trained personnel who have beenassigned to do this by the personresponsible for the plant.

(57)

04


The following maintenance and inspection schedules

cover the necessary steps for inspection of the motors.

Since the conditions under which the motors are required

to operate may differ considerably, the maintenance and

inspection schedules can only be recommended for the

intervals at which at least first inspection should be

carried out if operating conditions are normal. On the

basis of the experience gained with the plant, the

inspection intervals should therefore be selected to meet

such conditions as contamination, frequency of start-ups,

load, etc.

Inspection and Maintenance Schedule

A: Daily Inspection

B: First Inspection, no later than 6 months.

C: Following Inspection, no later than two (2) years (when required, dismantle the machine).

Relubricate the grease lub. Bearing

oil-lub bearing: Change the oil.

Clean and inspect the bearings.

For the intervals of maintenance work, see the lubrication instruction plate on

the machine.

Carry out the following oil changes with normal amb. temp.

Self oil lub.: 5000-8000 operating hours

Forced feed oil lub.: 15,000-20,000 operating hours

Check the machine for irregular noise and excessive vibration (Fig. 8).

Where possible, measure and record the bearing temperature.

Check the shaft sealing rubber ring for deterioration.

Where possible, measure the bearing temperature, oil pressure and flow rate.

Check that the oil-rings are operating correctly.

Check the oil flow, oil level and any oil leaks.

Check the contamination of lub. oil and change the lub. oil.

Check the axial play.

Check the shaft sealing for deterioration.

Inspect the bearing surface.

Clean and inspect the bearing insulation and insulation of the pipe.

Check the system, connections and piping for leaks.

Check the oil level.

Clean and inspect the oil filters and oil coolers.

Check to see that the enclosure is not clogging (blocking) the machine ventilation.

Check the gaskets for deterioration.

Check the enclosure for any deformities or damage.

Check the noise-suppression material for damage.

Machine part

Sleeve (white metal)

bearing

Forced feed oil

lub. system

Enclosure

Interval

A B CInspection and maintenance work

(58)



Check the enclosure including external cabling conduit connection for ingress

of water or dust.

For the wound rotor machine with continuous sliding brushes and open

enclosure machine, clean the entire winding and cooling air paths, including

the core packs-air duct.

For the open enclosed machine:

Clean entire winding and cooling air paths including the core packs-air duct.

Check end rings and support rings and the associated locking elements for

tight fit.

Check and clean the external cooling air paths.

Drain the drain plug, when provided.

Replace and clean the air filter, when provided.

Check the clearances to rotating parts.

Check the enclosure for corrosion.

Check earthing (grounding) terminals.

With loose leads: Check to see that the cable connections are properly insulated.

Check connection for good contact.

Check terminal insulators for damage.

Measure and record the winding temperature detectors, when provided.

Check and record the insulation resistance of windings.

Clean the windings, as far as possible.

For totally enclosed machines, clean the winding if required.

Check the slot wedge for tight fit.

Check condition of winding insulation, including end connections.

Check winding and bracing for tightness.

Clean the winding, as far as possible.

For totally enclosed machine, clean entire winding if required.

Check cage bars and end rings for fractures and loosely soldered connection.

Check cage for axial displacement.

Check and record the insulation resistance of windings.

Clean the winding, as far as possible.

For totally enclosed machines, clean the winding if required.

Machine part

Stator winding

Squirrel-cage rotor

Wound rotor winding

Enclosure

Junction (terminal) box,

terminals

Interval


(59)

04


Inspection and Maintenance Schedule

For the machine with continuous sliding

brushes or open enclosure machines,

clean entire winding and cooling air paths including the core packs-air duct.

Check leads of stator winding, slip ring leads of wound rotor machine and

their locking elements for tightness.

Compare brush noise, sparking and contact marking with conditions found in

previous inspection (monthly).

Inspect contact surfaces; they should be bright, free from rubbing or

threading and have a uniform skin.

Remove deposits of carbon dust from the slip ring chamber, slip ring and

brush holders.

Check to see that the mechanism, including the sliding surface of the shaft to

the short-circuit ring, is free form dust.

Check the slot wedge for tight fits.

Check the winding-end for deposits of oil and carbon dust.

Check the banding for tightness, and check for any loosely soldered joints.

Check bracings and wedges of winding end and ring circuits for tightness.

Vent the cooler while in operation (monthly).

Where possible, measure and record the water temperature.

Check the cooler, connection and piping for leaks.

Check and clean the cooler.

Inspect the corrosion protection (when provided).

Check the brush length and replace as necessary.

Check to see that the brushes can move freely in the brush holders.

Check the pigtail (connection) leads for discoloration and damage.

Take out and clean the air filter.

Check the holder for damage.

Check the tightness of slip ring, including separators and fixing studs.

For arm type brush holder, check brushes for screw tightness.

Avoid continuously sliding the brushes.

Avoid continuously rotating the thrust roller.

Check the abnormality of thrust roller and limit switch.

Check the sliding surface of short-circuit ring for corrosion.

Check setting of short-circuit ring to shaft.

For arm type brush holders, check brushes for screw tightness.

Re-lub. the reduction gear assembly.

Check the manually operated gear unit for damage.

Machine part

Slip ring, brushes

Slip ring, brushes

(cont’d)

Brush lifting mechanism

Enclosure

Water air cooler

(heat exchanger)

Interval


(60)



3600

1800

1200

900

720

600

60

30

20

15

12

10

0.15(3.8)

0.15(3.8)

0.15(3.8)

0.12(3.0)

0.09(2.3)

0.08(2.0)

Axial rotor placement should be kept by indication of the shaft on its

magnetic center.

Check and adjust the belt tension.

Check the external and internal fan for damage or corrosion.

Check rotor alignment.

Check the balancing weight for tightness.

Check all coupling bolts and locking elements for tightness.

Check the oil leakage of gear coupling.

Check the shaft keys for tightness.

Check the monitoring instruments and contact device for proper function.

Check the brush length and replace as necessary.

Check the holder for damage.

Machine part

Monitoring instruments

Ground brush

Shaft and coupling

Interval


5.1 General

It is important to keep the machines in good condition by

performing periodical maintenance to prevent the

insulation from being damaged by moisture, dirt and other

foreign matter.

If the machines have been operated under high humidity

conditions, not been used for a long time, or been

subjected to sudden changes in ambient temperature, the

insulation may have absorbed considerable moisture,

causing deterioration of the insulation.

Other causes of insulation breakdown include operation of

the machines at an overcurrent exceeding the rated

current, use under an ambient temperature exceeding the

specified values as may be possible with a heated air

blower which directly radiates heat over the machines,

and overheated windings resulting from dust accumulating

on the core packs and coil ends. All of the above items

impair insulation and reduce the life of the machine.

5.2 Cleaning of Coils

The method selected will depend on the type of

machines, type of insulation, kind of dirt, and other

conditions and circumstances.

Cleaning by Wiping with Cloth

Wiping cloths can be used for cleaning when the machine

Maintenance of Windings05

Fig. 8 Values of Vibration

Speed, rpm Rotational Frequency, Hz Rotational Frequency, Hz

(61)

05


is small, the surfaces to be cleaned accessible, and the

dirt to be removed dry.

Waste should not be used, as lint will adhere to the

insulation and increase the collection of dirt, moisture,

and oil. This is particularly objectionable on high-voltage

insulation, as it tends to cause concentration of Corona.

Cleaning by Means of Compressed Air

Compressed air, used to blow out dirt with a jet of air, is

usually effective especially where dirt has collected in

places that cannot be reached with a wiping cloth.

Cleaning can be done more quickly with compressed air

than with wiping cloth especially on the large machines. If

blowing with compressed air results in simply transferring

dirt from one place to another on the machine, little is

accomplished.

There are a number of precautions to be observed when

using compressed air: Air being blown should be dry,

especially if blowing against insulation. Moisture

condenses and accumulates in air lines and hoses.

Care should be taken to assure this has been completely

dried out before using the compressed air on insulation.

Compressed air should never be more than 3 ~ 4 kg/cm2

pressure. Higher pressures can damage insulation and

force dirt under loosened tape.

Care should be taken not to blow loosened dirt into inner

recesses where it will be difficult to remove and where it

might obstruct ventilating ducts.

Cleaning by Means of Solvents

Solvents are usually required to remove grease and oil

dirt. A lint-free cloth wet with solvent may be dipped in

the fluid.

Petroleum distillates are the only solvents recommended

for cleaning electrical apparatuses. These solvents,

classed as Safety-Type Solvents, have a flash point of

above 37.8 deg and are available from most oil companies

and other supply sources under various trade names:

- Mineral spirits, cleaner’s naphtha, and similar products

with a flash point above 37.8 deg.

- Gasoline, naphtha, and similar grades must not be used

for cleaning. They are highly volatile and present a great

fire hazard.

5.3 Use of Space Heaters

When the motor is operating, its interior is not humid and

in a dry condition. But it absorbs humidity at rest.

In order to prevent absorption of humidity, the space

heater installed inside the frame should be immediately

energized after the motor comes to a stop, and the

temperature inside of the motor should be controlled 3 to

5 deg higher than the ambient temperature.

If there is no space heater, a 100-150-W incandescent

lamp may be used.

5.4 Drying Insulation

Should the insulation resistance for the winding have poor

insulation resistance due to the ingress of moisture, then

the windings must be dried to improve the insulation

resistance to the minimum specified value before the

application of insulation resistance. The preferred method

of drying windings is the external heat method. The

alternative is the internal heat method.

1) The External Heat Method.

* Temperature-controlled oven

The best method is to dismantle the motor (including

Maintenance of Windings

Wear goggles when blowing dirt outwith compressed air and be careful notto direct the air jet toward others.Failure to heed this warning can resultin injury to the eyes.

Avoid prolonged or repeated contactwith petroleum distillates or breathingtheir vapors. These solvents can causesevere skin irritation, are toxic, and arereadily absorbed into the system. Failureto heed this warning can cause severepersonal injury or death.Do not use carbon tetrachloride ormixtures containing carbon tetrachloridefor cleaning purposes. Carbontetrachloride and its fumes are highlytoxic. Failure to heed this warning canresult in serious illness or death.Avoid excessive contact with cleaningsolvents and breathing their vapors.Some solvents are extremely toxic andreadily absorbed into the system.

Connect this heating system according toits output and reference voltage.Arrange the control so that the heatingsystem- switches on after the electrical machine

switches off.- switches off before the electrical machine

switches on.

(62)

bearings) and place the motor in a temperature-

controlled oven at between 110 max. for 8-10 hours

depending on oven efficiency to remove moisture.

* The alternative external heat method is to remove end

shields and covers, connect the anti-condensation

heaters, and fit additional “black heat” resistance in and

around the motor.

A temperature controller should control additional

resistance heaters with a probe adjacent to the winding at

the top of the motor. The temperature should be set for

100 to 120 The drying process will take approximately

10 - 16 hours once the correct temperature is achieved.

< Key Points to Remember >

1) Heaters must be the “black heat” types otherwise the

insulation might be burnt.

2) The motor may need to be covered by some thermal

insulation to retain the heat.

3) A vent opening should be placed in the tip of the

thermal insulation tent for the evaporated moisture to

escape.

4) Sufficient space should be allowed between the heaters

and any winding insulation so as not to generate local

excess heating of the winding insulation.

2) The Internal Heat Method

With this method, the heat is applied by passing current

through the windings to generate heat. Extreme caution

should be exercised using this method so that you do not

damage the internal insulation before the windings are up

to optimal temperature.

< Key Points to Remember >

1) Remove brushes and short the ring together with a

copper link in case of a slip ring motor (wound rotor).

2) Connect an AC supply voltage to the stator windings.

The applied voltage should be approximately 12%. In

this case the stator nominal voltage is 3,300 V and

since 415 V AC represents 415/3,300 x 100 = 12.5%,

this will be a convenient supply voltage. In case the

current is taken from the supply, it would be typically

70% of the full load rated current.

3) The power supply should be controlled with a

temperature controller operating from the internally

connected RTDs supplied by the motor manufacturer.

4) The shaft should be locked to prevent rotation.

5) Set the temperature controller to 110 maximum.

6) Drying will take approx. 8-12 hours once the windings

have reached 100 . The windings should take 6-8

hours to heat up to 110 .

Determination of Dried Insulation

During the drying process the insulation resistance should

be checked with a 500-V (low-voltage machine) or 1,000-V

(only high-voltage machine) DC low-energy source meter

(e.g. megger) and then recorded after 1 minute.

This process should be repeated every hour until the

results show the winding is dry.

Once the winding is completely dry, the insulation

resistance will stabilize. After the windings cool down, the

insulation value should increase.

Notes on Drying Insulation

1) A temperature-controlled oven should be used if the

windings have been completely immersed in water.

2) Should the windings contain contamination, the

windings should be properly cleaned before attempting

to dry windings. Contact your factory representative for

further advice.

3) All processes for drying insulation should be performed

under the supervision of qualified personnel. Failure to

observe proper procedures may result in permanent

damage to the insulation or winding system. For further

advice contact your factory representative.



Fig. 9 Change in Insulation Resistance

This method should only be used if allwinding resistance is greater than 1megohm.

(63)

06


Maintenance of Slip Rings, Brushes and Brush Holders

Fig. 10 Examples of Good Condition

Fig. 11 Examples of Poor Conditions

6.1 Slip Rings

Good Conditions

The slip ring must run true to the center of rotation. The

maximum permissible TIR (Total Indicator Runout) must be

no greater than 0.02 mm. If the TIR is greater than this,

the slip rings must be machined true. The surface of the

slip rings must be a smooth finish. The slip ring will

normally show a running band under the brush contact

area. This can be from light straw in colour to dark brown

(almost black). The most normal colour is “light brown”.

The surface should be consistent in colour around the

periphery and across the brush track. Sparking should not

be evident during operation and the rings should be dry

with no signs of contamination.

The Brush Running Band is a film on the ring basically

consisting of copper oxide and carbon. This film occurs

naturally during normal operating and it is essential for

good brush and ring condition. Do no try to remove it. The

film is easily maintained by ensuring the area is free from

contamination and the machine is properly loaded.

Poor Conditions

Poor ring conditions can be caused by several conditions.

The common causes of poor ring conditions are:

1) Brush loading is not optimum correction:

See Section “Optimizing Brush Wear”.

2) Contamination:

Such as oil, salt air, H2S or silicone vapours (even from

Silastic) may destroy the film builds up on the rings.

Correction : The contamination should be removed and

a new set of brushes fitted and bedded in. It is

preferred that slip rings be cleaned with a dry lint-free

cloth. If required, some “non-residue/noncorrosive”

electrical cleaning solvent could be used.

3) Corrosion of Brush Rings

This condition may occur if the motor has been at

standstill for a long time (e.g. after extended storage).

Correction : This should be removed by using a fine

“ommutator” stone available from most service shops

or brush suppliers. Rotate the motor either with a small

pony motor or run the motor on no load and uncoupled

with the slip rings short-circuited after accelerating to

full speed (do not start without rotor resistance starter).

4) Threading

If threading occurs, brush optimization should be

corrected first.

1) Light threading can be corrected the same way as

“corrosion”.

2) Heavy threading should be corrected by machining

the slip rings.

5) Out of round rings

This must be corrected by machining the slip rings.

Machining Slip Rings

Method 1 - Preferred:

Dismantle the motor and remove bearings. Place the rotor

in a lathe, centre bearing journals true and machine slip

rings.

Electrical solvent, if inhaled or absorbedthrough the skin, can be dangerous toyour health. Please refer to themanufacture safety information forproper advice

Although no voltage is present across therings during this operation you should- ensure the rings cannot open circuit,

otherwise high voltages could be present.- follow electrical safety rules.This procedure should only be performedby qualified and experienced personnel.

(64)

Method 2 - Alternative:

The rings are removed from the shaft with a puller which

can be attached to the hub of the slip ring assembly.

Access to the rings can be gained by removing the drive

end endshield and carefully disconnecting the rotor leads.

After the rings have been removed they can be machined

in a lathe.

Method 3 - Alternative:

Some motor repair shops offer on-site machining. This is

not a preferred method, but may be required for

emergency repair. If on-site machining is performed, the

following precautions should be adhered to

-- replace brushes after machining operation is complete.

-- all ring swarth to be removed from slip ring enclosure.

-- this operation should only be performed by experienced

personnel.

After machining, the rings should be kept clean and free

from fingerprints until ring film has developed during

operation.

6.2 Brushes and Brush Holders

General

The brushes must make good contact with the slip ring

surface. To ensure this, they must move freely within the

brush holder and pressure lever must apply the correct

pressure. The brush holder assembly is fixed. To replace

brushes, unclip the pressure level and undo the “pigtail”

from the holder assembly.

If satisfactory brush life has been obtained, replace the

brushes with the same grade as the original. Always make

sure brushes are bedded in after replacement.

It may be possible that brushes wear out quickly. A

common cause for this is a light load or brushes not

making proper contact with the rings. In this case consult

Section “Brush Optimization” or your carbon brush supplier.

If brush holders need replacing, the brush assembly may

be removed by taking off the drive end endshield. The

brushes are to be changed when they have worked down

to about 1/3 of their original length. The wear is not the

same for all brushes. It is important to keep the brush

housing clean and grease from excess carbon dust. Clean

out housing periodically, using vacuum cleaner and clean,

dry compressed air (max. 4 bars) where possible.

Bedding Brushes

When new brushes are fitted they should be bedded in. If

the slip rings wear, the diameter can vary, so the

diameters of the brush face and the diameter of the rings

may not be exactly the same. So, in all cases, brushes

should be bedded in.

Some abrasive sandpaper

should be placed around

the slip ring and the brush

fitted in the holder with

the tensator in place. The

abrasive is drawn back

and forth until all of the

brush is in contact with

the ring.

The brush surface contact area must not be less than 80%

of the surface of each individual brush.

During the initial run, if possible, it is desirable to apply

some bedding chalk to the rings before entering under the

brush surface, this will promote the final bedding in of the

brush.



Fig. 12 Brush Holder Assembly

Fig. 13 “Bedding” Brushes In

NOTE: Bedding chalk is usually available from most serviceshops or carbon brush suppliers.

Cleaning while operating is notrecommended, except in case ofexperienced operators. High velocitycompressed air can lift brushes or shortpigtails together.

Fig. 14 Example ofPoor Surface Profile

(65)

07


7.1 General

Transport, Storage

Always keep the cover and the cable entries tightly

closed.

7.2 Description

1) Application

In the terminal box, the connection is made between the

stator winding and the supply cable from the system. The

terminal box is mounted on the machine frame at an

easily accessible location.

2) Construction

A typical construction is shown in Fig. 15

3) Degrees of Protection

The terminal boxes comply at least with degree of

protection IP55 as per IEC 34-5.

4) Connection Part for Main Terminals

The connection part is suitable for connection with cable

lug depending on the equipment complement.

7.3 Installation

1) Termination

General

Ensure that the power supply agrees with the rating plate

data. The supply cables should be matched to the rated

current and plant-specific conditions (e.g. ambient

temperature, method of cable installation, etc.). Connect

the supply-cable conductors.

Connection by Means of Cable Lugs

The size of cable lugs must be matched to the size of the

supply cable. Use appropriate units with sufficient

current-carrying capacity.

Direction of Rotation

When the power supply phase conductors L1, L2, L3 are

connected to terminals U, V, W respectively, the motor

will rotate in a correct direction. If the connections to any

two terminals are reversed, i.e. if lines L1, L2, L3 are

connected to terminals V, U, W (or U, W, V or W, V, U)

respectively, the motor will rotate in a reverse direction.

Installing and Entering the Cable

The following steps are recommended for split entry:

- Cut the sealing insert so that its opening is some

millimeters smaller than the cable diameter.

- Introduce the cable into the cable gland. In the case of a

very small cable diameter, the cable diameter should be

increased by applying insulation tape at the securing

point to ensure concentric positioning of the cable in the

sealing insert.

- Provisionally attach the terminal box cover in order to

check whether perfect sealing is achieved both at the

flange surfaces and at the entry point with sufficient

prestressing. If this is not the case enlarge the sealing

insert cut out or adjust the cable diameter by means of

insulation tape. The securing bolts should then be

tightened alternately in steps.

- Unused entry openings always must be closed off by

suitable plugs.

These must

- be of permissible resistant material,

- conform to degree of protection IP55,

Terminal Box for High-voltage Supply

Fig. 15 Construction of Terminal Box(Example, delivered design may deviate in details)

Connection cables and cable ends mustnot exert any bending or torsion forceson the connection bolts!

Terminal box bodyPackingCable holderCable grommetInsulatorConnector

PackingTerminal box coverGland platePackingTerminal lugEarthing terminal

(66)

- be tightened so that they can be removed only by means

of a tool.

Earth Connection

An earth terminal for connecting the cable earth

conductor is provided in the terminal box.

The minimum connection cross-section of earth

connections should be selected according to IEC 34-1 with

reference to live conductors.

Make sure in any case of installation and maintenance

work that the equipotential bonding is maintained.

Final Checks

Before closing the terminal box, check the following:

- Conductor connections and, if applicable, the circuit

connections have been made correctly.

- Interior of the terminal box is clean and free from

remainders of cable material.

- All terminal screws and the appropriate cable entry parts

are firmly tightened.

- Clearance in air of 8 mm at 500 V, 10 mm at 660 V,

14 mm at 1 kV, 60 mm at 6 kV, 100 mm at 10 kV

are maintained. Remove any projecting wire ends!

- Connection leads are not subject to strain and the

insulation cannot be damaged.

- Unused entry openings are closed off by suitable plugs.

- All seals and sealing surfaces are in perfect condition. If

sealing of the joints is effected by metal-to-metal joints

only, the surfaces should be cleaned and thinly

regreased.

- Entry glands fulfill all requirements concerning degree of

protection, conditions of installation, permissible lead

diameter.

7.4 Operation

Safety Advice

Covers to prevent accidental contact with live or rotating

parts and those required for proper air guidance and thus

effective cooling should not be opened during operation.

During maintenance or inspection work in the immediate

vicinity of the terminal box or of the rotating machine

suitable measures should be taken to protect personnel

against hot gases escaping under short-circuit conditions.

7.5 Maintenance

1) Safety Advice

Before any work is started on the machines, particularly

before covers are removed from live parts, make sure that

the machine/plant has been correctly disconnected from

the power supply.

Please adhere to the general “5 safety rules”

- Isolate the equipment from the power supply,

- Provide a safeguard to prevent unintentional reclosing,

- Verify safe isolation from the supply,

- Earth and short-circuit,

- Provide barriers or covers for adjacent live parts.

2) Tightness, High-current Loading

The terminal boxes should be inspected regularly to

ensure that they are tight, that the insulation in

undamaged and that the connections are firmly attached.

If the terminal box is subject to extremely high current

loading it is recommended that the insulators, connecting

parts and cable connectors be checked.

If any dust or moisture has penetrated the terminal box,

clean and dry out the terminal box. The seals and sealing

surfaces should also be checked and the cause of faulty

sealing should be remedied.

3) Tightening Torque

Max. tightening torque for current-carrying bolted joints is

given in below table.



Only switch off the electrical machineduring the main running period in anemergency, in order to protect theswitchgear and electrical machine.

High-voltage power source must bedisconnected before working onequipment.Failure to disconnect power source couldResult in injury or death.Terminal box only to be opened byskilled personnel

NOTE: Replace the cover and tighten up the screws (takingsafety elements into consideration).

ScrewStrength class

M58.8

M68.8

8.0 8.0Tightening Torque(Nm)

M128.8

M108.8

M88.8

M168.8

704020 170

*The tolerance of tightening torques is 10%

(67)

08


8.1 General

Transport, storage

Always keep the cover and the cable entries tightly

closed.

8.2 Description

1) Application

The terminal boxes are employed for connection of

auxiliary circuits.

If specially ordered for anti-condensation heater, an

auxiliary terminal box for anti-condensation heater may be

supplied.

2) Construction

The typical construction is shown in Fig. 16.

3) Degrees of Protection

The terminal boxes comply at least with degree of

protection IP55 as per IEC 34-5.

8.3 Installation

1) Termination

When making the connections of auxiliary circuits note

wiring diagram for auxiliary circuits documented in the

approval specification.

The cross-section of a supply cable should be selected on

the basis of the rated current and plant-specific

conditions.

The connection terminals for auxiliary circuits are suitable

for conductor cross-sections of at least 2.5mm2.

The ends of the conductors should be stripped in such a

way that the remaining insulation reaches almost up to

the terminal.

2) Installing and Entering the Cable

In addition to the information given for cable selection and

preparation, the following specific notes apply, depending

on the type of entry fitting used :

To maintain the degree of protection IP all screwed-in

glands must be firmly tightened and sealed by suitable

measure, e.g. by means of an adhesive or by fitting

sealing ring. The same measures are required when fitting

screwed-in plugs.

The center rings of screw glands included in the scope of

supply are always screwed in place, fixed in position and

sealed in accordance with degree of protection IP55 by

use of LOCTITE. These glands also are fitted with blind

washers for transport protection.

For adapting the cable diameter to the gland conditions it

may be necessary to apply a layer of insulation tape to the

leads to enlarge its overall diameter or to cut out some

rings of the sealing insert.

With extreme lead diameter it may be necessary to

replace the glands by those of appropriate dimensions.

Entry plates of terminal boxes may be supplied undrilled

in order to allow selection of cable entry screw glands,

whose design, number and size are suitable for the cables

employed.

Terminal Box for Auxiliary Circuits

Fig. 16 Construction of Terminal Box(Example, delivered design may deviate in details)

Terminal box bodyPackingSupport ringRailTerminal block.

Cable grommetEarthing terminalPackingTerminal box cover

Hazardous Voltage.Will cause death, serious injury,electrocution or property damage.Disconnect all power before working onthis equipment

(68)

The entry elements should be selected so that

- they are suitable for the cable diameter,

- they conform to the degree of protection,

- they are suitable for the installation conditions.

The supply leads-particularly the protective conductor-

should be laid loosely in the terminal box with an extra

length to protect the cable insulation against splitting.

Unused entry openings always must be closed off by

suitable plugs.

These must

- be of permissible resistant material,

- conform to degree of protection IP55,

- be tightened so that they can be removed only by means

of a tool.

3) Earth Connection

A earth terminal for connecting the cable earth conductor

is provided in the terminal box.

9.1 Description

1) Application

Anti-condensation heaters fitted in electrical machines

warm the air inside the stationary machine to a

temperature above that of the surroundings, thus

effectively preventing moisture condensation.

2) Construction

The typical constructions are shown in Fig. 17, 18 and 19.



Fig. 17 O Type Anti-condensation Heater(Example, delivered design may deviate in details)

Fig. 18 U Type Anti-condensation Heater(Example, delivered design may deviate in details)

Anti-condensation Heating with Heating Tube09

Insulation materialsHeating conductorHeating pipeLead cable


(69)

09


The heating tube has a heating conductor which is

embedded in insulating material and arranged inside a

corrosion-resistant metal tube. The tube ends are sealed

to prevent the ingress of moisture.

3) Installation

The anti-condensation heater consists of one or more

tubular heating elements connected together. These

heating tubes are combined to form units and are

installed in the stator frame. The arrangement constitutes

the so-called “stabilized design”, i.e. the heating

temperature stabilizes itself at the rated voltage thanks to

the optimum balance of heater rating and heat

dissipation. Special temperature monitoring devices are

therefore not necessary. This applies to explosion-proof

versions as well.

9.2 Installation

1) Connecting the Supply Cable

The heater connections are brought to terminals which

are located in a separate terminal box and may be made

without cable lugs.

Connection must be made in accordance with wiring

diagram documented in the approval specification.

Examine the data plate to see that the voltage and the

power of the heating agree with the main supply. The

supply connection of the heaters must be interlocked with

the main breaker of the machine to ensure that the

heaters are switched off when the machine is running and

switched on once the machine has come to a standstill.

Through appropriate series connection of the heating

tubes, even the temperature of explosion

-- proof machines can be limited such that these machines

meet the requirements of “stabilized design” and do not

require any additional temperature monitoring

measures. For this reason, no changes may be made in

the original heating-tube connection!

2) Insulation Testing

The heater may only be put into operation if the specified

minimum insulation value of 0.5 Mega-ohm is obtained

from measurement of the insulation resistance with the

heater connected.

For the period after commissioning of machines equipped

for anti-condensation heating, it is assumed that either

the machine itself is in operation or the anti-condensation

heater is heating the stationary machine.

9.3 Maintenance

1) Safety Advice

The anti-condensation heater is switched on when the

machine has come to a standstill. Therefore, it must be

switched off before any protecting cover is opened for

maintenance work.

2) Cleaning

With respect to maintenance, occasional cleaning

performed during routine maintenance of the machine

and the replacement of any damaged parts is sufficient.

3) Repairs

Should replacement of the heating tubes become

necessary use the same type of heaters. Install the new

tubes securely and lock the fixing elements.

The heating tube units in explosion-proof machines may

only be replaced as a whole and must be purchased as

whole preformed units to suit the particular application. If

repairs and modifications to models covered by the

certificate for these machines are not performed in a

HYUNDAI workshop, an acceptance inspection by an

authorized engineer is necessary. If modifications not

covered by the certificate are made, the machine must be

newly certified.

Anti-condensation Heating with Heating Tube

Fig. 19 Strip Type Anti-condensation Heater forExplosion-proof Machines with “increased safety”(Example, delivered design may deviate in details)

Hazardous Voltage.Will cause death, serious injury,electrocution or property damage.Disconnect all power before working onthis equipment


(70)

10.1 Flange-type Sleeve Bearings (Ring Lubrication System)

1) Mounting

The flange-type sleeve bearings of electrical machines are

of the split type. They are ring-lubricated and are subject

to the following instructions supplementing and modifying

the operating instructions of the machine:

Corresponding to the operating conditions the sleeve

bearings of new machines have a favorable bearing

clearance which should not be changed. Also scraping

(spot grinding) is not allowed to do not make worse the

antifriction qualities.

It is recommended that the contour of the transmission

element remains within the hatched range (see Fig.19) to

remove the upper part of the bearing housing for

maintenance without removing the transmission element.

Before the machines are aligned and commissioned, the

bearings should be filled with lubricating oil, because the

machines are delivered without oil in the bearings (Oil

type is indicated on the nameplate for bearing).

2) Oil Change

Check the bearing temperature regularly. The governing

factor is not the temperature rise itself, but the

temperature variations over a period of time. If abrupt

variations without apparent cause are noticed, shut down

the machine and renew the oil.

The lubrication oil indicated on the data plate is used for

starting up the machines at an ambient temperature of

above +5 At lower temperatures (to about -20 ), it is

sufficient to preheat the oil. If the ambient temperature

are below -20 another type of oil according to the

special conditions is used. Do not mix oils of different

grades. Recommended oil changing intervals are about

3000 and 6000 operating hours in the case of intermittent

and continuous duty. When cleaning, first flush the

bearings with kerosene and then with oil. Pour in the

kerosene and oil through the top sightglass hole. Leave the

drain open until all the kerosene has been removed and

clean oil runs out. Now plug the drain and fill the bearing

with oil up to the centre of the lateral inspection glass.

When the machine has run up to speed, check the oil ring

through the top inspection glass to see that it rotates

correctly, and check the bearing temperature, Should the

bearing temperature not drop to the normal value after

the oil change, it recommended that the surfaces of the

bearing shells be inspected.

If the bearings are fitted with thermometers for checking

the bearing temperature, fill the thermometer well in the

upper bearing shell for thermofeeler with oil to improve

heat transfer and top up with oil every time the

lubricating oil is changed.

3) Dismantling, Assembling

When dismantling the machine the lower part of the

bearing housing need not be unscrewed from the end

shield, When opening the bearing housing, locate before,

if on which side of the machine the adjusting shims.(upper

and lower parts)are installed. These shims must be

installed at the same place when assembling the machine.

Exceptions are possible if the stator core was changed.

Drain the oil, take off the upper part of the bearing housing

and the upper bearing shell, lift the shaft very slightly and

turn out the lower bearing shell and the sealing rings in

peripheral direction. The oil ring can be withdrawn by

holding it at an inclined position to the shaft.

If only slight damage has occurred to the bearing surface,

it may be re-conditioned by scraping as long as the

cylindrical shape of the bore is maintained, so that a good

oil film can form. The lining must be renewed if more

serious damage is found. The oil pockets and grooves of

the new lining or scraped shell should be cleaned and

finished with particular care

The replacement bearing shells are delivered by the works

with a finished inner diameter. Only if the bearing shells

were delivered unfinished, the inner diameter is 1mm

smaller than the finished diameter. Oil rings which have

become bent through careless handling will not turn

evenly. Straighten or replace such rings. Replace any

damaged sealing rings.


THREE-PHASE INDUCTION MOTORS10 Maintenance of Bearings

Maintain Proper Oil Level.May cause damage to equipment due toimproper lubrication.Follow lubricating instructions carefully.Avoid adding oil while unit is running.

Fig. 20 Oil Pockets and Oil Grooves

(71)

10


Maintenance of Bearings

Fig. 21 Ring-lubricated Flange-type Sleeve Bearings (Example, delivered design may deviate in details)

1. Screw plug(thermometer mounting)2. Inspection glass3. Sealing ring for 24. Sealing ring for 15. Bearing housing, upper part drive end6. Cylindrical pin7. Sealing ring, upper half, drive end8. Guide pin to prevent twisting9. Upper bearing shell, drive end

10. Oil ring, drive end11. Lower bearing shell, drive end12. Bearing ring, lower half, drive end13. Sealing ring, lower half, drive end14. Taper pin15. Guide pin to fix bolted parts16. Sealing ring for 1717. Drain plug18. Bearing housing, upper part, non-drive end19. Sealing ring, upper half, non-drive end20. Upper bearing shell, non-drive end21. Oil ring, non-drive end22. Lower bearing shell, non-drive end23. Bearing housing, lower part, non-drive end24. Sealing ring, lower half non-drive end25. Upper adjusting shim, drive end26. Sealing cover drive end27. Lower adjusting shim, drive end28. Upper adjusting shim, non-drive end29. Sealing cover, non-drive end30. Lower adjusting shim, non-drive end31. Protective cap32. Pressure compensation opening

123

4

5

6

7

8

9

10

11

12

13

1716

2

3

15

14

12

34

18

6

19

8

20

21

22

23

24

17

16

2

3

15

31

28

29

3032

25

32

Limiting range for transmission element

27

a

d1d2

45

26

14

(72)

10.2 Flange-type Sleeve Bearings(Forced Lubrication System)

1) Mounting

These flange bearings of electrical machines are of the

split type. They are lubricated by and oil rings and is

provided for additional forced lubrication. They are subject

to the following instructions supplementing and modifying

the operation instructions of the machine: Corresponding

to the operating conditions the sleeve bearings of new

machines have a favorable bearing clearance which

should not allowed to do not make worse the antifriction

qualities.

It is recommended that the contour of the transmission

element remains within the hatched range to remove the

upper part of the bearing housing for maintenance

without removing the transmission element.

Before the machines are aligned, the bearings should be

filled with lubricating oil (oil type is indicated on the

nameplate for bearing), because the machines are

delivered without oil in the bearings.

Connect the bearings to the oil pump, oil tank and cooler

before commissioning the machines. No reducers must be

fitted in the piping. Install a regulating orifice on the oil

supply line to protect the bearing from flooding. If the oil

pump fails, the lubrication maintained by the oil ring is

effective for about 15 to 30 minutes, provided the oil

contained in the bearing does not drain away. To prevent

this, connect the oil discharge tube on that side where the

oil rings moves downward into the oil. In addition to this,

install a non-return valve in the oil supply line. As an

alternative, the oil 100 mm high, to raise the level of the

oil in the bearing. Oil discharge tubes must terminate

flush with the inside surface of the bearing housing to

prevent the oil rings from rubbing against the tubes.

Fill the oil tank with lubricating oil indicated on the data

plate. This oil is used for starting up the machine at an

ambient temperature of above +5 At lower

temperatures preheat the oil. It is recommended to use a

control system adjusted in such a manner to have an oil

temperature of 15 to 20 in the tank and to have a

preheated oil flow through the cold bearings for 5 to 10

minutes before starting up the machine. Do not mix oils

of different grades.

The necessary pressure of the oil entered the bearings

and the oil flow rates are indicated on the data plate.

Adjust to these values when starting up the machine for

the first time and correct them when the bearing has

attained its normal running temperature. The oil in the

bearing housing must not ascend over the center of the

lateral inspection glass.

If the bearings are fitted with thermometers for checking

the bearing temperature, fill the thermometer well in the

upper bearing shell for the thermofeeler with oil to

improve heat transfer and top up with oil every time the

lubricating oil is changed.

In the case of insulated bearings, make sure that the

insulation is not bridged by the tubes; interrupt the

electrical conductivity of the tubes near the bearings, e.g.

by installing oil-resistant fittings of plastic material or

hoses of rubber or plastic material.

Switch on the oil pump before starting up the machine.

The use of a pump driven from the shaft of the main

machine is permitted only in special cases, i. e. when the

acceleration and coasting times are short.

2) Oil Change

Check the bearing temperature regularly. The governing

factor is not the temperature rise itself, but the

temperature variations over a period of time, if abrupt

variations without apparent cause are noticed, shut down

the machine and renew the oil.

Recommended oil changing intervals are about 20,000

operating hours. After the machine is come to a standstill

and the old oil is drained out of the bearings and oil tank

operate the oil pump with kerosene for a short time and

then with oil to clean the bearings, the oil pump, the oil

tank, the cooler and the pipe lines. Pour in the kerosene

and then the oil through the filling opening of the oil tank.

Leave the drains open from time to time until all the

kerosene has been removed and clean oil runs out of the

bearings and oil tank. Now, plug the drains and fill the

tank with oil. Should the bearing temperature not drop to

the normal value after the oil change, it is recommended

that the surfaces of the bearing shells be inspected.


When dismantling the machine the lower part of the

bearing housing need not be unscrewed from the end

shield. When opening the bearing housing, locate before,

if and on which side of the machine the adjusting shims

(upper and lower parts) are installed. These shims must

be installed at the same place when assembling the

machine. Exceptions are possible, if the stator core was

changed. Drain the oil, take off the upper part of the

bearing housing and the upper bearing shell, lift the shaft

very slightly and turn out the lower bearing shell and the

sealing rings in periphera direction. The oil ring can be

withdrawn by holding it at an inclined position to the shaft.



Maintain Proper Oil Level.May cause damage to equipment due toimproper lubrication.Follow lubricating instructions carefully.Avoid adding oil while unit is running.

(73)

10


If only slight damage has occurred to the bearing surface,

it may be re-conditioned by scraping as long as the

cylindrical shape of the bore is maintained, so that a good

oil film can form.

The lining must be renewed if more serious damage is

found. The oil pockets and grooves of the new lining or

scraped shell should be cleaned and finished with

particular care.

The replacement bearing shells are delivered by the works

with a finished inner diameter. Only the bearing shells

were delivered unfinished, the inner diameter is 1mm

smaller than the finished diameter. Oil rings that have

become bent through careless handling will not turn

evenly. Straighten or replace such rings. Replace any

damaged sealing rings.


Fig. 22 Flange-type Sleeve Bearing for Forced-oil Lubrication (Example, delivered design may deviate in details)

1. Screw plug(thermometer mounting)2. Inspection glass3. Sealing ring for 24. Sealing ring for 15. Bearing housing, upper part drive end6. Cylindrical pin7. Sealing ring, upper half, drive end8. Guide pin to prevent twisting9. Upper bearing shell, drive end

10. Oil ring, drive end11. Lower bearing shell, drive end12. Bearing ring, lower half, drive end13. Sealing ring, lower half, drive end14. Taper pin15. Guide pin to fix bolted parts16. Sealing ring for 1717. Drain plug18. Bearing housing, upper part, non-drive end19. Sealing ring, upper half, non-drive end20. Upper bearing shell, non-drive end21. Oil ring, non-drive end22. Lower bearing shell, non-drive end23. Bearing housing, lower part, non-drive end24. Sealing ring, lower half non-drive end25. Upper adjusting shim, drive end26. Sealing cover drive end27. Lower adjusting shim, drive end28. Upper adjusting shim, non-drive end29. Sealing cover, non-drive end30. Lower adjusting shim, non-drive end31. Protective cap32. Pressure compensation opening33. Oil supply tube with orifice34. Oil discharge tube with sight glass

12 1

3

4

18

6

19

8

20

21

22

23

24

1716

2

3

15

142

3

4

5

6

7

8

9

10

11

12

13

1317

a 2526

27

32

33

34

d2

d1

3

2

15

14

3129

28

30

32

45

Limiting range for transmission element

(74)

10.3 Rolling-contact Bearings

1) Mounting

Electrical machines fitted with rolling-contact bearings

mentioned above are subject to the following instructions

supplementing and modifying the operating instructions of

the machine:

The locating bearings are deep-groove ball bearings for

horizontally mounted machines. These bearings may also

be in pairs with cylindrical roller bearings in the case of

bearings is not guide radially and is prevented from

rotating by compression springs.

The locating bearings for vertically mounted machines are

angular-contact ball bearings of type range 72 or 73

(angular-contact ball bearings with increased axial fixation

see supplementary operating instructions).

The floating bearings are deep-groove ball bearings or

cylindrical roller bearings. In case of deep-groove ball

bearings as floating bearings, the axial play is

compensated by means of compression springs.

2) Regreasing

Initial lubrication of the bearings is normally carried out in

the works with a Alvania RL#2 grease satisfying the

conditions of running test at a test temperature of 120

to DIN 51 806. If a different type of grease is required, this

is indicated on the data plate, provided that the particular

operating conditions were given in the order.

Keep the new grease meticulously clean. Greases having a

different soap base should not be mixed since this would

reduce the grease quality.

For regreasing, clean the lubricating nipple and press in

the grease quantity indicated on a data plate, using a

grease gun. The shaft should rotate during regreasing;

hence, the machines need not be stopped. After

regreasing, the bearing temperature will rise by a few

degrees and will drop to the normal value when the

grease has reached its normal service viscosity and the

excess grease has been forced out of the bearing.

It is recommended that the lubricating instructions be

strictly followed. Special cases may require lubrication to

special instructions, e.g. where there is an extreme

coolant temperature or aggressive vapours. The old

grease from several regreasing operations gathers in the

space inside the outer bearings caps. Remove the old

grease when overhauling the machines.

The model of bearing is favorably chosen as for direction

and size of load (type of construction, forces acting on the

shaft) and therefore it should not be changed.

The permissible values of axial and radial forces may be

taken from the list of machine or may be inquired.

The machines should operate in only one type of

construction as shown the rating plate, because another

type of construction required perhaps further measures in

addition to a modification of the model of bearing. Always

in this case an inquiry is necessary.

3) Lubrication

Regrease the bearings if the machines have been stored

unused for longer than 2 years.


For working on the locating bearing in the vertical position

of the machine, support or discharge the rotor.

It is recommended that new rolling bearings be installed

as follows: Heat the ball bearings or the inner ring of the

roller bearings in oil or air to a temperature of approx.



Fig. 23 Examples for Bearing Combination

NOTE: A common mistake is over-lubrication of bearings.When grease is added without removing the drain plug, theexcess grease must go somewhere and usually it is forcedinto and through the inner bearing cap and is then throwninto the windings. Excess grease in the bearing can causebearings to run hot and could lead to bearing failure.

May cause bearingdamage(brinelling) if outer race ofbearing is struck.BECAREFUL When replacing bearing.Avoid subjecting bearing to impact.

Deep-groove ball bearing

Cylindrical roller bearing

Angular contact ball bearing

(75)

10


80 and slip them onto the shaft. Heavy blows may

damage the bearings and must be avoided.

When installing single angular-contact ball bearings, make

sure that the broad shoulder of the inner ring (and the

narrow shoulder of the outer ring) in operating position

points upwards, i.e. in a direction opposite to that of the

axial thrust.

When assembling the machines, avoid damage to the

sealing rings. Rubber sealing rings (V-rings) should be

carefully fitted over the shaft as shown the illustration.

New felt sealing rings should be so dimensioned that the

shaft can run easily while proper sealing is still effected.

Before fitting new rings, soak them thoroughly in highly

viscous oil (normal lubricating oil N68 to DIN 51 501)

having a temperature of approx. 80

5) Locating Faults

The troubleshooting table helps to trace and remove the

causes of faults. It is partly difficult to be found the

damages of bearings. In case of doubt, it is recommended

to renew the bearings.

10.4 Insulation to Prevent Shaft Current (High-voltage and Large Machines)

To prevent the shaft current according to the unbalance of

magnetic reluctance in magnetic circuits, the insulator is

provided at end shield side as shown in Fig. 24.

With motors having one shaft extension, the bearing at

non-drive end is insulated. Motors with double end shafts

are insulated at drive & non-drive end bearings. When

double end shaft motor is coupled with driven load,

insulation must be supplied in the coupling of one end to

prevent bridging of bearing insulation.

Care should be taken to prevent shorting out this

insulation. All lines (lubrication oil pipes, B.T.D, vibration

sensors, etc.) fitted at the workshop are insulated from

the end shield, but it is necessary to ascertain whether or

not the insulation is required for all lines which are

connected at the time of the motor installation at the site.

The bearing cooling pipe for forced-oil lubrication is

insulated as shown in Fig. 25. The shaft voltage (peak to

peak) is high frequency voltage of usually 1 volt or less

and rarely several volts. When a shaft current by this

voltage flows, the shaft and journal part are tarnished and

in the worst case sparking can make minute black spots

on shaft and journal parts. There is a possibility that if the

oil film is broken locally, a bum-out trouble will develop.

When disassembling or assembling, be sure to measure

the insulation resistance. The value of 1 to 3 k will be

satisfactory.


NOTE: Insulation bearing any connection to this bearingmust be insulated from it to prevent bearing current.

Fig. 24 Bearing Insulation

Fig. 25 Bearing Cooling Pipe System for Forced-oil Lubrication

Hex, bolt & nut & S/WInsulation tubePackingInsulation flangeInsulation washer

(76)



Fig. 26 Floating Bearings (Example, delivered design may deviate in details)

1. V-ring 1)

2. Outer bearing cap 1)

3. Circlip 1)

4. Grease slinger 1)

5. Bearing housing 1)

6. Lubricating nipple7. Cylindrical roller bearing 1)

8. Inner bearing cap with felt sealing rings 1)

9. Deep groove ball bearing (floating-bearing) 10. Compression spring 1)

11. Bearing housing ring12. Bearing housing bush13. Cylindrical pin

1) Floating bearing side

1

2

3

4

5

6

7

8

8

1

1

2

2

3

3

4

4

116

10

12

13

9

8

5

6

9

10

Deep-groove ball bearingwith compensation of axial play

Cylindrical roller bearing

Deep-groove ball bearing withcompensation of axial play, withbearing housing bush andintermediate ring

(77)

10



Fig. 27 Locating Bearings (Example, delivered design may deviate in details)

14. Inner bearing cap with felt sealing rings 2)

15. Angular-contact ball bearing16. Bearing slinger 2)

17. Grease slinger 2)

18. Circlip 2)

19. Outer bearing cap 2)

20. V-ring 2)

21. Deep-groove ball bearing(Locatingbearing) or angular-contact ball bearing

22. Compression spring 2)

23. Deep-groove ball bearing 2)

24. Cylindrical roller bearing 2)

25. Oil seal for shaft 1) 2) 3)

1) Floating bearing side2) Locating bearing side3) Special operating conditions only

Fig. 28 Fitting Instructions for V-ring and Oil Seal for Shaft

Angular-contact ballbearing placed above

Angular-contact ball bearing placed below

14

20

19

18

17

16

6

15

14

15

18

6

17

18

19

20

14

14

14

14

21

21

24

24

23

23

22

22

16

16

16

16

6

6

6

6

17

17

17

17

18

18

18

18

19

19

19

19

20

20

Single bearing, shaft doesnot pass through the outerbearing cap

Single bearing, shaft passesthrough the outer bearing cap

Duplex bearing, shaft doesnot pass through the outerbearing cap

Duplex bearing, shaft passesthrough the outer bearing cap

Single bearing,shaft does notpass through theouter bearing cap.

(78)

11.1 Air Filter

Air Filter Cleaning Period

The cleaning period depends on the site conditions and

can change. The cleaning of the filter is requested if the

record of the stator winding temperature (using the stator

winding sensors) indicates an abnormal increase in

temperature.

Air Filter Cleaning Procedure

The filter element (flat or cylindrical) is immersed in a tank

of cold or warm water (temperature less than 50 ). Use

water with detergent added.

Shake the filter gently to ensure that the water flows

through the filter in both directions.

When the filter is clean, rinse it with clear water.

Drain the filter properly (there must be no more formation

of droplets).

Refit the filter on the machine.

11.2 Cooler

1) General Points

The purpose of the cooler is the remove machine heat

losses (mechanical, ohmic, etc). The exchanger is located

on the top of the machine.

Normal Operation

The air is pulsed by a fan fixed to the machine shaft.

Description of Air-Water Double Tube Exchanger

The double-tube technique keeps the cooling circuit from

being affected by possible water leakage. The double tube

provides a high safety level. In case of leakage, the water

goes from the inside of the internal tube to the coaxial

space between the two tubes. The water is drained axially

to a leakage chamber where it may activate a sensor. An

exchanger comprises a fin-tube block containing :

- a steel frame

- a fin-tube block expanded mechanically to the tubes.

The tube bundle is roll-expanded in the end plates. The

water distribution in the tubes is provided by two

removable water boxes. A water box is equipped with

collars for fitting the inlet and outlet lines. Neoprene seals

ensure water boxes and the end plates.

2) Cleaning

The frequency of cleaning operations depends essentially

on the purity of the water used. We recommend a

minimum of one inspection per year. The life of zinc block

for anticorrosion is about a year. Therefore, replace it with

a new one every year.

Cut off the water supply by isolating the inlet and outlet

lines and drain the water. Disconnect the leak sensor

(option with double-tube cooler) and make sure that there

are no leaks. Remove the water boxes on each side of the

machine. Rinse and brush each water box.

3) Stop the Machine

Leak detection for a double-tube exchanger. If a leak is

detected, cut off the power supply of the water in/outlet

lines and change to emergency operations, it is necessary

to ascertain and repair it. Remove the two water boxes,

apply a slight positive pressure in the leakage chamber

and thus between the two tubes (only concerns double-

tube coolers). If a tube is damaged, plug it at both ends.

Use a tapered plug. The plug should preferably be made of

saltwater-resistant aluminum bronze or of a synthetic

material.

4) Leak Detection (Float System)

A magnet float activates a switch located in the float-

guiding rod.


THREE-PHASE INDUCTION MOTORS11 Air Filter and Cooler

NOTE: Do not use a hard wire brush, as this will removethe protective tar-epoxy layer which has formed on thesurface of the water boxes. Clean each tube with a metalscraper. Rinse in soft water. Keep the leakage chamber dry(double-tube water-cooler only).

Fig. 29 Leakage Detector

Do not clean the filter using compressedair. This procedure would reduce filterefficiency.

(79)

11


5) Cooler Removal

The cooler unit is slid into its housing. It is possible to

remove the cooler from the housing without removing the

water boxes. The cooler is fastened to the housing via a

series of screws on the housing. Remove the supply and

return pipes. Provide two supports to hold the cooler

when it comes out of its housing. Remove the cooler

using slings that can be attached to the connecting

flanges.

6) Cooler Reassembly

Carry out the operations of the “Cooler Removal” in the

reverse order. Be careful to push the cooler completely

into its housing before tightening the fastening screws of

the cooler to the casing.

Air Filter and Cooler

Fig. 30 Cooler Removal

1. Cover2. Gasket for 13. Cooler housing4. Gasket for 55. Air-to-water cooling element

1

2

3

4

5

(80)

General

It is our recommendation that all electric motors are fitted

with motor protection. The preferred type of motor

protection should be provided the following protection

features:

1) Current limit by a programmable thermal limit curve

with thermal modeling based on winding temperature.

2) If RTD is installed for winding temperature detector,

winding temperature detection by RTDs should be

separated alarm and trip set points.

3) Ambient temperature RTD located in the motor ambient

air stream.

4) If installed bearing temperature indicator, alarm and trip

set points separate.

5) Calculation of motor thermal capacity available.

6) Ground fault detection.

7) Current unbalance detection.

8) Capacity for the protection system to learn motor

cooling times.

A motor protection system with these features should

reward you with better reliability and will allow you to

optimize the motor to its maximum performance

Protection Setting Recommended

Guide values for adjustment of tripping temperature.


THREE-PHASE INDUCTION MOTORS12 Protection

Insulation Class ‘F’

Description

Insulation Class ‘B’

PermissibleMax.

Temp.rise (T)

WindingTemperature

Max.140 °K

130 °K 140 °K

Max.95 °K

90 °K 95 °K

Max.100 °K

95 °K 100 °K

Max.10%

6%(10-sec delay)

10%(Inst.)

Max.155 °K

150 °K 155 °K

Max.95 °K

90 °K 95 °K

Max.100 °K

95 °K 100 °K

Max.10%

6%(10-sec delay)

10%(Inst.)

Bearing Temperature(Anti-friction*)

Bearing Temperature(Sleeve)

Current unbalance

Alarm TripPermissible

Max. Temp.rise (T)

Alarm Trip

- T means operation temperature including ambient temperature.- Max. permissible temp. rise includes ambient temperature.* When a suitable heatproof lubricant is used or a greasing interval

is changed, the limit of temperature rise shall be determined byagreement between manufacturer and purchaser.

(81)

13


Induction Motor Troubleshooting

Hazardous Voltage.Will cause death, serious injury,electrocution or property damage.Disconnect all power before working onthis equipment.

2. Great drop in voltage due to inadequate

line capacity and impedance drop

Power

source

& line

Starter

Motor

Load

a. A check is to be made on voltage at motor terminal before

and at time of starting.

b. Similar change in voltage is to be checked at motor

terminal.

a. Squirrel cage motor, rotor conductor is to be checked for

disconnection.

b. Wound motor, a check is to be made for line cutting and

unbalance.

c. Repairs or renewal is to be made.

a. Squirrel cage motor, motor is to be replaced with the one

having larger capacity and of the wound type.

b. Wound motor, tap for starting resistor is to be replaced.

a. Squirrel cage rotor, rotor bar and end ring are to be

checked for contact.

b, Wound motor, a check is to be made on coil for unbalance

and on brush for imperfect contact.

Load is to be checked, if load is normal, motor capacity is to

be changed.

A check is to be made on voltage drop of power source and

line.

Resistance and current are to be measured, and repairs are

to be made.

1. Drop in line voltage

3. Cut line or unbalanced

4. Erroneous wire connection

5. Cut line or unbalanced voltage

6. Drop in line voltage

7. Cut line or unbalance in starting resistor

8. Cutting of stator coil or of rotor coil

9. Erroneous connection of stator coil

10. Defect of rotor

11. Stator core is in contact with rotor.

12. Defective bearing

13. Insufficient starting torque

14

1. Inadequately low voltage.

2. Defective rotor.

3. Overload or inadequate torque

A check is to be made with a voltmeter.

Defective parts are to be repaired.

To be repaired

To be reconditioned

Compensator tap connection is to be raised.

Resistance is to be measured; repairs are to be made.

To be reconditioned

a. A check is to be made by turning by hand.

b. Bearing is to be disassembled and examined.

Load is to be reduced.

RemedyAbnormality

Motor fails

to start

Length of time

required for

acceleration after

starting

Probable cause

(82)



Two phases of U.V.W.(or R.S.T.) at starter or motor terminal

are to be changed.

a. A check is to be made with a voltmeter power source.

Voltage is to be raised.

b. Load is to be reduced.

A check is to be made with a voltmeter power source.

Voltage is to be reduced.

Resistance and current are to be checked and

reconditioned.

Judgment can be made according to noise; bent shaft,

bearing, etc., are to be corrected.

1. Unbalance of rotor

a. Bending of shaft

b. Loose joint

c. Residual unbalance

d. Critical speed of shafting

e. Dust attached to rotor

f. Imperfect connection between coupling

and shaft

5. Abnormal contact between shaft and

stationary part, such as end cover, etc.

9. Transmission of vibration from combined

machine

To be repaired

To be tightened by bolts securely

To be readjusted

To be cleaned

To be reconditioned

a. To be checked by turning manually

b. To be disassembled for detecting defects

Phase reversal

1. Overload

2. Overcurrent due to voltage drop

3. Excessive iron loss due to overvoltage.

4. Cut line or imperfect contact in one phase

5. Short-circuiting and grounding of coil

6. Contact between stator and rotor

7. Inadequate ventilation due to dust.

2. Improper magnetic center

3. Defective bearing

4. Coupling deflection

6. Unsatisfactory contact of brush

7. Improper alignment

8. Sinking of foundation

10. Unequal pitch of claw coupling

11. Improper bush of flexible coupling

Load is to be reduced (to rated current)

To be reconditioned

Cleaning is to be carried out.

To be reconditioned

Refer to the “Bearing” section

To be reconditioned

Brush is to be checked for contact.

To be reconditioned

To be reconditioned

Insulation for vibration

Reconditioning of pitch

Reconditioning of pitch

RemedyAbnormality

Rotation in reversal

direction

Motor body

overheated

Vibration

Probable cause

(83)

13



Causes of single-phase operation such as line cutting and

imperfect contact are to be detected; repairs are to be

made.

1. A check is to be made by turning manually.

2. To be disassembled for inspection

To be disassembled and defective parts are to be repaired.

1. Rotor shaft coil resistance is to be measured and

reconditioned.

2. Contact of brush or short-circuit ring is to be checked.

3. A check is to be made on endring contact of a squirrel

cage motor.

1. Care should be taken on shaft at time of assembling and

on bearing box at time of matching.

Machining accuracy and tightening of bearing box are to be

checked.

3. Short-circuits of layer and phase of stator

coil and rotor coil

4. Abnormal contact between shaft and

stationary part such as end cover

9. Crackings at brazed joint rotor bar and

end ring

1. Inclusion of dust and other foreign

substances or rust, bruises

1. Shaft or bearing box is distorted

elliptically.

1. Disagreement of air gap

2. Single-phase operation

5. Unsatisfactory foundation and installation

6. Loose bolts for foundation

7. Gap between foundation and base

8. Resonance with foundation

1. Voltage unbalance

2. Single-phase operation

3. Secondary circuit

1. Excess of tightening allowance

2. Erroneous selection of clearance

3. Minus operating clearance

4. Thermal expansion

2. Improper tightening

3. Inaccuracy due to improper matching

4. Deterioration with time

Causes are to be detected; repairs are to be made.

To be reconditioned

Readjustment of installation

Foundation bolts are to be tightened.

Reconditioning of installation

Readjustment of foundation

Power source and lines are to be checked and balanced.

Line cutting and improper contact are to be reconditioned.

2. Clearance is to be reinspected.

3. Care should be taken at time of assembly.

4. Examination of working condition

RemedyAbnormality

Noise

Unbalance of phase

current

Flaking

(a) Flaking of rolling

elements

(b) Local flaking of a

race

(c) Flaking all over a

race

(d) Flaking on

component parts

opposite to a race

Probable cause

(84)



Seizing

(a) Race ring and

rolling discolored

and turned soft

(b) Damage

Breakage

(total or partial)

(a) Fracture

(b) Cutting

Breakage of retainer

(a) Fracture

(b) Nonuniform

abrasion

(c) Wear of pocket

section

(d) Biting-off

Rust

(a) Rust formed all

over surface

(b) Rust on local

place

(c) Contact erosion

on joint surface

Wear

(a) Abnormal wear

of race and

rolling element

(b) Abnormal wear

of retainer

Electrode

(a) Crater-shaped

depression and

corrugated scars

(e) Flaking all overaround track center

(f) Flakingacross a race

(g) Flaking similar to pittingon a race

Careful handling

Examination of tightening

Examination of machining accuracy of shaft & bearing

housing

Careful handling and reconsideration of working condition

Examination of oil supply and lubricant

Inspection of storage room

Careful handling

Examination of rust-preventive reagent

Reexamination of machining of shaft & bearing housing

Reexamination of working condition

1. Advancement of flaking caused by shock

and below.

2. Great tightening allowance & large round

corner of fitted part

1. Moment load

2. Rotation at shift speed

3. Inadequate lubrication

4. Inclusion of foreign substances

1. Unsatisfactory condition of storage

2. Left alone

3. Inadequate cleaning

4. Rust-preventive reagent

1. Unsatisfactory packing

2. Sweet

1. Inadequate allowance of tightening

2. Change in load

1. Inclusion of foreign substances

2. Occurrences of wear

Inadequate lubrication

Abnormal thrust load

1. Shaft bending

2. Oblique fitting of outer and inner rings

1. Vibration during stoppage

2. Rust

1. Inadequate clearance


3. Improper overload of lubricant

Passage of current

Design of bearing system is to be checked.

Examination of working condition

Proper clearance is to be provided.

Oil amount of lubricant is to be checked.

Reconsideration of working condition and handling

Examination of lubrication and oil supply

Examination of design of bearing system

RemedyAbnormality Probable cause

(85)

13



Dent and

scratch

(a) Indentation (on a

race, etc.)

(b) Aventurine

hardening

(c) Dents given

during handling

(d) Scratches during

assembly

Smearing

biting-off on a

race and rolling

element

Creep

wear of outer and

inner surface,

sliking and

discoloring

Examination of lubricant and lubricating condition

1. Examination of tightening

2. Examination of machining accuracy of shaft and bearing

box

3. Examination of design

Examination of handling and assembling conditions

Careful handling

Careful assembling

Dust and foreign substances pressed

between race and body

Careless handling

(dropping, etc.)


2. Skewing of rolling element

3. Selection of lubricant

1. Inadequate tightening allowance

2. Inadequate tightening of sleeve

RemedyAbnormality Probable cause

(86)

14.1 HLA7 Horizontal-type Motor Construction


THREE-PHASE INDUCTION MOTORS14 Appendix

Fig. 1 HLA7 Horizontal-type Motor Construction (SQUIRREL CAGE)

*Disassembly and reassembly of HLA7 Type induction motor with antifriction bearingNotes: 1. Unless otherwise specified, reassembly of motors may be accomplished by reversing the disassembly steps.

2. Steps 7 to 11 are applied to both the Drive end and Non-drive end of the motors.

Uncouple, and perfom an alignment check at the motorand the drive machine

Lift the motor off and shift it to make enough room tomove the rotor

Remove the bolts securing the air seal and rest each parton the rotor shaft

Dismantle the connection box of the frame, if acc’y attached(BTD, grease pipe, etc.)

Remove the external bearing seal and slinger installed onthe bearing housing

Remove the fan cover

Remove the external fan

Remove the bearing housing

Remove the antifriction bearing

Remove the end shield (bracket) with fan guide

Remove the air guide

Remove the rotor from the stator

FLOW CHART

STEP

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Remarks

*A distance equal to the rotor’slength may be required at bothends of the motor drive end andNon drive end.

*Heat the fan hub to approx.80 ~ 100 both for easyassembly and for removal.

(87)

14


Appendix

14.2 HLS7 Horizontal-type Motor Construction

Fig. 2 HLS7 Horizontal-type Motor Construction (WOUND ROTOR)

*Disassembly and reassembly of HLS7 Type induction motor with antifriction bearingNotes: 1. Unless otherwise specified, reassembly of motors may be accomplished by reversing the disassembly steps.





Dismantle the connection box of the frame, if acc’y attached(BTD, grease pipe, secondary t/box cable, etc.)






Remove the end-shield with brush holder

Remove the end-shield with fan guide


Remove the air guide

FLOW CHART

STEP

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Remarks


*Heat the fan hub to approx.80 ~ 100 both for easyassembly and for removal

(88)

14.3 HRA7 Horizontal-type Motor Construction



Fig. 3 HRA7 Horizontal-type Motor Construction (SQUIRREL CAGE)

*Disassembly and reassembly of HRA7 Type induction motor with antifriction bearingNotes: 1. Unless otherwise specified, reassembly of motors may be accomplished by reversing the disassembly steps.









Remove the internal bearing seal

Remove the end shield (bracket)

Remove the internal fan

Remove the fan guide


FLOW CHART

STEP

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Remarks



(89)

14


14.4 HRP7(4P~) Horizontal-type Motor Construction

Appendix

Fig. 4 HRP7 (500 Fr.-2P & More Than 4P) Horizontal-type Motor Construction (SQUIRREL CAGE)

*Disassembly and reassembly of HRP7 Type induction motor with antifriction bearingNotes: 1. Unless otherwise specified, reassembly of motors may be accomplished by reversing the disassembly steps.













Dismantle the air cooler box, if necessary


FLOW CHART

STEP

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Remarks



(90)

14.5 HRP7(2P) Horizontal-type Motor Construction



Fig. 5 HRP7 (355 Fr.~450 Fr.-2P) Horizontal-type Motor Construction (SQUIRREL CAGE)








Remove the antifriction bearing housing







FLOW CHART

STEP

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Remarks


(91)

14


14.6 HRQ7 Horizontal-type Motor Construction

Appendix

Fig. 6 HRQ7 (355 Fr.~450 Fr.-2P) Horizontal-type Motor Construction (SQUIRREL CAGE)

*Disassembly and reassembly of HRQ7 Type induction motor with antifriction bearingNotes: 1. Unless otherwise specified, reassembly of motors may be accomplished by reversing the disassembly steps.











Remove the intermal bearing seal




FLOW CHART

STEP

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Remarks




(92)

14.7 HRP7(2P) Horizontal-type Motor Construction



Fig. 7 HRP7 (355 Fr.~450 Fr.-2P) Horizontal-type Motor Construction (SQUIRREL CAGE)















FLOW CHART

STEP

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Remarks


(93)

14


14.8 HRS7 Horizontal-type Motor Construction

Appendix

Fig. 8 HRS7 Horizontal-type Motor Construction (WOUND ROTOR)

*Disassembly and reassembly of HRS7 Type induction motor with antifriction bearingNotes: 1. Unless otherwise specified, reassembly of motors may be accomplished by reversing the disassembly steps.


FLOW CHART

STEP

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Remarks






Dismantle the connection box of the frame, if acc’y attached(BTD, grease pipe, secondary t/box cable, etc.)




Remove the end-shield with brush holder

Remove the end-shield with fan guide




(94)

14.9 HLB5 Horizontal-type Motor Construction



Fig. 9 HLB5 Horizontal-type Motor Construction (SQUIRREL CAGE)

*Disassembly and reassembly of HLB5 Type induction motor with antifriction bearingNotes: 1. Unless otherwise specified, reassembly of motors may be accomplished by reversing the disassembly steps.


FLOW CHART

STEP

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Remarks










Remove the bracket




(95)

14


14.10 HRQ7 Horizontal-type Motor Construction

Appendix

Fig. 10 HRQ7 Horizontal-type Motor Construction (SQUIRREL CAGE)
















FLOW CHART

STEP

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Remarks




(96)

14.11 HRQ7 (Sleeve Bearing) Horizontal-type Motor Construction



Fig. 11 HRQ7 (Sleeve Bearing) Horizontal-type Motor Construction (SQUIRREL CAGE)
















FLOW CHART

STEP

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Remarks




(97)

15


Memo

Memo

(98)



Memo

(99)

HEAD OFFICE 1 JEONHA-DONG, DONG-GU, ULSAN, KOREA TEL. 82-52-230-6601~6 FAX. 82-52-230-6995

SEOUL HYUNDAI B/D, 140-2, GYE-DONG, JONGNO-GU, SEOUL, KOREA (Sales & Marketing) TEL. 82-2-746-7627, 8473 FAX. 82-2-746-7648

ORLANDO 3452 LAKE LYNDA DRIVE, SUITE 110, ORLANDO, FLORIDA 32817 U.S.A.TEL. 1-407-249-7350 FAX.1-407-275-4940

LONDON 11TH FL., ST. MARTIN’S HOUSE, 1 HAMMERSMITH GROVE, LONDON W6 ONB, U.K. TEL. 44-208-600-7127, 8741-0501 FAX.44-208-741-5620

TOKYO 8TH FL., YURAKUCHO DENKI BLDG.1-7-1, YURAKU-CHO, CHIYODA-GU, TOKYO, JAPAN 100-0006TEL. 81-3-3212-2076, 3215-7159 FAX. 81-3-3211-2093

CAIRO APARTMENT NO. 503, 5TH FL., BLDG. NO. 7 BLOCK 2, 9TH DIVISION, EL-NASR ROAD, NEW MAADI, CAIRO, EGYPTTEL. 20-2-520-0148~9 FAX. 20-2-754-7528

SOFIA 1271, SOFIA 41, ROJEN BLVD. BULGARIATEL. 359-2-938-1068 FAX. 359-2-936-0742

www.hyundai-elec.com

HH

IS-W

Z-R

E-006-01 2004. 1 D

esigned by Design K

orea

(100)

PETRO VIETNAM GPPMB



abcd POWER SYSTEMS

i

SECTION 2. MECHANICAL SEAL

(101)

John Crane EAA Engineered Sealing Systems

GB

Instruction Manual Reference No.: IOM-K/02408

Mechanical Seal Type 1648

John Crane Assembly Code.: 0600/1648/01/K02408 John Crane Eng. Ref. No.: John Crane Order No.: Customer: HHI Customer Order No.: Plant Owner/Site/Unit HNON TRACH CCPP1 Plant Item Number

s

This seal may only be installed, commissioned and maintained by an authorised plant machinery

pecialist, paying close attention to these instructions and all other relevant regulations. Failure to do this relieves the manufacturer from any liability or warranties.

In the interest of continuous development, John Crane reserve the right to alter designs and specifications without prior notice.

For your nearest John Crane facility, please contact one of the locations below

John Crane International - Major Regional Centres North America Europe Middle East, Africa, Asia Latin America John Crane Inc. John Crane UK John Crane Middle East John Crane Brazil North America Buckingham House P.O Box 61040 Av. Paulista, 475 - 16 andar 6400 Oakton Street 361-366 Buckingham Ave Dubai Bela Vista Morton Grove Slough, England SL1 4LU United Arab Emirates 01311-980 Sao Paulo SP . Illinois 60053 USA Brazil Tel: 1- 847-967-2400 Tel: 44-1753-224000 Tel: 971-48839510 Tel: 55-11-3371-2500 Fax: 1-847-967-3915 Fax: 44-1753-224224 Fax: 971-4-883-7766 Fax: 55-11-3371-2599

Instruction Manual Author: John Crane Buckingham House Engineering 361 – 366 Buckingham Avenue Tel: 44-1753 224000 Slough, Berks. SL1 4LU Fax: 44-1753 224150

(102)

Instruction Manual

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Contents 1 General ........................................................................................................3

1.1 Introduction...................................................................................................3 1.2 Range of Application ....................................................................................3 1.3 Declaration of Incorporation (98/37/EC) .......................................................3 1.4 EU “ATEX” Directive (94/9/EC).....................................................................3

2 Safety & Environment ................................................................................4 2.1 Symbols........................................................................................................4 2.2 Safety Instructions ........................................................................................4 2.3 Environmental Aspects.................................................................................5

2.3.1 Company policy extract ......................................................................5 2.3.2 Recycling ............................................................................................5

3 Transportation and Storage ......................................................................6 4 Description of the Mechanical Seal ..........................................................6

4.1 Construction .................................................................................................6 4.2 Function........................................................................................................7 4.3 Operating Conditions....................................................................................7

5 Installation and Removal ...........................................................................7 5.1 Preparation for Fitting ...................................................................................7 5.2 Installation Tolerances..................................................................................7

5.2.1 Shape and Positional Tolerances .......................................................7 5.2.2 Surface Finish.....................................................................................7

5.3 Installation ....................................................................................................8 5.3.1 Tightening Torques.............................................................................9 5.3.2 Lubricants ...........................................................................................9

5.4 Seal Removal ...............................................................................................9

6 Commissioning and Decommissioning .................................................10 7 Maintenance/Repair..................................................................................11

7.1 Maintenance ...............................................................................................11 7.2 Reconditioning............................................................................................11 7.3 Spare Parts.................................................................................................11

8 Malfunction, Causes and Correction ......................................................11 9 Accompanying Documents .....................................................................11

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Instruction Manual

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1 General

1.1 Introduction This Instruction Manual is provided to familiarise the user with the seal arrangement and its use. The Instructions must be read and applied whenever work is done on the seal, and must be available to the operating and maintenance personnel.

These instructions will help to avoid danger and increase reliability.

John Crane reserve the right to change the seal and specifications described in this manual where it is necessary for technical development and without prior notice. The latest issue supersedes all previous versions.

1.2 Range of Application Mechanical sealing systems are used for the sealing of rotating shafts; they must be operated within their performance limits (see

4.3 Operating Conditions).

If the process or operating conditions are changed from those referenced in this Manual, John Crane must be consulted to ensure the sealing system is safe.

1.3 Declaration of Incorporation (98/37/EC)

Only relevant to equipment operating in EEC countries, see below.

1.4 EU “ATEX” Directive (94/9/EC)

These instructions are intended for use with the mechanical seals operating in Equipment Group II, category 2GD and 3GD.

John Crane UK Engineered Sealing Systems Buckingham House 361-366 Buckingham Ave. Slough Berks, SL1 4LU Phone (01753) 224000 Fax (01753) 224150

Declaration of Incorporation

E.C. Machinery Directive (98/37/EC)

Section 1.0 - Machinery Description:

Type 1648 John Crane Assembly Code.: 0600/1648/01/K02408

Section 2.0 - Applicable Harmonised Standards:

EN 292, EN 809, EN 1127-1, EN 13463-1, EN 13463-5

Section 3.0 - Declaration:

We John Crane, declare that the seal assembly described in Section 1.0 above is intended to be incorporated into other machinery or assembled with other machinery to constitute machinery as covered by this Directive. The seal assembly, covered by this declaration must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the Directive.

Paul Martin

Director of Design Engineering Services Date February 29, 2008. (104)

Instruction Manual

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2 Safety & Environment The safety notes refer to the arrangement supplied. They must be used in conjunction with the relevant safety regulations for the machine, auxiliary equipment, plant and sealed fluid.

2.1 Symbols The following symbols are used in this Instruction Manual to highlight information of particular importance:

Danger Mandatory instructions designed to prevent personal injury or extensive damage.

ATTENTION Special instructions or information to avoid damage to the seal or its surroundings.

Note: Information for easy installation and efficient operation.

Environmental Note

2.2 Safety Instructions

ATTENTION Every working practice which compromises safety is to be avoided.

In the event of an operating problem the machinery must be switched off immediately and made safe! Problems must be solved promptly.

A slight leakage will occur during normal seal operation. Depending on the duty, this leakage can appear as a gas, a liquid or a solid. In case of a worn or defective seal the leakage will increase. The leakage may be hazardous or toxic, and a safe collection system is required.

Hot surfaces have to be protected against accidental contact.

In order to avoid unforeseen hazards do not make unauthorised changes to the fluid to be sealed, the specified duty, or the seal parts.

ATTENTION

Some mechanical seals are used in conjunction with an ancillary support system; this is clarified by the flush plan description described on the seal arrangement drawing. It is important for the safe function of the seal that the support system is assembled and incorporated into the equipment before operation. This Instruction Manual should be read in conjunction with the appropriate documentation for auxiliary systems and rotating equipment.

Alarm systems are often included in the ancillary support system and the operator must ensure appropriate action is taken promptly in the event of an alarm.

Maintenance with steel tools must be avoided in the presence of substances classed as explosive group IIc according to EN50014.

If the equipment is being used in an ATEX zone 21 or 22 regular cleaning of dust from exterior surfaces is required.

It is dangerous to smoke while handling products made from PTFE.

Compounds containing PTFE, fluorocarbons and perfluoroelastomers should never be burnt as the fumes and residues are highly toxic. If this accidentally occurs protective equipment should be worn as hydrofluoric acid may be present.

Follow the local relevant guidelines for the safe and environmentally friendly disposal of assembly lubricants, supplied fluids and scrapped components.

(105)

Instruction Manual

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Edition 5

2.3 Environmental Aspects

2.3.1 Company policy extract “It is the policy of John Crane to manage its business activities in an environmentally responsible manner, comply with all relevant laws and regulations, prevent pollution, and continually improve its environmental performance, certification to the latest issue of ISO 14001 ensures compliance.” John Crane adopts the ‘Design For the Environment’ (DFE) principle in making this product. Using this product will benefit the environment directly by:

Reducing waste of precious resources through decreasing the risk of leakage & minimising energy consumption

Preventing pollution through controlling harmful emissions to the atmosphere

Preserving valuable materials resources through the re-use of these high quality durable seals due to their ability to be refurbished.

2.3.2 Recycling

Product refurbishment This product has been designed for potential reuse. Depending on its post operation condition, the seal may be repaired or rebuilt for further use. All metal components may be reused. The Primary & Mating Rings may be relapped and reused. Drive screws and springs are replaced. O-Rings must be replaced. Please consult John Crane for assessment of seal condition and its potential re-conditioning. Only qualified John Crane Engineers at recognised John Crane Customer Support Units should carry out re-conditioning & repair of this product

Disposal When the product is considered to be beyond economical repair and potential reuse, it should be disposed of by environmentally beneficial means. The product can be disassembled with ease.

Scrapped components These should be handled with extra care due to possible contamination. They should be recycled through local industrial recycling plants. Special materials Follow the local relevant guidelines for the environmentally friendly disposal of assembly lubricants, supplied fluids and scrapped components. Compounds containing PTFE, fluorocarbons and perfluoroelastomers should never be burned as the fumes and residues are highly toxic. Please refer to Safety Instructions- Section 2.2.

Packaging All packaging materials used are made from recyclable, environmentally friendly materials.

When in doubt or for further information and advice on this subject, please consult John Crane.

(106)

Instruction Manual

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Edition 5

3 Transportation and Storage Transport and store the seal in its original packaging.

To ensure seals remain in good condition they should be stored in the following environment:

• dry and dust-free

• ventilated at room temperature

• protected from direct effects of heat and ultraviolet light

• elastomers require replacement after 24 months except fluoro- and perfluoro-elastomers that require replacement after 60 months

• for further information on elastomer storage refer to ISO 2230

If used seal parts are to be transported to the manufacturer or a third party they have to be cleaned, decontaminated and require safe handling instructions externally attached.

For additional information on transportation and storage refer to John Crane document I-Storage-E.

The sealing system does not require any preservatives, it is resistant against all normal environmental conditions.

If any machine, with an installed seal, has been stored with preservatives before putting it back into operation then seal must be removed, cleaned and dried. Particular attention must be applied to the cleanliness of the faces and condition of the elastomers.

Ensure preservatives and cleaning agents do not affect the elastomers. Once the seal is fitted on the equipment and the position is set using setting devices do

not re-engage them for transportation and storage.

4 Description of the Mechanical Seal

4.1 Construction All mechanical seals are composed of the same basic elements (also refer to the installation drawing in Section 9).

Fig. 1: Typical Pusher Mechanical Seal Primary seal components

a) primary ring b) mating ring

Secondary seal component

c) dynamic seal d) static seal

Spring component

e) multiple spring

Drive and retaining components f) retainer

ATTENTION Fig. 2: Typical Metal Bellows Mechanical Seal Primary seal components

ATTENTION a) primary ring b) mating ring

Secondary seal component

c) static seal

d) static seal

Spring component

e) metals bellows

Drive and retaining components f)compression collar

(107)

Instruction Manual

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Edition 5

4.2 Function The hydraulic pressure and the spring force press the rotating and axially flexible primary ring against the stationary mating ring. Wear at the primary seal is minimised by a very thin lubricating film. Lubrication is provided by the sealed fluid; in the case of gas, the mechanism is usually enhanced by spiral grooves. The leakage is minimised by flat lapping to a fine surface finish.

Without the intended lubrication the seal face temperatures will

PaIw

4•

•

•

•

•

•

•

•

1,5 mm

1 mmRadius

20°

Fig. 3

5.2 Installation Tolerances The performance and reliability of the sealing

increase and may provide an ignition source in a potentially explosive atmosphere.

roper operation of the equipment and dherence to the recommendations in this nstruction Manual and associated manuals ill prevent this occuring.

.3 Operating Conditions Refer to data recorded on drawing in

Section 9.

If no data available refer to John Crane’s published Data Sheet specific to the seal type used, or consult John Crane direct.

Maximum static seal chamber pressure is equal to the maximum dynamic pressure rating – see published data sheet.

Maximum Surface Temperature, zones 1, 2, 21 and 22. (ATEX, 94/9/EC only) = 85 °C

5 Installation and Removal

5.1 Preparation for Fitting Check whether the seal is complete, clean

and undamaged.

Clean all machinery abutments, sealing and fitting surfaces (use only absorbent and fluff-free polishing cloth for cleaning).

Remove any protective coatings.

Check all relevant machinery dimensions, and that correct chamfers (see fig. 3) exist on all leading edges. Refer to drawing in annex.

system is influenced by the installation tolerances. Ensure that the tolerances do not exceed the required limits.

5.2.1 Shape and Positional Tolerances

Component Type Tolerance

Shaft to Housing Squareness 0.08 mm*

Shaft to Housing Concentricity 0.13 mm

static ± 0.25 mm**Shaft End Float Axial _______________________________

dynamic ± 0.04 mm

Shaft or Sleeve Ovality 0.05 mm

Housing to Shaft Runout 0.05 mm* API requires <0.5 µm/mm of chamber bore, FIM. **Figure stated on general arrangement drawing (Section 9) should take precedence

5.2.2 Surface Finish

Seal Type Value

dynamic O-ring 0.3/0.8 µm Ra (ground or polished)

static O-ring <1.6 µm Ra (turned)

elastomer bellows 0.8/1.2 µm Ra (turned)

PTFE bellows 0.8/1.2 µm Ra (turned)

dynamic and static wedge

0.1/0.25 µm Ra (polished)

(108)

Instruction Manual

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5.3 Installation Carefully protect the lapped sealing surfaces of primary

and mating rings during fitting. Minor damages to sensitive surfaces, such as scratches and chips, reduce the sealing effectiveness of the mechanical seal.

ATTENTION

ATTENTION

Carry out fitting according to the installation drawing (section 9) and with the following procedure: • Maintain cleanliness during fitting.

• Lubricate shaft with a suitable fluid in the installation area.

• Lubricate the shaft and housing sealing components with a suitable fluid (see Section 5.3.2), also ensuring they maintain their correct position during fitting.

EP-elastomer O-rings and bellows are not resistant to mineral oil or grease.

Silicone-elastomer O-rings are not resistant to silicone oil or grease.

When the sleeve is fixed to the shaft by shrink disc, the area under the clamp must be kept free of lubricant.

The seal faces should not be lubricated with oil or grease as this may prevent introduction of the sealed fluid in operation, leading to overheating and failures.

• Ensure the seal arrangement is orientated correctly, according to the housing, pipework, and shaft connections (e.g. studs, keyways, pins and drive holes).

On double-ended pumps ensure the drive-end and non-drive-end seals are appropriately selected

• Slide the seal assembly over the shaft and into position.

If a flexible graphite seal is used as the shaft/sleeve seal remove this before sliding the seal assembly into position. Follow-up by inserting the flexible graphite sealsand the follower.

• Tighten bolts, nuts and fasteners evenly to the torque levels indicated in the installation drawing. If not indicated refer to Section 5.3.1. Torque levels for gland plate studs or bolts must conform to those given in the relevant rotating equipment manual.

ATTENTION

For high temperature metal bellows seals eg, 1604, 2609,

3609 etc the pump shaft must be dimpled to ensure adaquate drive. Bolt the seal assembly to the pump back plate and finish assemble the pump so that the shaft is in its final position relative to the casing. In the case of hot pumps where thermal growth is known to be a problem, allowance can be made by offsetting the shaft by the required amount. Remove the collar set screws and using a drill of clearance size, drill through to mark the centre of each screw. The shank of the drill should be protected by masking tape to avoid damaging the threads. Remove the seal assembly and using a drill 2mm larger, dimple the shaft to the full diameter. Carefully remove all burrs to avoid damaging the seal sleeve.

ATTENTION

ATTENTION

ATTENTION

ATTENTION If setting devices are used, they must be removed after the seal is fixed securely in place in its final position. They can then be disengaged and fixed or appropriately stored.

ATTENTION

On double ended pumps the drive collar set-screws or sleeve drive component must be tightened after the bearing brackets have been fitted. When the seal is radially located from the shaft (no gland spigot) the gland nuts must also be tightened after the bearing brackets have been fitted.

ATTENTION

• If possible check for freedom of movement by hand turning the shaft.

Check on all pipework, hoses and fittings: ATTENTION • Correct location, alignment and support

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Instruction Manual

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Edition 5

• Correct connections. Refer to installation drawing (see Section 9) and relevant rotating equipment manual.

• Correct specification

• All unused connections must be plugged with the as supplied metal pipe plugs. Check whether drain connection should be open or piped to a collection area.

• All pipework on liquid barrier/buffer systems and cooling circuits are orientated to ensure effective venting.

• Lack of damage and leaks

5.3.1 Tightening Torques

Tightening Torques [Nm] (u 0.125 lubricated)

Socket Socket Socket Thread Size Setscrew Setscrew Setscrew

Size Code (ASTM A453-Gr

(316) (High Tensile Steel (14.9)

660 C) Part Code Part Code Part Code Size/305/712 Size/305/001 Size/305/050

M4 77** 1.5 2.3 M5 78** 3 4.5 M6 79** 4 7.5 M8 80** 11 18 M10 81** 30 16 36 M12 82** 50 40 60 M14 83** M16 84** M20 86** 1/4 - 20 35** 6 4.5 8.8 5/16 - 18 36** 10 17.5 3/8 - 16 37** 13.5 30 7/16 - 14 38** 32 48 1/2 - 13 39** 45 69

Thread Size Steel Screw Steel Screw Size Code (Class 12.9) (316 A4-70)

Part Code Part Code Size/301/050 Size/310/001

M4 77** 4.5 2 M5 78** 9.4 4 M6 79** 16 6,5 M8 80** 38 16 M10 81** 77 32 M12 82** 135 55 M14 83** 215 90 M16 84** 340 140 M20 86** 663 275

5.3.2 Lubricants The following lubricants are recommended by John Crane

Lubricant Note elastomeric O-rings except silicon rubber

Silicone grease, (Chloride Free) potable water or glycerine

Apply very thinly by hand

O-rings of silicone rubber

PTFE paste Apply very thinly by hand

Bolts, screws, nuts and fasteners

Molybdenum or nickel based anti-seize compound

Apply with brush or by hand

Elastomer bellows on shaft

Potable water or glycerine

Apply with sprayer

5.4 Seal Removal Removal is essentially the reverse procedure to installation.

Work on the seal must only be carried out when the machine is stationary, and secured against any unforeseen start-up.

Before the seal is removed the seal chamber or machinery must be depressurised and drained.

If the equipment has been used on toxic or hazardous fluids, ensure all precautions are taken to avoid personnel hazards, such as correct

decontamination. Note, fluid is often trapped during draining and may exist outside the seal. The relevant rotating equipment manual should be consulted to check for any special precautions.

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ATTENTION

ATTENTION

6 Commissioning and Decommissioning

Note before start-up: • ensure transit plugs are removed and

seal drain connections are correctly piped or open.

• ensure valves controlling circulation, flush and quench are correctly positioned.

If a heat exchanger is included in the support system and isolating valves are used in the coolant supply, a pressure relief valve should be incorporated between the isolating valves.

• ensure the seal chamber and/or barrier, buffer and cooling circuits are fully vented. (Not necessary on 2800 range of seals).

With liquid lubricated seals avoid dry running under any circumstances, as it will damage the seal. (Not relevant to 2800 range of seals and dry containment seals).

For hot duties (above 150°C) ensure pump has been brought up to operating temperature prior to start-up. Rapid axial differential thermal growth between shaft and pump casing could result in seal malfunction.

• If the seal is unidirectional, check the correct rotation direction.

Check the correct setting and operation of electrical warning systems associated with seal operation.

Before start-up, ensure that all personnel and assembly equipment have been moved to a safe distance, that guards are fitted and there is no contact with rotating parts.

To meet ATEX equipment specification it is important to ensure seal flush rates, temperatures, and cooling water flow rates are to specification.

In case of pressurised double seals note:

• The sealant system must be pressurised before priming the machine.

• For wet seals refer to the system drawing for barrier pressure settings. If not given the minimum barrier pressure must

be 1 bar plus 10 % above the maximum process seal chamber pressure. The maximum barrier pressure should be within the published seal operational limits.

• For gas seals the barrier pressure must be (2 bar for 2800ER, 3 bar for 2800BD and 5 bar for 2800HP) above the maximum process seal chamber pressure, unless other values have been given.

• Use a suitable and clean medium as the barrier fluid. This must have an auto ignition temperature above the maximum operating temperature of the pump.

• When using thermosyphon systems, ensure that the circuit minimises flow restrictions and can be effectively vented. Contact John Crane for more information.

ATTENTION

When the machine is stopped, the seal system pressure should be maintained until the machine itself is unpressurised.

Notes on decommissioning see Removal, Section 5.4.

ATTENTION

If a water test has been applied when flexible graphite seat/mating ring seals are used, they must be replaced or thoroughly dried before use on a hydrocarbon service.

(111)

Instruction Manual

Type

Page: 11 of: 11

Edition 5

7 Maintenance/Repair

7.1 Maintenance Carry out the following procedures for trouble free operation: Check daily:

• that the connections are leak free • seal leakage • barrier gas flow for 2800 range of

seals • Condition of alarm signals

in addition for double seals • barrier/buffer liquid level • barrier/buffer liquid temperature • barrier/buffer pressure

in addition for dry containment seals

• For dry contacting containment seals (S48SC, 48SC, SBOP & ECS) a monthly check with a 1.0 bar gas test is recommended.

• buffer gas flow when applied, check monthly

• Wear parts for dry contacting containment seals require replacement after 24000 hrs dynamic operation.

If buffer or barrier liquid systems need replenishment this should only be done with fill systems that exclude air ingress and/or prevent gas leakage to the atmosphere.

7.2 Reconditioning The mechanical seal will always require reconditions after operation. In order to maximise reliability, and minimise safety risks, it is strongly recommended that used seals are returned to John Crane for rebuilding to as-new specification (essential for 2800 range of seals). Alternatively ask for John Crane service personnel to visit site.

It is the responsibility of the equipment user to ensure that any parts being sent to a third party have appropriate safe handling instructions or decontamination

certification externally attached to the package. Without this information there may be a refusal to handle the goods. Rebuilding seals to as-new specifications must be carried out by qualified personnel.

Note: It is recommended that a low pressure integrity test is carried out after repair and before installation on the equipment.

7.3 Spare Parts Only John Crane spare parts should be used to recondition seals.

It is advised to stock on site a spare seal cartridge or the minimum replacement parts shown on the installation drawing (Section 9). The order codes for spare parts can be found in the parts list on the installation drawing. (Section 9). In the case of the 2800 range of seals only complete cartridges should be stored.

The following data is necessary for spare part orders: seal assembly code part description component code quantity.

8 Malfunction, Causes and Correction

John Crane must be consulted in the event of any malfunction of the sealing installation or sealing system. Excessive leakage rate, premature failure, high relative temperatures are all considered examples of abnormal malfunction.

9 Accompanying Documents Drawing K/02408

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PETRO VIETNAM GPPMB



abcd POWER SYSTEMS

1

SECTION 3. GEAR COUPLING Contents 1.0 Structure --------------------------------------------------------------------------------------- 2

2.0 Installation ------------------------------------------------------------------------------------- 3

3.0 Lubrication ------------------------------------------------------------------------------------- 5

4.0 Maintenance ----------------------------------------------------------------------------------- 6

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PETRO VIETNAM GPPMB



abcd POWER SYSTEMS

2

1. STRUCTURE

NR Gear coupling consists of the internal spur gears in its sleeves and the external spur gears with crowned teeth on its hubs, both of which are in mesh when assembled.

NARA GEAR COUPLINGS

G SERIES 1. Sleeve A 2. Sleeve B 3. Two hubs 4. Reamer bolts sets 5. Lubrication plugs 6. Side 0-Rings 7. Center 0-Ring

CROWNED HUB TEETH (Pitch diameter on a curve type)

Since these spur gears are so designed as to employ an involute tooth profile and to have a specialform on the top and bottom lands of their teeth, taking account of the tilting and lubrication, and equal speed rotation and smooth power transmission can be obtained even when a little tiltingsoccur between the sleeves and the hubs .

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PETRO VIETNAM GPPMB



abcd POWER SYSTEMS

3

2. INSTALLATION

2.1 ASSEMBLING

1) Ensure all parts are clean.

2) Apply a light coat of grease to the 0-Rings and insert 0-Rings into grooves of sleeves.

3) Place sleeves over shaft ends. Care should be taken not to damage 0-Rings.

4) Install hub on their respective shafts with the longest hub end towards shaft end or towards machine bearing depending on the type. Hub faces have to be flush with shaft end.

5) Install units to be connected in place and check the spacing between hubs. See below tabulation for correct hub spacing. (Table. 1)

6) Align the two shafts, check alignment using a dial gauge. (Fig.1) (Table.2)

7) Coat hub and sleeve gearings with grease and slide sleeves over hubs.

8) Insert reamer bolts into bolt holes of sleeve and sleeve or, sleeve and flange.

9) Remove both lube plugs of one sleeve and add grease in sufficient amount to overflow with lubricant holes in horizontal position. Re-install the 2 plugs.

10) In case of doubt, please consult us.

2.2 DISASSEMBLING AND INSPECTION

1) Remove bolts.

2) Slide sleeves off hubs.

3) Control gearing and sealing.

4) Control alignment.

5) In case of doubt, please consult us.

2.3 CENTERING

1) SPACING BETWEEN HUBS AND ALLOWABLE ERROR

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PETRO VIETNAM GPPMB



abcd POWER SYSTEMS

4

TABLE 1.

2) ALIGNMENT

FIG.1

SIZE 125 140 160 180 200 224 250 280 315 355 400

GAP 8 8 10 10 10 12 12 14 14 16 16

∆d -0.5 ~ 2.5

-0.5 ~ 2.5

-0.5 ~ 3.0

-0.5~ 3.0

-0.5~ 3.0

-0.5~ 4.0

-0.5~ 4.0

-0.5~ 4.5

-0.5 ~ 5.5

-0.5 ~ 5.5

-0.5~ 6.5

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PETRO VIETNAM GPPMB



abcd POWER SYSTEMS

5

TABLE. 2

3. LUBRICATION

3.1 GREASE FEEDING

When assembling, pack the coupling sleeve and the coupling hub with the recommended grease until their become invisible, and after tightening the reamer bolts, add the grease through the oil plug hole using a grease gun, etc. (Fig.2)

FIG. 2

HOW TO APPLY GREASE

ALIGNMENT ALIGNMENT SIZE

OFF-SET ANGULAR SIZE

OFF-SET ANGULAR

125 BELOW 0.03 BELOW 0.06 250 BELOW 0.07 BELOW 0.14





224 BELOW 0.06 BELOW 0.12

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PETRO VIETNAM GPPMB



abcd POWER SYSTEMS

6

3.2 RECOMMENDED LUBRICANTS AND QUANTITY

1) Recommended lubricants

TABLE. 3

2) Lubricant quantity list

TABLE.4

4. MAINTENANCE After about 3 months of the initial operation, feed fresh oil or grease to the coupling after thoroughlyremoving the old oil or old grease and abrasion particles from the inside of the coupling by means of disassembly, and thereafter add or change the oil or grease using the plug hole every 6 months (every 4000 hours).

Makers Grease

Esso Pen-o-led EP 35

Shell Alvania EP grease 1

Caltex Multifak EP 1

Mobil Sovarex L O

Grease(gf) Size

Upper Lower

250 390 265

280 500 345

315 750 500

355 900 600

400 1350 900

Grease(gf) Size

Upper Lower

125 50 35

140 70 50

160 90 65

180 130 90

200 180 120

224 270 180

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PETRO VIETNAM GPPMB



abcd POWER SYSTEMS

7

1) Remove both plugs of one sleeve.

2) Position lube holes at horizontal and by means of a grease gun, force grease into grease flows one hole until clean out of the opposite hole.

3) Re-install the plugs.

(119)


ESB International

Owner

PETRO VIETNAM GPPMB

PECC2

EPC Contractor


Issued by


Subcontractor

abcd


Project



ALSTOM Document Code NHT/01/M/-------B20/DS/001

Revision History


A 25.04.2007 D.E.YANG J.W.SHIN Y.H.KIM First issue

B 10.05.2007 D.E.YANG J.W.SHIN Y.H.KIM 2nd issue

C 10.04.2008 D.E.YANG J.W.SHIN K.R.KIM Title page updated


DATA SHEET FOR CONDENSATE EXTRACTION PUMPS © ALSTOM 2007. All rights reserved.

(120)

Enclosure D1 Rev.B

. Originator ALSTOM Power Turbo-Systems

Identification number NHT/01/M/-------B20/ES/001

Rev. B

Date 10.05.2007

Lang.en

Sheet 1/3

© ALSTOM 2007. All rights reserved.

EQUIPMENT DESIGN DATA

1. GENERAL Plant : Nhon Trach 1 System / component : Condensate Extraction Pump Quantity x Duty : 3 x 50 % KKS No. :

Manufacturer : _Hyundai Heavy Industries Co., Ltd._________________ Type : _Vertical Can _________________

2. OPERATING DATA 2.1 Main Pump units rated normal normal normal normal normal normal runout Temperature °C 36.7 35.1 42.30 40.20 36.70 35.10 36.70 36.70 Vapour pressure

bara 0.06 0.06 0.08 0.07 0.06 0.06 0.06 0.06

Spec. gravity kg/m³ 994.37 994.94 992.21 993.05 994.37 994.94 994.87 994.37 Flow m³/h 334.87 298.51 280.59 247.25 309.54 271.37 324.02 402.00 Total head m 120 125.5 127.8 131.6 124 128.9 121.8 105.4 Speed rpm 1486 1486 1486 1486 1486 1486 1486 1486 Efficiency % 79 77.3 76 73.2 78 75 78.5 79 NPSH required *

m -0.5 -0.7 -0.7 -0.6 -0.7 -0.7 -0.5 0.4

*corresponding to erection level ( see Enclosure C2, section 2 )

2.4 Complete Unit

units rated max normal min flow Power required kW 138 145.2 127.8 81.6 Recommended driver power

kW 160 160 - -

2.5 Maximum / Minimum Data

Data units values ** remarks Max. flow * m³/h 402 contin. allowable Min. flow * m³/h 100 contin. allowable Shut-off head*** m 144.3 range f. constructional tolerance ±5% units sound pressure level

dBA 82 at 1 m distance

* for pumps with variable speed the max. and min. flow should be defined for any speed

(characteristic curve) ** all data at rated speed *** to be guaranteed

삭제됨: A

삭제됨: __________________

삭제됨: __________________

삭제됨: A

삭제됨: 19.01.2006

(121)

Enclosure D1 Rev.B



Rev. B

Date 10.05.2007

Lang.en

Sheet 2/3


3. CONSTRUCTION 3.2 Main Pump

Shaft position : [] vertical Nuber of stages : [] ___four______________________

Casing type : [ ] vertical split (ring section)

[] ___Diffuser___________________

Bearing type : [ ] ball [ ] roller [] sleeve & ball / roller [ ] sleeve & tilt segment [ ] _____________________________ Lubrication : [ ] grease [] oil / Thrust bearing [ ] circulating oil[] self pumped water / sleeve bearing

Thrust compensation : [ ] disc with mechanical/magnetic lifting device [] roller bearing [ ] drum & tilt segment Shaft seal : [ ] packing [ ] _____________________________ [] mechanical seal [ ] _____________________________ Rotation from motor to pump : [] clockwise [ ] counter clockwise Nozzle position suction : [ ] top [] side

discharge : [ ] top [] side 4. MATERIALS OF CONSTRUCTION 4.1 Main Pump

Casing : _____A48 CL.35B_______________ Stage casing : _____A48 CL.35B ______________ Shaft : _____A276 410H_________________ Shaft sleeve : _____A276 410H ________________ Impeller first stage : _____A743 CA15_________________ Impeller further stages : _____A48 CL.35B _________________ Casing ring : _____A743 CA40_________________ Diffuser (Bowl) : _____A48 CL.35B _______________ Balancing disc/drum : ________N/A_____________________ Gland (Mechanical seal) : _____A276 304____________________

5. DIMENSIONS

삭제됨: A

삭제됨: A

삭제됨: 19.01.2006

(122)

Enclosure D1 Rev.B



Rev. B

Date 10.05.2007

Lang.en

Sheet 3/3


5.1 Main Pump

Impeller diameter variations : minimum _255 / 330_____ (1st / Following) Design _265 / 342_____ maximum _275 / 355_____ Nozzle diameter/class suction : _DN 400_ / _CL. 150 discharge : _DN 250_ / _CL. 300

6. CUSTOMER DATA SHEETS

Enclosed Customer Data Sheets Part 4 Volume 1 Section 6.3

삭제됨: A

삭제됨: A

삭제됨: 19.01.2006

(123)

Enclosure D2 Rev.B



Rev. B

Date 06.03.2007

Lang. en

Sheet 1/2


ACCESSORIES DESIGN DATA 1. GENERAL

Plant : Nhon Trach 1 Accessories to : Condensate Extraction Pump KKS - No. :

Pump unit accessories : [] unit internal piping & valving [] electric motor [ ] standard coupling [] spacer coupling 2. UNIT INTERNAL PIPING AND VALVING Sealing water system : [] shaft sealing The entire unit internal sealing water piping and valving shall be provided with one common inlet connection. Venting system : [] suction nozzle [] pump head The entire unit internal venting piping and valving shall be provided with one common connection to the condenser vacuum system.

5. ELECTRIC MOTOR

Manufacturer : Hyundai Heavy Industries Co., Ltd. Type : squirrel cage induction Frame, size : _____315______________________ Position of shaft : [] vertical Rated motor power : ________160_______________ kW Frequency : _________50_______________ Hz Rated speed : ________1486_____________ rpm Rated voltage : _________400_______________V Service factor : _________1.1________________ - Efficiency at rated load : _________94________________ %

(100% load) Motor enclosure : [ ] IPW 24 [] IP 54 [] IP55 [ ] ___________________________ [ ] ODP [ ] WP I

삭제됨: A

삭제됨: A

삭제됨: 19.01.2006

(124)

Enclosure D2 Rev.B



Rev. A

Date 19.01.2006

Lang. en

Sheet 2/2


[] TEFC [ ] WP II [ ] ___________________________

Motor cooling : [] fan cooled [ ] water cooled Class of insulation : ___________F_____________________ Motor bearing : [] ball [] roller [ ] sleeve Lubrication : [] grease [ ] oil [ ] circulating oil Space heaters : [ ] no [] yes Rated voltage : __________230_______________ V

6. COUPLING

Intermediate Flexible Coupling

Manufacturer : _________Nara____________________ Type, size : ___Flexible gear, SVAM 224 (BE=200)_

삭제됨: A

(125)

PetrovietnamPECC2/ESBI

Nhon Trach 1 CCPP ProjectBidding Document

6-3. CONDENSER & OTHER ASSOCIATED PLANT continuedHogging Air Ejector (continued)

* MaterialsEjector bodyNozzle

* Characteristic curve Ref. No.

CONDENSATE EXTRACTION PUMPSPumps

* Description* Manufacturer Hyundai Heavy Industries Co., Ltd.* Place of Manufacturer South Korea* Number per unit 3* Type Vertical Can* Pumped fluid

Density kg/m3 994.41Temperature oC 36.6Viscosity cP -Vapour pressure bar a 0.06Performance requirements :

* Duty capacity m3/n 334.87* Suction head m -* Discharge head m -* Total head m 120* Efficiency % 79* NPSH required m -0.5 (at pump floor level)* NPSH available m 1.96 (at pump floor level)* Absorbed power kW 138

Pump description :* No of stages 4 (four)* Speed rpm syn. 1500* Type of pump bearings Thrust : Anti-friction

Radial : Carbon+NiMaterials of major parts :

* Casing A48 CL.35B* Bowl A48 CL.35B* Column A36+A53 GR.A* Impeller (1st / Following) A743 CA15 / A48 CL.35B* Shaft A276 410H* Shaft sleeves A276 410H

* Operating characteristic curve Ref. No. K320-CV2230

Signature:For and on behalf of:Date:

Part 4 - Volume 1 - Section 6Version 3 - July 2006 Page 1 of 2

(126)

PetrovietnamPECC2/ESBI

Nhon Trach 1 CCPP ProjectBidding Document

6-3. CONDENSER & OTHER ASSOCIATED PLANT continuedCONDENSATE EXTRACTION PUMPS continuedElectric motors

* Manufacturer H.H.I* Place of Manufacturer Korea* Type designation TEFC* Frame size 315* Enclosure classification (IP No.) IP55* Class of insulation F* Rated power kW 160* Speed rpm 1486

Direction of rotation facing driving end C.W* Voltage V 400* Efficiency at rated output (100% load) % 94* Power factor at rated output 0.89

Full load current A 276Max. starting current A 1794Min. starting voltage V 320Max. starting torque % FLT 80% / 210%

* Type of bearings Anti-FrictionBearing lubrication GreaseBearing size (dia τ length) mm -

Weight (per pump set)

Pump kg 2200Motor kg 1500Others kg 1680Total kg 5380

Signature:For and on behalf of:Date:

Part 4 - Volume 1 - Section 6Version 3 - July 2006 Page 2 of 2

(127)


ESB International

Owner

PETRO VIETNAM GPPMB

PECC2

EPC Contractor


Issued by


Subcontractor

abcd


Project



ALSTOM Document Code NHT/01/M/-------B20/MD/002

Revision History



B 10.05.2007 D.E.YANG J.W.SHIN Y.H.KIM 2nd issue

C 10.04.2008 D.E.YANG J.W.SHIN Y.H.KIM Title page updated


PERFORMANCE CURVE FOR CONDENSATE EXTRACTION PUMPS © ALSTOM 2007. All rights reserved.

(128)


ESB International

Owner

PETRO VIETNAM GPPMB

PECC2

EPC Contractor


Issued by


Subcontractor

abcd


Project



ALSTOM Document Code NHT/01/M/-------B20/DD/004

Revision History



B 28.06.2007 D.E.YANG J.W.SHIN K.R.KIM 2nd issue

C 14.09.2007 D.E.YANG J.W.SHIN K.R.KIM 3rd issue

D 10.04.2008 D.E.YANG J.W.SHIN K.R.KIM Title page updated Description latest Revision:

MECHANICAL SEAL DETAIL DRAWING & DATA FOR CONDENSATE EXTRACTION PUMPS © ALSTOM 2007. All rights reserved.

(135)


ESB International

Owner

PETRO VIETNAM GPPMB

PECC2

EPC Contractor


Issued by


Subcontractor

abcd


Project




Revision History




C 14.09.2007 D.E.YANG J.W.SHIN K.R.KIM 3rd issue

D 10.04.2008 D.E.YANG J.W.SHIN K.R.KIM Title page updated Description latest Revision:

COUPLING DETAIL DRAWING & DATA FOR CONDENSATE EXTRACTION PUMPS © ALSTOM 2007. All rights reserved.

(139)


ESB International

Owner PETRO VIETNAM

GPPMB

PECC2

EPC Contractor


Issued by


Subcontractor

abcd


Project



ALSTOM Document Code NHT/01/M/-------B20/LS/001

Revision History





SPARE AND WEAR PART LISTS FOR CONDENSATE EXTRACTION PUMPS

(142)

SPARE PART LIST (for start-up, commissioning and performance test)

KKS NO. 18LCB10AP001 18LCB20AP001 18LCB30AP001

EQUIP.NAME Main Condensate Pumps

Document Code : NHT/01/M/-------B20/LS/001 PROJECT NAME : Nhon Trach 1 CCPP, Vietnam REV. NO. : A SHEET NO. : 1 OF 5

Description QUANTITY (UNIT) PRICE (in USD CIF, Free site)SERIAL

NO. PARTS NAME

Material INSTALLED

PER ONE SETPROVIDED QUANTITY

MAKER'S NAME &

MODEL NO.

ADDRESS (CONTACT

POINT) UNIT PRICE

TOTAL PRICE

REMARKS (Erection item No.)

Φ4×1220ℓ EA EA 1 Rubber Ring

NBR 2 6

HHI 400x250VWDB4

ULSAN, KOREA (Hyundai Heavy

Industries Co., Ltd.) - -

M01B20V001


NBR 2 6

HHI 400x250VWDB4



M01B20V002


NBR 2 6

HHI 400x250VWDB4



M01B20V003


NBR 1 3

HHI 400x250VWDB4



M01B20V004


NBR 1 3

HHI 400x250VWDB4



M01B20V005

- EA EA 6 Gasket

Non-asbestos 3 9

HHI 400x250VWDB4


Industries Co., Ltd.) M01B20V006

(143)

SPARE PART LIST (for start-up, commissioning and performance test)

KKS NO. 18LCB10AP001 18LCB20AP001 18LCB30AP001




NO. PARTS NAME

Material INSTALLED


MAKER'S NAME &

MODEL NO.

ADDRESS (CONTACT

POINT) UNIT PRICE

TOTAL PRICE

REMARKS (Erection item No.)

P-345 EA EA 7 O-Ring

NBR 1 3

HHI 400x250VWDB4



M01B20V007

G-265 EA EA 8 O-Ring

NBR 1 3

HHI 400x250VWDB4



M01B20V008

(144)

RECOMMENDED SPARE PART LIST FOR 2 YEARS (OPTION)

ITEM NO. 18LCB10AP001 18LCB20AP001 18LCB30AP001



DRAWING NO QUANTITY (UNIT) PRICE (in USD CIF, Free site)SERIAL

NO. PARTS NAME

PARTS NO. INSTALLED


MAKER'S NAME &

MODEL NO.

ADDRESS (CONTACT

POINT) UNIT PRICE

TOTAL PRICE

REMARKS

NHT/01/M/-------B20/DD/001 SET SETS

1 Mechanical Seal 1893 1 1

HHI 400x250VWDB4



NHT/01/M/-------B20/DD/001 EA EA

2 Shaft Sleeve 1320A/B-1,2,3,4,

1320C 7 7

HHI 400x250VWDB4



NHT/01/M/-------B20/DD/001 EA EA

3 Sleeve Bearing 1540A/B-1,2,3,4,

1540C 7 7

HHI 400x250VWDB4



NHT/01/M/-------B20/DD/001 EA EA

4 Casing Ring 1230A/B/C 6 6

HHI 400x250VWDB4



NHT/01/M/-------B20/DD/001 EA EA

5 Thrust Bearing 1440 1 1

HHI 400x250VWDB4



(145)






NO. PARTS NAME

Material INSTALLED


MAKER'S NAME &

MODEL NO.

ADDRESS (CONTACT

POINT) UNIT PRICE

TOTAL PRICE

REMARKS


NBR 2 6

HHI 400x250VWDB4




NBR 2 6

HHI 400x250VWDB4




NBR 2 6

HHI 400x250VWDB4




NBR 1 3

HHI 400x250VWDB4




NBR 1 3

HHI 400x250VWDB4



- EA EA 11 Gasket

Non-asbestos 3 9

HHI 400x250VWDB4


Industries Co., Ltd.)

(146)






NO. PARTS NAME

Material INSTALLED


MAKER'S NAME &

MODEL NO.

ADDRESS (CONTACT

POINT) UNIT PRICE

TOTAL PRICE

REMARKS

P-345 EA EA 12 O-Ring

NBR 1 3

HHI 400x250VWDB4



G-265 EA EA 13 O-Ring

NBR 1 3

HHI 400x250VWDB4



(147)


ESB International

Owner

PETRO VIETNAM GPPMB

PECC2

EPC Contractor


Issued by


Subcontractor

abcd


Project



ALSTOM Document Code NHT/01/M/-------B20/LS/002

Revision History Rev. Revision Date Created by Checked by Approved by Description



SPECIAL TOOL LIST FOR CONDENSATE EXTRACTION PUMPS © ALSTOM 2007. All rights reserved.

(149)


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Owner

PETRO VIETNAM GPPMB

PECC2

EPC Contractor


Issued by


Subcontractor

abcd


Project



ALSTOM Document Code NHT/01/M/-------B20/LE/001



B 01.10.2008 D.E.YANG J.W.SHIN K.R.KIM 2ND issue

C 03.26.2008 D.E.YANG J.W.SHIN K.R.KIM 3RD issue


KKS NUMBER LIST FOR CONDENSATE EXTRACTION PUMPS © ALSTOM 2007. All rights reserved.

(151)

MAIN CONDENSATE PUMPS- KKS LABEL LIST -

REV: A

KKS-No. (Line 1) DESCRIPTION (Complete; notpart of the label)

DescriptionVietnamese

Line 2 (max. 20 char's incl. blanks)



DescriptionEnglish


DescriptionEnglish


18LCB10AP001 MAIN CONDENSATE PUMP MAIN CNDS PUMP #1 N/A18LCB10AM001 MOTOR FOR MAIN CEP MOTOR CNDS PUMP18LCB10CT001 THRUST BEARING TEMP.

TRANSMITTERTEMP. TRANSMITTER THRUST BEARING

18LCB10CL001 LEVEL INDICATOR FOR LUBEOIL BOX

LEVEL INDICATOR LUBE OIL BOX

18LCB10CP001 SUCTION PRESSURE GAUGE PRESSURE GAUGE PUMP SUCTION

18LCB10CP002 DISCHARGE PRESSUREGAUGE

PRESSURE GAUGE PUMP DISCHARGE

18LCB10AA001 GLOBE VAVE FOR BRGCOOLING INLET

GLOBE VALVE BRG COOLING INLET

18LCB10AA002 GLOBE VAVE FOR BRGCOOLING OUTLET

GLOBE VALVE BRG COOLING OUTLET

18LCB10AA004 CHECK VALVE FOR M/SEALINLET

CHECK VALVE M/SEAL INLET

18LCB10AA005 GAUGE ROOT VALVE FORSUCTION PG

ROOT VALVE SUCTION PRESSURE GAUGE

18LCB10AA006 GAUGE ROOT VALVE FORDISCHARGE PG

ROOT VALVE DISCHARGE PRESSURE GAUGE

18LCB10AA007 GLOBE VALVE FOR SUCTIONVENT LINE

GLOBE VALVE SUCTION VENT

18LCB10AA009 GLOBE VALVE FOR DRAINLINE

GLOBE VALVE DRAIN LINE

18LCB10CF001 SIGHT GLASS FOR M/SEALINLET

SIGHT GLASS M/SEAL INLET

18LCB10CF002 SIGHT GLASS FOR M/SEALOUTLET

SIGHT GLASS M/SEAL OUTLET

18LCB10CT008 THERMISTOR ("U" PHASE) N/A N/A18LCB10CT009 THERMISTOR ("V" PHASE) N/A N/A18LCB10CT010 THERMISTOR ("W" PHASE) N/A N/A18LCB10CT011 THERMISTOR ("U1" PHASE) N/A N/A18LCB10CT012 THERMISTOR ("V1" PHASE) N/A N/A18LCB10CT013 THERMISTOR ("W1" PHASE) N/A N/A18LCB10CT002 MOTOR BEARING TEMP.

TRANSMITTER(DE SIDE)TEMP. TRANSMITTER(DE)

MOTOR BEARING

18LCB10CT003 MOTOR BEARING TEMP.TRANSMITTER(NDE SIDE)

TEMP. TRANSMITTER(NDE)

MOTOR BEARING

18LCB10AU001 COUPLING COUPLING N/A






PAGE 1 OF 3 (152)


REV: A






DescriptionEnglish


DescriptionEnglish
























MOTOR BEARING



MOTOR BEARING















PAGE 2 OF 3 (153)


REV: A






DescriptionEnglish


DescriptionEnglish
















MOTOR BEARING



MOTOR BEARING


PAGE 3 OF 3 (154)


ESB International

Owner

PETRO VIETNAM GPPMB

PECC2

EPC Contractor


Issued by LILAMA CORPORATION – HYUNDAI ENGINEERING

Subcontractor


Project

NHON TRACH1 CCPP PROJECT


ALSTOM Document Code NHT/01/M/-------B20/MD/101


A 30.04.2007 I.J.KANG J.W.SOHN K.J.KANG First issue

B 08.06.2007 I.J.KANG J.W.SOHN K.J.KANG Second issue

C 09.08.2007 I.J.KANG J.W.SOHN K.J.KANG Third issue

D 04.03.2008 I.J.KANG J.W.SOHN K.J.KANG For Final


TECHNICAL SPECIFICATION FOR INDUCTION MOTOR © ALSTOM 2007. All rights reserved.

(202)

1. 2 sheets

2. 1 sheets

3. 1 sheet

4. 1 sheet

5. 1 sheet

6. 1 sheet

7. 2 sheets

8. 2 sheets

9. 4 sheets

10. 1 sheet

11. 2 sheets

12. 11 sheets

Heater Terminal Box Ass'y(NHT/01/M/-------B20/DD/105) ------------------------------

Main Terminal Box Ass'y (NHT/01/M/-------B20/DD/103) -------------------------------

General Assembly Drawing (NHT/01/M/-------B20/DD/102) -----------------------------

Acc'y Terminal Box Ass'y(NHT/01/M/-------B20/DD/104) --------------------------------

CONTENTS

Motor Data Sheet (NHT/01/M/-------B20/DS/101)-------------------------------------------

Outline Dimension Drawing(NHT/01/M/-------B20/DD/101) -----------------------------

Painting Procedure (NHT/01/M/-------B20/DD/108) ---------------------------------------

Speed Torque & Current Curve (NHT/01/M/-------B20/DD/106) -----------------------

Thermal Limit & Time Current Curve (NHT/01/M/-------B20/DD/107) ---------------

Motor Test Plan & Test Procedure(NHT/01/M/-------B20/MP/101----------------------

Wiring Diagram Drawing(NHT/01/M/-------B20/TC/101) --------------------------------

Instruments List(NHT/01/M/-------B20/LI/101) ---------------------------------------------

(203)


ESB International

Owner

PETRO VIETNAM GPPMB

PECC2

EPC Contractor



Subcontractor


Project



ALSTOM Document Code NHT/01/M/-------B20/DS/101





D 30.10.2007 I.J.KANG J.W.SOHN K.J.KANG Fourth issue

E 04.03.2008 I.J.KANG J.W.SOHN K.JKANG For Final


MOTOR DATA SHEET © ALSTOM 2007. All rights reserved.

(204)

kW - P

DESIGN NO :

Item No. Rev. No. [ ] Project No. Quantity

)D.O.L. Y-

VΦ A

F B H A

Less than meterLess than %

(Max.)

B

Kg.mKg.mKg.m

Load GD referred to motor shaft Direct V-Belt Single Double Motor GD

Main Steel Cast Iron dB(A) Terminal Aux. Yes No mm/sec.(rms) Box Location Refer to Outline Drawing 3 \ 2

Paint Application Area Classification Outline Dimension Drawing \ Motor Weight(Approx.) Applicable Standard B3

B5 HHI Stand. V1

ACCESSORIES1) Thermistor : 2EA/PHASE2) Bearing Temp. Detector(Pt 100Ω, Dual type) : 2EA/Motor3) Space Heater : 230V,164W,1PH Acc'y Terminal Box Ass'y

Wiring Diagram

SPARE PARTS

HHI W230-131-1 * In case of Inverter or V.V.V.F Motor:Performance data is based on sine wave tests. A4(210mm X 297mm)

%100

80

B5 V1

Starting6218C3/7219DB

40

NEMA Design100% Load

Indoor Outdoor

90

1.1 0.89

220.3

Speed at Rated Load RPM1486 Torque (D.O.L)

Rated83.9

%104.9

Rotor Type55 Squirrel Cage

Output Poles

HP 160 KWP4

400

% Power Factor(P.U)

94.0100% Load

Note: Others not mentioned in this specification shall be in accordance with HHI standard. Above technical data are only design values and shall be guaranteed with tolerance of applicable standard.

Grease(Alvania RL2)

(Viewed from Drive End)

Lubricant

Coupling Method Shaft Extension

External Thrust Not applicable

Not applicable

Frame No.

Maker Test Report

TEFCIC4A1A1

315HLB4 310-40V

(IP

1000

Type

3

Model No.or RFQ No.

GENERAL SPECIFICATION PERFORMANCE DATA Project Name 3Sets

2

50 Hz

Enclosure(Protection)

Frequency Phase

Cooling Method

Location Altitude

at 1.0 S.F

Humidity

Insulation Class Temp. Rise at full load (by resistance method)

210

1794.0

80

Bearing DE/NDE Type

%

Ambient Temp. Duty Service Factor Electric Design Construction

K.J.KANG

Date DSND CHKD

2007.06.08 I.J.KANG J.W.SOHN S.H.KO

CHKD APPD

of TEFC

REMARK

Munsell No. 7.5 BG 6/1.5 Starting Duty

SUBMITTAL DRAWING

Starting Method(*)

160

Efficiency(%)

Rated Voltage Rated Load Start'g-D.O.L

Current276.0

4DATA SHEET

Noise Level (dB(A)) Vibration(Velocity)

Break down

AC INDUCTION MOTOR

Continuous(S1)

Anti-frictionB3

20071150RMM062 ALSTOM

Cold timetimes Hot

Kg.m80 at 1m from motor(No-load)

3.8

Kg

General Ass'y

NHT/01/M/--------B20/TC/101

Main T-Box Ass'yNHT/01/M/--------B20/DD/102

NHT/01/M/--------B20/DD/104NHT/01/M/--------B20/DD/103

CONDENSATE PUMP

Inspection and Performance TestIEC

- Kg.m8.0

1500NHT/01/M/--------B20/DD/101

2

2

2

2

2

1

1

(205)


ESB International

Owner

PETRO VIETNAM GPPMB

PECC2

EPC Contractor



Power Island Contractor


Subcontractor







C 09.08.2007 I,J,KANG J.W.SOHN K.J.KANG Third issue

D 04.03.2008 I,J,KANG J.W.SOHN K.J.KANG For Final


SPEED- TORQUE & CURRENT CURVE © ALSTOM 2007. All rights reserved.

(211)

CURVE NO.

-

MOTOR TYPE : Kw P HZ

RATED TORQUE : kg.m RATED SPEED : RPM

GD² OF MOTOR : kg.m² VOLTAGE : V

GD² OF LOAD : kg.m² RATED CURRENT : A

A: SPEED-TORQUE CURVE AT RATED VOLTAGEB: SPEED-CURRENT CURVE AT RATED VOLTAGEC: SPEED-TORQUE CURVE AT 80 % RATED VOLTAGED: SPEED-CURRENT CURVE AT 80 % RATED VOLTAGEE: SPEED-TORQUE CURVE AT 75 % RATED VOLTAGEF: SPEED-CURRENT CURVE AT 75 % RATED VOLTAGEL: SPEED-TORQUE CURVE OF LOAD

REV. CONTENTS DATE DSN CHK APPD

0RM-W230-091-1 A4(210mm x 297mm)

7RMM062

HLB4 310-40V

276.0

104.9

400

1486

8

7

SPEED-TORQUE & CURRENTCURVE

STARTING WITH VALVE CLOSED

ORIGINAL ISSUE 2007-04-23 J.H.CHOI Y.S.KIM

STC

160 4 50

K.J.KANGORIGINAL ISSUE1 2007-06-09 J.H.CHOI Y.S.KIM K.J.KANG

REMARK.

NOTE

B

D

A

C

F

E

L

(212)


ESB International

Owner

PETRO VIETNAM GPPMB

PECC2

EPC Contractor



subcontractor


Project







C 09.08.2007 I.J.AKNG J.W.SOHN K.J.KANG Third issue



THERMAL LIMIT & TIME CURRENT CURVE. © ALSTOM 2007. All rights reserved.

(213)

CURVE NO.

-

MOTOR TYPE : Kw P HZ

RATED TORQUE : kg.m RATED SPEED : RPM

GD² OF MOTOR : kg.m² VOLTAGE : V

GD² OF LOAD : kg.m² RATED CURRENT : A

NOTE : A: THERMAL LIMIT CURVE AT HOT CONDITIONB: THERMAL LIMIT CURVE AT COLD CONDITIONC: TIME - CURRENT CURVE AT RATED VOLTAGED: TIME - CURRENT CURVE AT 80% RATED VOLTAGEE: TIME - CURRENT CURVE AT 75% RATED VOLTAGE

REMARK. REV. CONTENTS DATE DSN CHK APPD

0RM-W230-091-1 A4(210mm x 297mm)

7RMM062

310-40VHLB4

ORIGINAL ISSUE

276

104.9

8

7

400

1486

STARTING WITH VALVE CLOSED

THERMAL LIMIT & TIME CURRENTCURVE

2007-04-23 J.H.CHOI Y.S.KIM

TLC

160 4 50

K.J.KANG1 ORIGINAL ISSUE 2007-06-09 J.H.CHOI Y.S.KIM K.J.KANG

B

A

D

C

E

(214)

NO : 20071150

1 / 3

1. SCOPE This procedure defines the painting and rust prevention procedure at shop.

But non-ferrous metal will not be painted.

2. SURFACE PREPARATION All surfaces to be painted shall be cleaned of oil or grease or other similar

materials with solvent and then shall be brushed and blasted with air to remove

rust or scale.

Prior to above preparation, mill scale, rust scale, chips and other foreign

materials shall be removed in accordance with painting schedule.

3. PROCEDURE 3.1 Detail painting procedures refer to attached data sheet.

3.2 Painting conditions.

3.2.1 Temperature : Min. 10 deg. C (50 deg. F)

Max. 43 deg. C (109.4 deg. F)

3.2.2 Humidity : 40 ~ 80%

3.2.3 Drying : Natural drying

3.3 Related conditions

No paintings shall be applied outdoor when it is foggy, rainy or excessive

wind. If chemical contamination occurs in paint it should be removed by

by washing with water or solvent before painting.

4. APPLICATION DETAILS 4.1 Preparation of paintings

Paintings should be prepared for application according to the instructions.

Individual components of multi-component paintings must be stirred before

mixing. If the thinner is required, only designated thinner should be used

and thinning rate may be adjusted according to the job condition.

4.2 Application method

4.2.1 Airless spray may be most effective in obtaining specified thickness

at once.

4.2.2 Keep the spary gun at constant distance and perpendicular to the surfaces.

4.2.3 Brush or roller may be required to achieve the specified thickness.

PAINTING PROCEDURE FOR MOTOR

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NO : 20071150

2 / 3

4.3 Application work

4.3.1 Welding seams, corners and edges should always receive a stripe coat

before full coating in order to obtain adequate film built.

4.3.2 Bolt jointing surroundings and flange matching faces should be blanked

off or otherwise protected from painting unless otherwise accepted.

4.3.3 Special care should be taken to gain uniform thickness.

4.3.4 Each coat should be allowed enough to dry and interval between coats.

4.4 Cleaning of tools

The application tools and equipments should be cleaned with the thinner

immediately after use.

5. INSPECTION After painting, the surfaces shall be inspected visually for wrinkle, swelling

and other harmful defects.

If repair coating is required, applicable surfaces shall be arranged by sand

paper and re coated with the same paint.

6. STORAGE OF PAINT The storage area should be well ventilated and protected from sparks, flame,

direct exposure to sun or excessive heat, preferably located in isolated room.


(217)

NO : 20071150

3 / 3

7. PAINTING SYSTEM 7.1 Item : Motor

7.2 Painting schedule

KOREPOX ZINC RICH PRIMER

First or External and Maker : KOREA CHEMICAL CO., LTD

Prime coat. internal Manufacturer's designation : EZ175C

surface of motor (Two - Component)

Colour : Metallic gray 1184

Dry film thickness : 30 x 2 coat

Coating time : After preparation of surface.

Coating method : spary and/or brush

KOREPOCX MICACEOUS IRON OXID

Intermediate External surface Maker : KOREA CHEMICAL CO., LTD

coat. of motor Manufacturer's designation : EM877

Colour : Metallic gray 9210

Dry film thickness : 50 x 1 coats

Coating time : After preparation of surface.


POLYURETHANE

Finish coat. External surface Maker : KOREA CHEMICAL CO., LTD

of motor Manufacturer's designation : UT2578

Colour (Munsell No.) : 7.5BG 6/1.5

Dry film thickness :50 x 1 coats


Curing method : Self Curing

Total Dry film thickness Min. 160


(218)


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PETRO VIETNAM GPPMB

PECC2

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Project



ALSTOM Document Code NHT/01/M/-------B20/LI/101







LIST OF INSTRUMENTS © ALSTOM 2007. All rights reserved.

(220)

INSTRUMENT LISTPROJECT NAME : Vietnam / Nhon Trach 1 CCPP Project - Main Condensate Pump Document No. : NHT/01/M/-------B20/LI/101

1 18LCB10CT008 TH THERMISTOR FOR MOTOR WINDING TEMP. SENSOR ('u' Phase)

- 0-180 DryContact ≥130 N/A Lead Wire Type - PN2-13 HHI NHT/01/M/-------B20/FD/001 Embedded in the startor

winding 'U' Phase. B

2 18LCB10CT009 TH THERMISTOR FOR MOTOR WINDING TEMP. SENSOR ('v' Phase)


winding 'V' Phase. B

3 18LCB10CT010 TH THERMISTOR FOR MOTOR WINDING TEMP. SENSOR ('w' Phase)


winding 'W' Phase. B

4 18LCB10CT011 TH THERMISTOR FOR MOTOR WINDING TEMP. SENSOR ('u1' Phase)


winding 'U1' Phase. B

5 18LCB10CT012 TH THERMISTOR FOR MOTOR WINDING TEMP. SENSOR ('v1' Phase)


winding 'V1' Phase. B

6 18LCB10CT013 TH THERMISTOR FOR MOTOR WINDING TEMP. SENSOR ('w1' Phase)


winding 'W1' Phase. B

7 18LCB10CT002 TE Motor bearing Temperature sensor(Drive Side) - 0-200 Resistande (Ω) ≥100

≥105N/A

Pt100ohm -dual-3Wire

- 4m-040819 HHI NHT/01/M/-------B20/FD/001 B

8 18LCB10CT002 TIZA Motor bearing TemperatureTransmitter (Drive Side) - 0-200 4 ~20mA ≥100

≥105N/A - - T32.30.000 WIKA NHT/01/M/-------B20/FD/001 Without local indication B

9 18LCB10CT003 TE Motor bearing Temperature sensor(Non Drive Side) - 0-200 Resistande (Ω) ≥100

≥105N/A

Pt100ohm -dual-3Wire

- 4m-040819 HHI NHT/01/M/-------B20/FD/001 B

10 18LCB10CT003 TIZA Motor bearing TemperatureTransmitter (Non Drive Side) - 0-200 4 ~20mA ≥100

≥105N/A - - T32.30.000 WIKA NHT/01/M/-------B20/FD/001 Without local indication B

ELEMENTMATERIALSETTINGMEASURING

RANGESIGNALRANGE

PROCESSCONN. SIZE

ELEMENTTYPE REVMODEL NO. MAKER P & ID NO.

(ALSTOM Document Code) REMARKSERVICE FLUIDNO. KKSTAG NO.

INST.TYPE

1 OF 2 (221)


ESB International

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Project



ALSTOM Document Code NHT/01/M/-------B20/MP/101





E 04.03.2008 I.J.KANG J.W.SOHN K.J.KANG\ For Final


MOTOR TEST PLAN & TEST PROCEDURE © ALSTOM 2007. All rights reserved.

(222)

: REV. No. : 2

INSPECTION & TEST PROGRAM :

: PAGE : 1 OF 2

WORK DESCRIPTION : THREE PHASE INDUCTION MOTOR.

20071150RMM062 160KW 400V 4P 50Hz ------ 3 SETS

HYUNDAI HEAVY INDUSTRIES CO., LTDELECTRO ELECTRIC SYSTEMS DIVISIONROTATING MACHINERY DESIGN DEP'T (TEL.82-52-202-6619)

2 2007. 07. 03 J. H. CHOI Y. S. KIM K. J. KANG FOR APPROVAL



REV. NO. DATE PREPARED BY REVIEWED BY APPROVED BY DESCRIPTIONHHI A24-418(A)-1 A4 (297mmx210mm)

I.T.P No.

ALSTOM(SWITZERLAND) LTD.

VIETNAM/NHON TRACH,CEP

ITP-71150RMM062

PROJ. NAME

CUSTOMER

(223)

I. INSPECTION & TEST PROGRAM CUSTOMER ; ALSTOM(SWITZERLAND) LTD INSP. & TEST DESCRIPTION: PROJECT No.: 20071150 REV. NO. 2 CONTACT No.; THREE PHASE INDUCTION MOTOR I.T.P.No.: ITP-71150RMM062 PAGE 2 OF 2

DESCRIPTION OF APPLIED INSPECTED BYNO. CLASSIFICATION TEST & INSPECTION CODE

ALSTOMQ'TY LOCATION REMARK

1 FINAL INSPECTION 1.1 Visual & dimensional inspection APP.SPEC.,IEC60034 H W W T HHI/ULSAN 1.2 Measurement of winding resistance IEC 60034 H W W T KOREA 1.3 Locked rotor test IEC 60034, IEEE 112 H W W S 1.4 No-load test and direction of rotation IEC 60034 H W W T 1.5 Measurement of noise level IEC 60034 H W W S 1.6 Measurement of vibration IEC 60034 H W W T 1.7 Determination of characteristic IEC 60034, IEEE 112 H W W T 1.8 Temperature rise test IEC 60034, IEEE 112 H W W S 1.9 Measurement of insulation resistance IEC 60034 H W W T 1.10 High voltage test IEC 60034 H W W T 1.11 Overspeed test IEC 60034 H W W S 1.12 Shaft voltage measurement H W W T 1.13 Bearing temperature rise test APP.SPEC.,IEC60034

1.14 Other tests (RTD & SPACE HEATER) M.STD H W W T

INSPECTION CATEGORY : M.STD : MAKER STANDARD W : WITNESS POINTH : HOLD POINT R : REVIEWT : TOTAL INSPECTION S : SAMPLE INSPECTION (1SET PER EACH SAME TYPE)

HHI A24-418(B)-1 A4 (297mm×210mm)

HHI

W SIEEE 112

H W1

2

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1 OF 9

HHI Ⅱ. INSPECTION & TEST PROCEDURE WORK DESCRIPTION : THREE PHASE INDUCTION MOTOR PJT. No : 20071150

I.T.P No. : ITP-71150RMM062 REV. No. : 2 PAGE :

: VIETNAM/NHON TRACH,CEP

: ALSTOM(SWITZERLAND) LTD.

: THREE PHASE INDUCTION MOTOR

: 160KW 400V 4P 50Hz ------ 3 SETS

HYUNDAI HEAVY INDUSTRIES CO., LTDELECTRO ELECTRIC SYSTEMS DIVISIONROTATING MACHINERY DESIGN DEP'T (TEL.82-52-202-6619)

2 2007. 07. 03 J. H. CHOI Y.S.KIM K. J. KANG FOR APPROVAL



REV. DATE PREPARED BY REVIEWED BY APPROVED BY DESCRIPTIONHHI-A24-716(A)-0 A4(210mmx297mm)

3. WORK DESCRIPTION

2. CUSTOMER

1. PROJECT NAME

20071150RMM062

(225)

2 OF 9



1. Final Inspection

1.1 Visual & dimensional inspection

1.1.1 Method of inspection1) Outline dimensions of main parts and dimensions related to outside connectionshall be confirmed to be in conformity to the approved drawings.

2) The following items shall be confirmed to be in conformity to the relatedspecifications and the approved drawings.- Model, form & type, rating, class of insulation, name plate, painting, accessories, and quantities.

1.1.2 Judgment1) In accordance with approved spec. & drawings.

1.2 Measurement of winding resistance

1.2.1 Method of test1) The resistance of the stator winding shall be measured between terminals at anambient temperature.

2) The measurement shall be carried out by digital meter.

1.2.2 Judgment1) Maximum unbalance of resistance between phase and phase shall not exceed±1% of mean value.

HHI-A24-716(B)-0 A4(210mmx297mm)

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3 OF 9



1.3 Locked rotor test

1.3.1 Method of test

1) With the rotor locked at the appropriate position at an ambient temperature,primary current, supply voltage, and input power shall be measured by applyingapproximately the rated load current of the rated frequency, 1/2 the rated frequencyand 1/4 the rated frequency to the stator windings.

2) For special squirrel cage motors, locked rotor test shall also be carried out atthe rated frequency and approximately 200% of the rated primary current.

1.3.2 Judgment1) In accordance with judgment of determination of characteristics

1.4 No load test and direction of rotation


1) The no-load test of the motor shall be performed by measuring the primarycurrent, the input power and nominal speed by operating the motor at no-loadcondition with rated voltage and frequency at an ambient temperature.

2) During operation with no-load, the following items shall be confirmed.(a) Direction of rotation(b) Direction of cooling air flow(c) Noise and vibration

1.4.2 Judgment1) The difference between the no-load current in each line and mean value shallnot exceed 5% above or below of the mean value.

HHI-A24-716(B)-0 A4(210mmx297mm)

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4 OF 9



1.5 Measurement of noise level

1.5.1 Method of test1) With the motor driven at its rated speed at no-load and giving its rated voltage,noise level of the motor shall be measured with sound level meter.

2) It is desirable to select the place and method such that the sound reflection isas small as possible.

3) The measurement shall be made at 4 points 1[m] apart from both sides and bothshaft ends of motor respectively at the height of shaft center.

4) The noise level of the motor shall be obtained by the mean value of each points.

1.5.2 Judgment1) In accordance with approved spec.

1.6 Measurement of vibration

1.6.1 Method of test1) The motor shall be run at no load with rated frequency and rated voltage.2) The levels of vibration severity shall be measured on the bearing housings in thethree coordinate directions of horizontal, vertical and axial.

1.6.2 Judgment1) The vibration value shall not exceed the limit specified in the approved spec.2) If not specified in approved spec., the levels of vibration severity shall notexceed the following:

Application code : IEC 60034Maximum r.m.s. values of the vibration velocity

Nominal speed for the shaft height H (mm)Machines measured in a state of free suspension Rigid mounted

(rev/min) 56 ≤ H ≤ 132 132 ＜ H ≤ 225 H ＞ 225 H ＞ 400(mm/s) (mm/s) (mm/s) (mm/s)

≥ 600 ≤ 1800 1.8 1.8 2.8 2.8＞1800≤3600 1.8 2.8 4.5 2.8

HHI-A24-716(B)-0 A4(210mmx297mm)

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5 OF 9



1.7 Determination of characteristics

1.7.1 Method of determination of characteristics1) Determination of load characteristics shall be calculated based upon theequivalent circuit calculation method based on the result obtained from no-load, locked rotor test and winding resistance.

2) Below data shall be submitted for each load ; 25%,50%, 75%, 100% & 125%- Primary current - Power factor- Efficiency - Slip

3) Others- Locked rotor current - Locked rotor torque- Breakdown torque

1.7.2 Judgment1) Tolerances in (Table 2) are applied to the guaranteed values of characteristicsof induction motor.

2) In case where the minimum or maximum value is guaranteed in the specifications,no tolerances shall be applied.

3) Applicable code : IEC 60034-1

(Table 2)Performance Tolerance Remark1 Efficiency (η)

a) Conventional efficiency up to and including 150kW (-) 15% of (1 - η) above 150kW (-) 10% of (1 - η)

2 Power factor at rated output (cosφ) (-) 1/6 × (1 - cosφ) Min. : 0.02Max. : 0.07

3 Slip (%) (±) 20% × Guaranteed value4 Breakdown torque (-) 10% × Guaranteed value5 Locked rotor torque (%) (-) 15% × Guaranteed value6 Locked rotor current (%) (+) 20% × Guaranteed value

HHI-A24-716(B)-0 A4(210mmx297mm)

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6 OF 9



1.8 Temperature rise test

1.8.1 Method of test1) Reference ambient temperature ;In case temperature of air is taken as the reference ambient, it shall be measuredby means of thermometers or RTD, place at different points around and at a distanceof one or two meters from the motor and half as high as its height, and protectedso as to avoid effect of heat radiation and stray draughts.The mean of the measured values shall be taken.

2) Loading method ; Equivalent Loading MethodThe motor to be tested is operated at no-load from a main power source, and auxiliary power of different frequency is superposed.Generally, temperature rises are determined by adjusting the voltage and frequency of auxiliary power generator so that the primary current is nearly equal to the rated value.

3) Temperature rise of windings are determined by resistance method as followingformula. They give the mean temperature rises of windings.t ＝ (R2 / R1) (235 ＋ t1) － (235 ＋ t2)where, R2 ＝ resistance of windings hot, [ohm]

R1 ＝ resistance of windings cold, [ohm]t1 ＝ temperature of windings at the time when R1 is measured.t2 ＝ the ambient temperature at the time when R2 is measured.235 ＝ constant for copper

4) The measurement of temperatures after shutdown by the resistance methodrequires a quick shutdown of the motor at the end of the temperature test.If the initial resistance reading is obtained within the time interval indicated in thefollowing (Table 3), this reading is accepted as the temperature measurementand extrapolation to the instant of switching off power is unnecessary.

(Table 3)Rated output, PN [kW] Time interval after switching off power [s]

1.8.2 Judgment1) In accordance with approved spec.

HHI-A24-716(B)-0 A4(210mmx297mm)

3090120201 to 5000

50 or LESS51 to 200

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7 OF 9



1.9 Measurement of insulation resistance

1.9.1 Method of test1) The measurement shall be carried out before and after high voltage test.2) Insulation resistance shall be measured between windings and earth withD.C 2500(V) megger on high voltage windings and D.C 500(V) meggeron low voltage windings.

1.9.2 Judgment1) Shall be more than 100 Mega-ohm

1.10 High voltage test


1) The test voltage shall be applied, as specified in (Table 4), between the windingsunder test and the frame of the machine, with core and any windings or sections ofthe windings not under test and electrical circuits of auxiliary components connectedto the frame.

2) The test voltage shall be of power frequency and as near as possible to a sinewave form. However, for machines with a rated voltage 6kV or greater, whenpower frequency equipment is not available, then by agreement a d.c. test maybe carried out at a voltage 2.7 times the r.m.s value given in Table 4.

3) The test shall be started at a voltage not exceeding half of the full test voltage,and then the voltage shall be increased to the full value, steadily or in steps of notmore than 5% of the full value, the time allowed for the voltage increase from halfto full value being not less than 10 s. The full test voltage shall be maintained for1 minute.(Table 4)Item

23

HHI-A24-716(B)-0 A4(210mmx297mm)

Auxiliary components 1500V

1 Primary windings 1000V plus twice the rated voltagewith a minimum of 1500V.

Secondary windings 1000V plus twice the secondary voltage

Parts to be tested Test voltage (r.m.s)

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8 OF 9



1.10.2 Judgment1) All windings shall withstand without any injury.

1.11 Over speed test

1.11.1 Method of test1) The motor shall be run for 2 minutes at 120% of the maximum rated speed.

1.11.2 Judgment1) The motor shall withstand without any mechanical injury.

1.12 Shaft voltage test

1.12.1 Method of test1) The shaft voltage shall be measured between D.E shaft-end and N.D.E shaft-end while the motor is running under the no-load condition at the rated frequency and voltage.

1.12.2 Judgment1) Where bearing is not insulated to prevent flow of shaft currents, Shaft voltage shall not exceed 0.5 V(peak).2) Where bearing is insulated to prevent flow of shaft currents, the shaft voltage value is only reference ( Judgement is not applied ) (Applicable code : IEEE 112)

1.13 Bearing temperature rise test

1.13.1 Method of test1) Ambient temperature (1) In case temperature of air is taken as the reference ambient, it shall be measured by means of thermometers or RTD, place at different points around and at a distance of one or two meters from the motor and half as high as its height, and protected so as to avoid effect of heat radiation and stray draughts. The mean of the measured values shall be taken. (2) If coolant is in bearing cooling system, the ambient temperature is inlet coolant temperature.

HHI-A24-716(B)-0 A4(210mmx297mm)

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9 OF 9



2) Temperature rise of bearing are determined by means of RTD or thermometers as following formula.

t1 ＝ T1 - T2where T1 ＝ Temperature of bearing at the time T2 ＝ Ambient Temperature at the time

1.13.2 Judgment1) Shall not exceed 55 degree.

1.14 Other tests (RTD & SPACE HEATER)

1.14.1 Method of test1) Measurement of resistance2) Measurement of insulation resistance3) High voltage test

1.14.2 Judgment1) In accordance with approved spec.2) The value shall be more than 10 Mega-ohm3) Shall withstand without an damage.

HHI-A24-716(B)-0 A4(210mmx297mm)

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