INSTRUCTION MANUAL

FOR

VERTICAL A.C. MOTORS

MOTOR ENGINEERING DEPTT.

BHARAT HEAVY ELECTRICAL LIMITED

HEAVY ELECTRICAL EQUIPMENT PLANT
BHOPAL 462022
CONTENTS

Description Module No. Page No.

1. Preface 197-1 1

2. Three Phase Motors 197-2 2-16

3. General Instructions 197-3 17-20

4. Commissioning Instructions 197-4 21-22

5. Maintenance & Inspection Schedule 197-5 23-24

6. Preservation Measures V 197-6 25-26

7. Maintenance (.,f Winding,, , 197-7 27-28

8. Drying of Winding & Measuring the 197-8 29-33

Insulation Resistance .

9. Anti Condensation Heating 197-9 34-35 .

10. Fault Diagnosis Chart 197-10 136-37

11. Safety Precautions 197-11 38

12. Environmental Guide Lines 197-12 39

PREFACE

Careful maintenance and inspections permit, any defects to be detected and to

be detected and corrected at any early stage before they are able to develop into
serious damage. Maintenance and inspections thus help to preserve the worth of
the machine, to avoid expensive outages and to increase the reliability and
availability of the machine.

The following maintenance and inspection schedules cover the necessary steps
for inspecting the mechanical and electrical parts of-the machine. Reference is
also made to those chapters which provide information of a descriptive nature
and on any maintenance work that might become necessary.

Since the conditions under which the machine is required to operate may differ
considerably, the maintenance and inspection schedules can only recommend
the intervals at which at least one 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. It Is `therefore recommended
that the accessible parts of the machine be inspected visually after about 500
operating hours.

Moreover the inspection intervals given in the maintenance schedules

presuppose undisturbed operation. If disturbances and unusual operating
conditions occur (e.g. overload, short circuit, incorrect synchronizing, runaway of
the machine etc.) which overstress the machine, the respective inspection(s)
should be carried out immediately.

The supply systems should be kept under continual supervision while the
machine is operating. Regularly read the instruments provided for monitoring
temperatures, pressures, rates of flow, etc.

It is recommended, moreover, that the elements most important for the

satisfactory operation of the machine, e.g. the brush performance of slipring
machines, sealing elements, etc., be inspected visually at short intervals.
Deviations from normal conditions occurring over prolonged periods indicate a
reduction of the operating reliability of the plant. To avoid damage, the causes
should be determined and any defects remedied as soon as possible.

If no BHEL specialists are called in for this inspection work, it should only be
entrusted to skilled personnel which has experience in working on large electrical
machines.

We suggest that this personnel be instructed by a BHEL specialist during his

presence for erection, commissioning, or inspection.
Repairs going beyond an inspection or normal maintenance, as well as
subsequent modifications and the like, should only be performed by BHEL
specialist erectors.
Please consult your BHEL representative.

The safety and protective measures required by local regulations should be taken
when carrying out inspection and maintenance work.
THREE PHASE MOTORS

1.0 INTRODUCTION

This is a Vertical Squirrel Cage Induction motor for general purpose.

This is a general purpose machine meant to drive mechanisms such as pumps
etc. The motor is suitable for ' operation under normal atmospheric Conditions i.e.
not containing any corrosive or explosive gases, The motor is of robust
construction and is designed to operate under tropical ~tic conditions of ambient
coolent temperatures upto + 50C (unless specially designed for ambient coolent
temperature agreed with customer) and maximum relativity humidity of upto
%. However, the temperature of the surroundings should not be below 5C.
Rating of motor is valid for an attitude of
up to 1000 meters above mean sea level,The motor is suitable for direct on line
voltage starting. The starting of the motor from cold and hot states shall be strictly
as per the agreement between the customer and the supplier.

The motor is suitable for one particular direction of rotation only (as indicated
arrow plate fixed on the motor body).

The motor generally conforms to IS:325 other relevant Indian Standards. The
technical data of the motor is enclosed with the manual.

2.0 SALIENT CONSTRUCTIONAL FEATURES

2.1 STATOR

The stator consists of stator frame, which is a rigid welded construction of steel.
Silicon steel sheet are used to form stator core. Between the core packets,
ventilating stampings are placed to form radial canals through which cooling air
passes and carries away the heat. The stator core is held under pressure
between stator end plates.

The stator winding of the motors is provided with fU11CA!_ASTIC class "F"
insulation system employing vaccum pressure impregnation (VPI) technology.
2.2 ROTOR

The rotor consists of a rigid ample sized shaft made out of ultrasonically tested
steel forging. The shaft is either round having shrink fitted spider or ribbed,
depending upon the size and construction. Rotor core is made out of silicon steel
sheet laminations. The rotor core is shrunk fitted on ribbed shaft or through
intermediate spider. The rotor bars are firmly fitted in the slots of rotor core. The
bars are inductively brazed to copper short circuiting rings. `

2.3 UPPER BRACKET

The upper bracket is a steel fabricated construction. Thrust bearing, upper

guide bearing and oil cooler for thrust and guide bearings are housed in the
Upper bracket. It is so designed that deflection due to static load and hydraulic
thrust on pump runner is limited to a very small value. It also provides oil sump for
thrust bearing and upper guide bearing.

2.4 LOWER BRACKET

The lower bracket is also a steel fabricated construction. It accommodates the

lower guide bearing and oil cooler. The guide bearing is partially dipped in oil
sump.

2.5 THRUST BEARING

The thrust bearing is of segmental type. The bearing is self lubricated and is
immersed in oil bath.
The thrust bearing consists of thrust bush mounted on the shaft and fixed to it by
means of locking ring. Thrust bearing runner (with mirror surface finish) is fixed to
the thrust bush and properly insulated to the thrust bush and properly insulated to
prevent the flow of bearing currents. The thrust bearing rotates over babbitted
surface of the thrust bearing segments.

2.6 GUIDE BEARING

Guide bearing is of self adjustable, segmental pad type. The guide bearing
segments are insulated from rest of assembly to prevent the flow of bearing
currents. The segments are lined with high quality babbitt and immersed in oil.
One spiral type water cooled oil cooler for lower bearing is placed in the oil sump
of lower bracket.

2.7 VENTILATION.

2.7.1 SCREEN PROTECTED DRIP PROOF (SPDP) MOTOR

There are self ventilated motor two fans are mounted on the two sides of the
rotor spider. Air circulates in two parallel paths in open cycle system of cooling.
Air enters into the stator frame from the atmosphere from the windows provided
on two opposite sides. The air after cooling the winding and core goes out to the
atmosphere

through the windows provided on the other two sides of the stator frame.

2.7.2 CLOSED AIR-AIR COOLER (CACA) MOTORS

These motors are designed two distinct cycles of ventilation i.e. internal closed
cycle and external open cycle.
The air within the motor enclosure is made to circulate by the helps of radial fans
and the centrifugal action of rotor itself. Air enters into the stator frame from the
Windows provided on two opposite sides. The air after cool the winding and cores
enters back in to the Air Coolers provided on the two sides of the motor.

The external fan mounted on the top of the shaft sucks air from the atmosphere
through the opening provided in the fanes in casing. This air passes through the
tubes of the two Air Coolers, cooling
The hot internal circuit air and mixes again with the atmospheric air, thus forming
an open cycle.

3.0 TERMINAL BOXES

The electrical connections of the stator winding are made In the main terminal
box..

Extra auxiliary terminal boxes are fitted When necessary for connecting any
auxiliary equipment such as anticondensation heaters, temperature monitoring
devices etc.

The minimum degree of protection of the terminal box is IP 54 to IS 4691, IEC 34-
5.

The actual number, arrangement and type, of terminal boxes for particular
machines are given on the dimension drawing.

Details of the main and auxiliary circuits are given in the relevant circuit diagrams.
Technical details and other information of the main terminal boxes are given in
the relevant supplimantry instructions. The general information contained in such
instructions informations is also applicable to the auxiliary terminal boxes.

4.0 AUXILIARY EQUIPMENT

Depending on the type of construction and order specifications various items of

auxiliaries equipment may be fitted on the machine i.e. anticondensation heaters,
bearing and winding temperature monitoring devices etc.

5.0 CAUTION: BEFORE Commissioning

Remove the following which are put at the time of packing the motor.
(i) Locking plate fitted with the shaft end.

(ii) Rubber packing between Thrust bearing segments and runner in the upper
bracket if provided.

(iii) In the air gap between stator and rotor if provided.

(iv) Plugs in the openings of the oil and water pipe fine, use only
recommended quality of water.
(v) Between the Thrust Bush/Guide Bush and Guide bearing segment (if any).

(vi) Clean thoroughly the Upper Bracket and Lower Bracket oil sumps and all
the bearings components before filling the oil. Use only recommended grade of
oil to required level.

(vii) For lifting of the motor, use four lifting hooks provided on the stator frame.

DISASSEBLY AND ASSEBMBLY OF VERTICAL MOTOR

Disconnect the power and water supply lines. Decouple the machine from
driven equipment. Remove the fasteners fixing motor on stool and lift the motor.
Place it a reasonably leveled spare stool. Drain out oil, remove side covers/
louvers, dial type temperature indicators, sealing ring (bottom) and coupling.

Remove header air cooler, fan casing and fan external, as applicable.

Remove lower plate/oil cooler of oil sump (bottom), and lower guide
bearing segments. Removal of oil cooler and guide bearing segments will not be
necessary for the purpose of inspection of items other than fitted in lower
brackets.

Firmly place wooden sleepers under the shaft extension end to support the
rotor.

Remove checkers plate (top covers), oil coolers (upper), and upper guide
bearing segments.

Remove locking ring, used for fitting thrust bush on the shaft.

Remove locking plates fixing thurst bush on shaft. Remove

thurst bush using fixture (refer sketch) and remove the thrust bearing pad
assembly. Protect mirror surface of thrust runner from getting damage.
Remove upper bracket, oil draining pipe and baffle assembly.

Mount the lifting arrangement on shaft (top side) and lift the rotor.

Follow the above sequence in reverse order for assembly of the motor

Note: Disassembly and assembly of the motor should be carried out by the
experienced technician under the supervision of BHEL expert.
ERECTION

Embedments necessary for installation of vertical motor are not supplied with
motor as the motor is mounted on the erected stool which is a part of the driver
equipment (pump). Stool is installed on foundation by the supplier of driver
equipment. Horizontal level of stool flange over which motor will be fitted should
be maintenance within 0.5 MM /meter.

It is advisable to use non shrinking free flow high strength grout for grouting the
embedments of the driven equipment.

There should be proper contact (approximately 80% uniformly distributed)

between the motor and the stool flanges. If required, carry out blue matching for
the proper contact shims should not be used between the motor and stool
flanges.

Follow the recommendation of the coupling supplier for coupling mounting and
alignment. Care should be taken so that rotor is not jacked up while mounting
coupling. Radial and axial alignment should be maintain within 0.05 mm.
Paid Type thrust and guide bearings

INTRODUCTION:

Pad type thrust and guide bearings are used in large vertical motors. These
bearing are oil lubricated. A combination of these mounted in the upper bracket
and set of guide bearing pades/segments only is used in lower bracket. Thrust
bearing takes all the down ward load and guide pads/ segments keeps the rotor
in position in the air gap between rotor and stator. Radial load is taken by these
segments.

BEARING

Motors are being supplied with bearing clearances adjusted appropriately for
operating conditions. These should not be altered at site. Blueing and scraping is
also forbidden as it would have an adverse effect on the smooth running. Bearing
temperature should be checked at regular intervals. Recommened maximum
operating temperature of bearing is 80C. In case s udden temperature variation is
observed without any apparent cause, the machine should be stopped and
replace the oil.
Remove thrust bush for inspection of runner, thrust pads. Firm support of wooden
sleeper must be provided on the end face of shaft extension before removal of
bush. Any correction on bearing should be done by BHEL technicians or should
be carried out under the supervision of BHEL expert. Insulation is provided in
between the thrust bush and runner to prevent flow of bearing current. Thrust
bush
should be placed carefully on wooden sleepr rubber mat after removal and
surface finish of the running should be adequately protected. Bolts used for
mounting runner on thrust bush should not be tightened without any specific
reason Otherwise , perpendicularity of the rotor will get disturb resulting to higher
vibration. Particular attendtion be paid to made oil pockets in the pads when new
guide bearing pads/ segments are being used. Carry out blue matching of new
guide bearing segment with thrust bush. Thrust bearing is an imported unit and
slight height adjustment of rotor by raising or lowering its pads is not possible.

COUPLING

It is advisable to mount the coupling as per the recommendation of the coupling

supplier. Care should be taken so that rotor is not jacked up while mounting
coupling.
LUBRICATING OIL

Lubricating oil as per data plate should be fitted in the sumps, provided in the
upper and lower brackets, up to the level marked on oil Level indicators. Brackets
should be thoroughly cleaned first by kerosene and then by the same oil to be
used for lubrication. Two pipes are provided in both upper and lower brackets. Oil
should be poured through a pipe. When the ambient temperature is lower; the oil
must be pre heated to +15C to +30C before filling . Different grade of oils should
not be mixed.

Oil must be changed after the first 500 hours of operation and for subsequent
changes the condition .Won of oil should be checked after 500-600 Hrs. of
operation. In case the properties of the oil are found to have been detoriated, the
oil must be changed. In this regards. Oil supplier may be consulted if required.

Cooler

Cooler are provided in the upper and lower brackets. Lubricating-oil/bearings are
cooled by the cooling water circulating through the cooler tubes,
Use Strictly only the, recommended type of cooling water. Cooling water should
be as per the agreement between supplier and customer.

Approval must be sought from `the manufacturer for using water other than
recommended type. Don't use sea water for cooling purpose. Vlisually examine
the cooling tubes to assess the extent of scale formation. It will be possible to
estimate the required general degree of cleanness for the tubes. If considerable
amount of deposits are observed, then tubes should be flushed out with water jet
(Maximum pressure 3 bars). Water should be injected in opposite direction to the
normal flow of water. If it proves to be adequate, then clean the tubes from inside
with bristly brush or brush made of soft brass wires/nylon. In case scaling is found
to be very hard which cannot be cleaned by brushing, then chemical treatment
would be necessary. Chemical treatement should be under taken in the presence
of chemist.
Three Phase Motors IVC (Rolling Control Bearings)

NOTE:

The relevant catalogues and quotations are the only authoritative source of
infomation on the available type variant of the machines.

STANDARDS AND SPECIFICATIONS:

The machines comply with the requirements of DIN and 1 S Standards and VDE
0530. They can also be provided with the requirements of various , classification
societies and foreign standard and specifications.

Unless otherwise stated, the rated output values apply to continuous operation at
the frequency to 50 Hz, a cooling air temperature 40and site altitude of 1000M
above sea level.

The degree of protection of machines supplied given on the dimension drawing.

COOLING AND VENTILATION

SCREEN PROTECTED DRIP PROOF MOTORS (SPDP)

These are self ventilated motors. Two fans are mounted on the two sides of the
rotor spider. Rircirculates in two parallel paths in open cycle system of cooling. Air
enters into the stator frame Crom the atmosphere from the windows provided on
two opposites sides. The air after cooling the winding and core goes out to the
atmosphere 1hrough the windows provided on the other two sides of the stator
frame.

STATOR FRAME AND WINDING

The stator frame is of welded construction. The aminated stator core is placed
centrally in the frame and is secured to prevent rotation or displacement.

The stator winding of the high voltage machines s a duouble layer coil winding
with class-F MICALASTIC insulation. It is a special type of insulation employing
ground mica and synthetic resin impregnation.

ROTOR

The rotor core is shrink fitted on the ribbed shaft. The bars of the cage fit tightly in
the slots of the motor core and are brazed to forged short circuiting rings. The
rotors of the machines are dynamically balanced with a half key in the shaft
extension.

END SHIELDS

The end shields D.E. and N.D.E. sides are in the form of flat dises/fabricated
stuctures suitably designed to accept the appropriate bearing capsules for the
particular type of machine construction.

BEARINGS

Depending upon the load requirements, the bearings are either grease-lubricated
rolling contact bearings or oil lubricated pad type thrust and guide bearings.
Normally, where the motor bearing has to sustain its own rotor weight only grease
lubricated angular contact ball-bearing at top and grease lubricated deep groove
ball bearing at bottom are provided.

TERMINAL BOXES

The electrical connections of the stator winding are made in the main terminal
box.
Extra auxiliary terminal boxes are fitted when necessary for collecting auxiliary
equipment such as anti-condensation heaters, temperature monitoring devices,
etc.
The minimum degree of protection of the terminal boxes is 1 P54-to IEC 34-5.
AUXILIARY EQUIPMENTS

Depending upon the requirement, various auxiliary equipments may be fitted on

or in the machines, e.g. anticondensation hearters, bearing and winding,
monitoring devices, etc.
Rolling Contact Bearings

The electrical machine is fitted with rolingcontact bearings to which the following
supplements and modifications of the machine, operating instructions apply :

INSTALLATION

Mounting :

The locating bearings are deep-groove ball bearings for horizontally mounted
machines. These bearings may be paired with cylindrical roller bearings. When
paired, the outer ring of the deep groove ball bearings is not guided radially and is
prevented from rotating by compression springs.

The locations bearings for vertically mounted machines are angular-contact ball
bearings of type range 72 or 73.

The floating bearings are either deep-groove ball bearing or cylindrical roller
bearings. If the floating bearing is a deep-groove ball bearing, the axial play is
compensated by means of compression springs.

The combination of particular has been best selected to meet the direction and
magnitude of the load (type of construction, forces acting on the shaft) and
should.therefore not be changed. The permissible value of axial and redial forces
may be seen from the machine list or an enquiry submitted

Deep Groove Ball Bearings

Cylindrical Roller Bearings

Angular Contact Ball Bearings

The machines must be Operated only in the type of construction shown on the
rating plates because other types of construction may not only necessitate a
modification to the bearings combination but the adoption of other measures as
well. It is essential to submit an enquiry in such cases.
Lubrication :

The bearings should be relubricated (See "Maintenance") if the time between

delivery and commissioning of the machines exceed 4 years, assuming that they
have been stored under favorable condition (i.e. in a dry, dust and vibration-free
room) or two years if they have been stored under unfavorable condition Charge
the position by rotation of shaft from time to time to prevent damage to bearings.

MAINTENANCE

Regressing

Lubricating grease servo gen 3 of Indian oil Corporation or equivalent any lithium
based grease having a drop point not less 160C sho uld be used.

If special operating conditions necessitating different kind of grease were known

to prevail when the machines were ordered, the definition of the grease (type,
thickener and basic oil) can be seen from the rating plate.
Besides the definition of the grease, the regressing. interval and the necessary
amount are also given on the rating plate.

It is recommended that the greasing instructions be strictly followed. Mixing

greases with different thickners and basic oils impairs the quality and should
therefore be avoided. Only in special cases should exceptions be made to the
normal greasing data. The regressing intervals should be shortened, for instance,
if the machine$ are operated at coolant temperatures higher thah originally
allowed for, if crossive vapour occur or should extremely heavy contamination be
present.

Clean the grease nipple and force in the grease stipulated on the rating plate by
means of a grease gun. The shaft should be simultaneously rotated in order to
distribute the fresh grease uniformly in the bearing. After regreasing, the bearing
temperature rises by a few degrees but will drop to the normal value when the
grease has attained its normal service viscosity and the excess grease has been
expelled.

The old grease from previous regreasing operations accumulates in the space
inside the outer bearing caps. Remove it when overhauling the machines.

Dismantiling, assembling:

Support or relieve the rotor of load when

performing any work on the thrust and locating bearing in a vertical position.

It is recommended that new rolling contact bearings be fitted as follows :

Heat the ball bearings or he inner ring of the bearings in oil or air to a
temperature of approx. $0C and slip them into the shaft. heavy blows may
damage the bearings and must be avoided.
When fitting single angular-contact ball bearings, ensure that the broad shoulder

of the inner ring ( and the narrow shoulder of the outer ring ) face upwards in the
operating position, i.e. in the opposite direction to that of the axial thrust .

During assembly, care should be taken to see that the sealing rings are properly
fitted (fig. 4)

When fitting shaft sealing-rings (V-ring)The correct axial position of the V-ring is
attained when the bearing cap end face and the outer edge of the V-ring are
flush. It is recommended that an appropriate mounting disc be used for this
purpose.

New felt sealing rings must first be impregnated with 80C hot high-viscosity oil
(lubricating oil) DIN 51517-CI00) before fitting them in the bearing caps. They
should be dimensioned so that the shaft slides easily in them but it will enclosed
by them.
 Causes Faults Remedy
Bearings Over Bearings Bearings
head Screeches Knocks
Felt Sealing Fit rings into
rings pressing grooves or
on shaft replace them
Stain Applied Improvement
by coupling alignment of
machines
Excessive belt Reduce belt
tension tension
Bearing Clean or renew
Contaminated bearing,
inspect seals
Ambient Use special
Temp. Heigher high temp.
Than 40* C grease
Lubrication in - Lubricate to
Sufficient instructions
Bearing Canted Check
Mounting
Condiation
,install outer
ring with
lighter fit.
To Little Fit Bearings
bearing plate with large play
Bearing Renew
Corroded bearings
inspect seal
Scratches on Renew
raceways Bearings
Scorings
excessive
bearings plate

causes of faults and remedy

it is sometimes difficult to recognize damage to brings. If any doubt prevails, it is

recommended that the bearings be placed.

spare parts
when ordering spare parts from the manufacturer's works, state the type and
serial number of the machine.

When ordering spare bearings, indicate the bearing indentification code as well
as the symbol which follows it for the particular bearing type. Both these forms of
identification can be read off the fitted bearing or seen from the list in the case of
standard type machines.
GENERAL INSTRUCTION
Instruction Module No. ME:FES:197-3
Transport, storage :

The rotor of the machine is locked in position for transport by a shaft block to
prevent damage to the bearing. Do not remove this shaft block until the
transmission element is fitted.

Other measures may be necessary in special cases if the machine is to be

transported after the transmission element is fitted.

Machines of vertical type of construction should be transported in a vertical

position. In exceptional cases in which machines with angular-contact ball
bearings have to be transported horizontly, lock the rotor by a shaft block before
carefully moving the machine into a horizontal position. Machines with a round-
velded stator frame have pairs of holes in the longitudinal ribs into which shackles
can be screwed to lift and set down the machine in a horizontal position. When
setting down the machine, make sure that a safeguard is provided to prevent it
rolling away, also ensure that the machine is set down sqarely only on the flanges
of the stator frame, because the shell is not designed to take the full weight of the
machine.

if a machine is not put into service immediately after arrival, store it in a dry,
vibration-free room. Change the position by rotation of shaft from time to time to
avoid damage to bearings.

All care should be taken to safeguard against any damage to various type of
mounting, such is temperature indicators, oil gauges and terminal boxes etc.

INSTALLATION

Mounting

The lubrication measures for normal bearings

to be carried out before or during erection of the machine are contained in the
additional instructions "Rooling Contact Bearings" and "Sleeve Bearings"
respectively. Install the machine in such a manner that the cooling air has free
access and can escape unobstructed. Remove the shaft block, if provided.
Adhere to the instruction attached to the shaft extension and shown in the
terminal box. The rotor has been balanced dynamically with a half feather key
fitted in the shaft extension. For transport, the feather key in the shaft extension is
locked to prevent it from failing out. Operation of the machine without fitted
transmission element is not permissible.

Blue match the motor flange with stool. Align the machine carefully and
accurately balance the elements to be fitted on the shaft to ensure smooth
and vibration-free running. Transmission elements must be fitted and removed
only by means of the suitable tool.

If the shaft end of the machines faces vertically upwards, make sure that water is
prevented from entering the upper bearing. Attention is invited to the measures
necessary to prevent, contact with rotating parts (couplings, belt pulleys, etc.)

Connecting up

Examine the rating plate data to see that they agree with the power circuit to
which the machine is to be connected. Select the size of the supply cable as
required for the particular current rating. Connect the supply-cable conductors in
accordance with the diagram shown in the terminal box.,

The terminal markings specified in IS4728 for three-phase machines are definded
as follows, e. g. :

Identification No. of pole number (only for pole 1

changing motors; the low number is for the low
speed)

Phase designation V
U -, V -, W - Stator connection
K -, L -, M - Rotor connection)

Identification No. of winding starts 1

and ends of taps (if more than
one connection is provided per winding).

The rating plate of the machines running in only one direction of rotation shows
an arrow. Note the direction of rotation specified for the particular plant (non-
reversing lock, for instance). The direction of rotation can be reversed by
interchanging two supply-phase connection in the terminal box provided.The
bearings and ventilating fans are suitable.
Check to see before closing the terminal box that :
- the interior of the terminal box is clean and free of cable residue;
- all terminal screws or bolts are firmly tightened
- the minimum clearances in air are maintained (> 10 mm for 500 V, 14 mm
for 1 KV and > 60mm for 6KV; note any projecting wire ends);
- unused entry openings are closed off with the plugging elements firmly
screwed in;
- for `maintaining the degree of protection, all sealing surfaces of the
termi,nal box are in order. If sealing of.the joints is effected by metal-to-metal
joints only, these surfaces should be cleaned and thinly regreased.
Before starting and during operation, make sure that all relevant safety
regulations are complied with.
Insulation testing

Before commissioning and after long periods of storage or standstill the insulation
resistance, of the winding to the frame must be measured with DC voltage.

Operation

Covers which prevent accessibility to rotating and live parts- as well as those
required for proper air guidance and effective cooling must not be opened during
operation.

Maintenance

Safety measures

Before starting any work on the machine, make sure that it has been isolated
from the supply that a safeguard has been provided to prevent unintentional
starting.

Cleaning

Passages which transfer cooling air from the ambient atmosphere should be
cleaned with dry oil-free compressed air at regular intervals in accordance with
the degree of pollution Lubricating oil should be checked and replace at regular
intervals.

Dismantling, assembling

Before forcing off a part, it is recommenced that two of the upper fixing screws
be replace by longer ones or headless bolts which will support the, part after it
has been forced out of the cantering recess.

Machines of vertical type of construction may be dismantled in a horizontal

position. Refer to Transport storage" for the measures required to set down, lift
and transport them. Before In performing any work on the locating bearing with
the machine in a vertical position, first brace the rotor.

Spare parts

When ordering spare parts, please state the type and serial number of the
machine as show on the data plate.
Storage Instruction (HT AC MOTORS)

Introduction

New machines are being supplied by the manufacturer duly packed in a

sufficiently strong packing box; preventing any damage to machines during
transportation and storage at site. General instructions on storage are covered 'in
the 0 & M manual being supplied along with the machines.

Normally, storage period at site is 4 to 6 months prior to erection of the machines.

In some of the eases, machines are being unloaded just at
f the foot step of foundation where these will be erected and commissioned.

When erection and commissioning of the project is delayed beyond the normal
time of storage at site, then customers should ensure below listed guide lines,
so that machines could be protected from the harmful effects. Guidelines for
normal storage period are also covered.

Inspection :

Open the packing box from a small portion only as faras possible so that
inspection could be made possible of the consignment as per the
packing/shipping list. Care must be taken to prevent any damage to numbers and
handling symbols marked over the box. Machine/items are additionally covered
by a sufficiently covered by a sufficiently thick- polythene sheets which should not
cut more than requirement while carrying out inspection. After inspection,
dismantled portion of the packing box should suitably be covered with the
removed wooden planks/steel sheet.

Store :

Floor level of the store/storage area should be sufficiently above the ground level.
Normally 250 to 350 mm are considered to be a satisfactory. However, customer
should examine the intensity of rainfall flood of the area. If required, level may be
suitably increased or special care be taken to prevent the spreading of flood
water in the storage area.

Earthen floor should not be used for storage. It should be cemented and leveled,
to withstand the load of the machine. Storage area should be so selected which
could give maximum protection against ground dampness, dirt, verm in and
termites.

It is desirable that store should be a room with proper ventilation. In case of any
problem in construction of room for the storage purposes, then a shed must be
used. Shed should be sufficiently large in size so that rain could not reach up to
the packing.

Additionally packing boxes should be covered with tarpaulin. Tarpaulin should not
come in direct contact with the packing box. A clearance of about 30 to 50 mm
must be maintained between tarpaulin and packing box. For this purpose, a
wooden frame may be used. Packing boxes should be protected from direct sun
also. If required, curtains may be used for protection against direct sun rays.

The relative humidity of the air should not exceed 50% with opened packing box
and 80% with intact packing box and temperature should not fall below 10C.

Packing boxes should be so placed such that their numbers can be easily
readable. Related parts/Machines should be stored in,a sequence in which they
are to be erected. Stored goods should not be over loaded by stacking.

No chemicals, acids, alkalis or storage batteries should be stored along with the
machines

In case of anti friction bearing, a few balls/rollers may get rusted and pitted.
Therefore, rotor should be rotated a few revolution once in between six to nine
months. Experience has shown abnormal sound from the bearing of
machine, stored from longer duration than normal period and bearing were
required to be replaced during commissioning of machines.

Machines with antifriction bearing should not be stored on a vibrating floor if

vibration of the room/area can not be avoided, then sufficientely thick rubber cock
or felt should be placed beneath the boxes.

Storage area should have fancying There should not be any try pass from the
storage area. security must be provided and arrangement must be made to meet
any eventuality against fire.

In case machines are subjected to heavy rain/cyclon/flood then manufacturer

must be informed prior to taking up erection and commissioning of machines.
Commissioning Instructions

Instruction Module No:FES:197- 4

PREPARATIONS

The following instructions are a summary of the detailed information given in the
supplementary instructions.
The following cheeks and tests should be performed after initial installation and
subsequent inspections :

- Machine correctly aligned

- Drive elements correctly adjusted depending upon type (e.g. belt tension
with belt drive, tooth flank and crest clearance with gear drives, radial and axial
play with couplings, radial play, axial control and correct axial position with
couplings of sleeve-bearing machines with two self-aligning bearings).
- Minimum insulation resistance of the windings satisfactory (also check
after extended shutdowns).
- Specified direction of rotation
- Cooling air-flow not obstructed
- Rotor revolves freely without touching
- All fixing bolts, fastening devices and electrical connections tight
- Earthing and potential-equalizing connections satisfactory
- Bearings properly lubricated according to type and supplementary
instructions
- No bridging of any bearing insulation fitted .
- Any auxiliary devices fitted properly connected and serviceable (e.g.
temperature monitoring instruments in windings and bearings, anticondensation
Heaters, etc.)
- All protection measures against contact with moving or live parts properly
implemented
- Any separately driven fans are operational and connected for the specified
direction of rotation and do not affect the running smoothness of the generator
- Water cooler is connected, filled, vented and operational with any air,
water closed-circuit cooling system (also check after extended shutdowns)

START-UP

The following commissioning procedure is recommended following erection or

inspection :

- Move starter into "start" position.

- Close circuit-breaker and reopen following motor start (set motor in

motion). If motor does start, do not switch starter to higher step, but shutdown
motor. Establish and rectify cause of non-starting.
- Check for mechanical noise or vibration in the bearings and end shields
during coast down.
- If motor runs satisfactorily, startup motor again, ,switching start gradually
to highest step. Observe motor briefly

running at no-load. (Switch on any separate fan and water cooler for longer
observation).
With uneven running and strange noises, switch off motor and establish cause
during coast down. Shortly before standstill, reset and brush lifting shutting down
device to "start". If running improve immediately following switch off, the causes
are magnetic or electric. If running does not improve, the causes are mechanical,
e.g out-of-balance of motor coupling or coupled machine or unsatisfactory
alignment of machine set. When motor is running satisfactorily switch on any
cooling devices (separate fan, water cooler etc.) and load motor. Check running
smoothness and record readings of voltage, current, etc., if possible, also record
corresponding
value from prime mover.
- Monitor and record temperature v bearings windings, etc. until steady is
reached.

SHUTTING DOWN:

Open circuit-breaker, reset starter to start .Let motor cast down unbaked shortly b
standstill, reset brushes to start if manual brush lifting device available.

Switch off any separate fan and cooler immediately.

Switch on anti-condensation heaters if this is not done automatically as

recommended. Beware of possible danger of freezing with any water-cooled
system.
Maintenance and Inspection Schedule
Instructions Module no. ME :FES:19-5
Careful maintenance and inspection allow any faults detected and corrected at
any early stage before they are able to develop into serious image. Therefore
they help to preserve the value of the machine, prevent costly out ages and
increase its reliability and availability.

Since the conditions under which the machines are required to operate can vary
widely, it is only possible in maintenance and inspection schedules to recommend
maximum intervals between inspections for normal conditions experience. ice
gained at the actual place of installation must be used subsequently to adjust the
inspection intervals when necessary to take account of factors such as
contamination, frequency of startup, load, etc. It is recommended, therefore, that
the accessible part machine are inspected visually about 500 hrs. after
commissioning.

Further more, the inspection intervals given in the maintenance schedules

presuppose no operation disturbances. If any disturbances or unusual operating
conditions occure (e.g. ;overload short circuit, incorrect synchronizing machine ,
runaway, etc.) which cause electrical mechanical overstressing of the machine
appropriate inspections must be carried out immediately.

If BHEL engineers are not called upon to carry out the inspection work it should
only be entrusted to trained personel who have had adequate experience on
large electrical machines.

We suggested suggest that such personnel is instructed by a BHEL engineer

during his presence for installation commissioning or inspections. Repair work
which goes beyond normal maintenance or inspection procedures and any
subsequent modification, etc. should always be carried out by BHEL engineers.
Your local BHEL representative will be pleased to make the necessary
arrangements.

The relevant safety and protection measures demanded by local regulations must
be implemented when carrying out inspection and maintenance work.

FIRST INSPECTION

The first inspection should be made after approx.500 hours. It should then be
determined on the basis of the rate of fouling, whether the cooling air ducts will
require cleaning before the second inspection normally carried out after approx. 1
year.
The following checks should also be carried out -running smoothness of machine
satisfactory,
- rotor alignment within tolerances,
- no subsidence or cracks in the foundation,
- all fixing bolts of mechanical and electrical joints tight.
- insulation resistance of windings satisfactory (compare with previous
reading or the minimum values given in "General remarks and record)
- no bridging of any bearing insulation. - windings connection leads and
insulating parts in satisfactory condition and no discolouration.
Any excessive deviations or changes ascertained during the checks must be
corrected immediately. Damaged or used locking elements from released bolted
joints must be renewed.
Subsequent inspections:
Unless a shorter interval has occurred with the first inspection, the second
inspection should be carried out after approx. 1000 switching
operations or after approx. 1 year at least the Subsequent inspection intervals
should then we set depending upon contamination of the cooling air ducts and
the degree of brush wear.
Information on oil changes, regreasing etc is, given on the lubrication instruction
plate on the machine or in the supplimentary instruction for bearings.

The checks stated for the first inspection should be repeated during subsequent
inspection and all cooling air ducts should be cleaned with dry compressed air.

For normal inspection it is generally not necessary to dismantle the machines

Dismantling only becomes necessary when the bearings are renewed it should
than also be checked that slot A wedges in the stator and rotor cores are tight.
Preservation Measure for assembly but non Operative Machine (Without
Regular Maintenance )

Inspections Module No. ME: FES:197-6

Commissioning of a machine or restarting of a machine after a period of
shutdown can only take place after the preservation agents have been removed.
There are three stages in shutting down a machine.

SWITCHING OFF

switching off the machine as described in commissioning and shutting down" (not
applicable to machines that have not yet been ,in operation but are already
assembled.

PRESERVATION

Preservation for the duration of shutdown (also applies to machines not

commissioned for a long time after assembly).

STATOR, ROTOR

Prevent condensation from forming in the machine, i.e. keep relative air humidity
below 50% and, where necessary, make provision for heating and air circulation.

POSSIBLE MEASURES

Pack machine moisture proof in sealed polyethylene folium. Place desiccant and
humidity indicator inside cover (recommended value; 105 g/MZ folium surface
and month duration of application). Check desiccant and renew if necessary.

If the machine cannot be packed; fit the machine, under critical circumstances
(e.g. op" air, storage) with dehumidifies, and especially at low temperatures make
provision for heating and air circulation.

In less critical cases (e.g. storage in warehouses) switch on anticondensation

heating or blow a constant stream of warm air through the machine by means of
fan heaters.

Apply coat of anti-corrosion agent (e.g. Tectyl 506) to all bright surfaces outside
the bearings. If the rotor contains components (e.g. end bells) made of material
subject to stress corrosion cracking (if necessary check with manufacturer), these
must be protected by preventing stress corrosion cracking in end-winding covers.

BEARINGS

Drain oil from bearings. Open sleeve bearings. Coat the bearing parts and
journals of the shaft with anti-corrosion agent (e.g. Tectyl 506). Remove bearing
shells for this purpose (uncouple the machine if necessary and refit after coating.
Close bearings.

Follow the manufacturer's recommendations concerning preservation of rolling

contact bearings.

Rotors equipped with rolling contact bearings must be stayed radially or axially to
prevent the rotor from being damaged by vibration. Spare machines must be kept
in a place not exposed to vibration and change to position by rotation of shaft
from time to time to prevent bearing damage.

ATTACHMENTS

Apply a coat of anti-corrosion agent (e.g. Tectyl 506) to all bright surface e.g.
couplings.
Fill backstops with anti-corrosion oil (e.g. ShellEnsis 152).

Oil Supply and Cooler

Remove oil lines. If necessary, clean and coat inside with oil-soluble anti-
corrosion agent (e.g. Tectyl 472).

Carefully seal open pipe ends.

Clean cooler pipes and chambers. Fill clean cooler with mixture of water, anti-
freeze and anticorrosion agent.

The composition of the mixture should be suited to the local climatic conditions.
Keep a list of preservation measures that have been taken. The effectiveness of
these measures should be checked by qualified staff at regular intervals.
If any deterioration is noticed, remedy this immediately and remove any percag,
corrosion and other damage.

Reactivating

Restore the machine to its original condition before all above measures were take
and make. everything, ready for commissioning Before starting the machine,
carry out all pertinent operations described in "Commissioning and shutting
down".
Maintenance of Winding

Instructions Module no:ME:FES:197-7

NOTE

Before beginning any work on the machine isolate it from the supply; earth it and
ensure that it con not be switched again inadvertently lock the rotor against
unintentional turning.
first remove the parts of the enclosure necessary to gain access to the windings
for visual inspections and for necessary

cleaning the windings

with machines in which the stator can be adjusted, shift it in the correct direction
(see dimension drawing) with the aid of the tackle provided.

important :

when cleaning the windings care must be taken not to damage the insulation
through the use of unsuitable sharp edged tools or excesive stressing of winding
parts by applying too much be (blow or treading on the windings, etc.)
windings, air ducts, etc. which are thickly covered with loose dust should be
cleaned by blowing out the dust with dry compressed air ex. 4 bar) and or sucking
it out with a suitable vacuum cleaner. The compressed air and vacuum
equipment should have a plastic nozzle.

Layers of dirt sticking firmly to the winding should first be wiped down sith a dry
rag. This is particularly true for areas where oil has been deposited and those in
which brake dust has also accumulated. Should these measures not be
adequate, use clean rags soaked with perch loroethylene, white sprit or a
perchloroethylene and white spirit mixture. Wiring out the rags to ensure that only
dirt and not the varnish coating is removed during cleaning. Use a moistened rag
wound into a strip of wood or plastic where access is difficult.

Do not use brushes

It is important that all deposits be removed from the connecting points, the
cording, bracing, elements, ring-circuit conductors and outgoing leads.
Wipe down treated areas with dry rags until a fresh rag shows no trace of dirt.

Important

Coil-side and overhang corona shielding may be damaged by solvents. For this
reason do not use solvents in the space between the core and the curved part of
the conductor or coil.
When using solvents the regualtions governing safety'at work must be complied
with.

Mild alkaline cleaning agents (e.g. "Grisiron" made by Hoechst Co. Germany or
its equivalents) may be used in accordance with the maunfacturer's instructions
for machines which can be throughtly flushed out and dried after cleaning.

Checking the windings

Check the insulation of the windings and connections check spacers, cording, slot
wedges, bandings and struts for tightness. Cheek the winding coils and
connecting points, for breaks, unsatisfactory soldering, Inter-turn short circuits
and short-circuits to frame. In the unlikely event of any irregularities being found
when comparing parts of the windings, the nearest BHEL representative should
be informed immediately.
Cheek that all leads are properly connected, and that all fixing and terminal
screws are tight. Tighten if necessary, using only new locking elements.

Re-varnishing the windings :

If the coating of varnish on the windings is

damaged during cleaning or checking, these patches must be touched up with an
oil-resistant air drying insulation varnish. Such a varnis available from the BHEL
Hardwar under designation ISI : 805.

Note

It is most
important that the varnish used should be compatible with that used during
manufacture and that also exhibits good adhesive properties In doubtful cases
the local BHEL representative will be able to recommend a suitable type in
hazardous locations must have been approved by the competent agencies.
The varnish should be applied in even layer as thinly as possible, either by
spraying or brushing and afterwards allowed to dry thoroughly:

Measuring the insulation resistance.

When all maintenance work has been carried out, check the insulation resistance
with magneto generator. For detailed measuring instrucitons and minimum
permissible values see "Drying the windings and measuring 1 insulation
resistance ME: FES: 197-8.
Drying of winding and Measuring the insulation Resistance

Instructions Module No: ME:FES:197-8

General

BHEL MICALASTIC insulation is basically not affected by moisture. Terminal as

well as conductor bars, coils or connections fitted during the Installation that are
not insulated to the same
degree as the rest of the winding can, however, be endangered by moisture.
Shipping, storage, construction work or a long period of standstill can causes a
film of moisture to form inside the machine on the surface of the insulation which
must be dried before commissioning by one of the methods described here.
because a film of moisture on the insulation inside the machine cannot always be
visually ,detected, other detection methods such as insulation resistance and
polarization index must be used.

The insulation resistance should always be determined because information on

the condition of the winding can be derived from this. Record the measures
values and compare them with earlier values, if available.

During the drying process the surface moisture driven off by heating the windings.
If individual portions of the winding installed at site, for example after closing the
stator joints, these parts must be dried before varnishing preferably by hot, dry
air.

In the case of micafolium insulation, drying is always necessary after a long

standstill.

Where anticondensation heating is fitted, this should be switched on as early as

possible in order to prevent the ingress or condensation of moisture. The rotor,
winding is normally. heated sufficiently by the surrounding air when the stator is
heated by passing current through it. drying
the machine whilst running is preferable to drying at standstill.

Insulation resistance of HV windings

The insulation resistance provides information about the surface moisture

content, contamination and any damage to the windings. The measuring
procedure is detailed in "Measuring the Insulation Resistance of Electrical
Machines" 1075.
With HV windings the following values should be measured :
1. Insulation resistance of each phase to earthed frame and to the other
earthed phases.
2. Insulation resistance of all winding phases to earthed frame.
The insulation resistance tester should produce a voltage of 500 to 30000V,
preferably 1000V. The temperature of the, winding is measured by build-in
sensors (normally resistance thermometers).

Polarization Index

The insulation resistance is taken at 30s. 1 min and then at every minute up to
12min after the test voltage has been applied:
The length of the measurement period is determined by the absorption current
which is caused by the polarization of the dielectric. The dielectric polArization
index is also used as an indication of the condition of the winding insulation. It is
the ratio of two readings of the insulation resistance taken at specified time
intervals during the same measurement i.e. at the same temperature (Rsos=
insulation

Resistance reading 60 sec after the test voltage has been applied.

Comparative R60s R10mm Drying

Rating R30s R1mm
PI or N

PI or N=Polarization Index
Dangerous ----- <1 Yes
Poor <1.1 1 to 1.5 Yes
Questionable 1.1 to 1.25 1.5 to 2 Recommended
Satisfactory 1.25 to 1.4 2 to 3 no
.Good 1.4 to1.6 3 to 4 No
Very Good >1.6 >4 no

The polarization index should be determined before and after drying-in the event
that the winding requires drying-at the same temperature because to a certain
extent the index is temperature dependent.
Minimum value of the insulation resistance The insulation resistance of the
complete winding to earth should have a certain minimum value which is shown
in Fig. 1 as a function of the winding temperature. In order to eliminate the
dependence of the insulation resistance on

the size of the machine, the ordinate isformed

by the (constant) product of the winding capacitance and the insulation
resistanace
is known as the insulation time resistance contact J=R10 x C in M omega uf or
s.The insulation, resistance is the 10 min value which considered to be the final
measurement value.

If machines are subject to foreign standard the minimum values contained there
in must be observed.

In certain cases the formula R10 min KV +1 in M omega may also be used with
refer to IEEE recommendation ST 43-1974 for the minimum value of the
insulation resistance where R10 Min is the value at 40C and KV is the rated
machine voltage*)

The winding capacitance C (all three pt earth) may be determined from a loss
contact tangent test it carried out, by measure current input- at 220 V AC (50 Hz
or 6oHz) or by means of a capacitance measuring bridge

C= 1 R10 KV+1
U.w 2( 8 - 4)
10

Fig .1 Minimum Value of the insulation time consistent and example of drying process.

In practice it is sufficient with small and medium machines i.e.up to approx. 20

MVA, to use the minimum insulation value in accordance with the IFEE formula
given above. The measured value R1min (i.e. 1 minute value) is sufficient.
Evaluation according to Fig. 1.

To determine the insulation resistance at other temperatures, the rule of thumb

can be used, i.e. for 10K temperature rise the insulation resistance is halved and
for 10K temperature op it is doubled.

The exact conversion can be seen in Fig. 1 (see also drying Methods") Drying
can be stoped the minimum insulation resistance is reached.
If either of the measurement methods polarization index or insulation resistance
produced value that are too low, the winding should initially be visually examined
for moisture, contamination or damage. If deficiencies cannot

be detected or cannot be dealt with then the winding should be dried. Of course
drying is also necessary when in sprite of good polarization index and insulation
resistance values, moisture Is visible on the windings.

Low insulation resistance values of new or repaired windings can also be caused
by resin before it has completely cured In this case the final insulation resistance
value is only attained after an extended operating period (several. 100 hours). If
doubtful measurement results are obtained, it is important to determine the
cause. In any case, when low Insulation resistance values are obtained, carry out
through cleaning and also. if reauired. drying.

Insulation resistance of LV windings

For LV windings using MICALASTIC insulation basically the same applies as for
h.v. windings. a Here the insulation resistance can be in the K omega
range at higher temperatures; it is therefore advisable to carry out the
measurement with voltages less than 500 V, for example 100V. The
insulation resistance of the rotor windings is
measured relative to the earthed shaft.

Drying methods

For the purpose of drying windings, heat can be applied in three ways.
1. By producing heat losses in the machine itself, i.e. by operating the
machine on short circuit.
2. By feeding current from external energy sources to produce heat losses in
the windings e.g. with the aid of m.g. welding sets or controllable high current
rectifiers.
3. By applying heat after suitably covering with tarpaulins, wood cladding etc.
With all these methods some air circulation must naturally be provided to allow
the moisture to escape.
A steady state temperature of about 60C is desirab le drying process. However,
this value should be first achieved about four hours with Micalastic and about
eight hours with mica folium after starting the drying process. The magnitude of
the current in the winding or the quality of heat applied should be controlled so as
to fulfill this requirement i.e. starting with low values and regulated according to
the temperature rise.
With hydrogen-cooled machines, normal fresh air is used for drying due to the
exchage of air. For this reason the short-circuit current must be kept low due to
the increased temperature rise. Bushings and post-type insulators should be
cleaned with dry rags before drying.
During the drying process, only the insulation resistance of the whole winding to
earth is measured, i.e. the 10 min value, according to Fig.

1. The insulation resistance are converted to the reference temperature of

75C from curve B.
Example: Measured at 40C. R1040 33 MS2 R,075=0.1 25x33=4.1 MQ
Avoid temperature variations during the drying process..With fully encapsulated
machines provision should be made (by removing covers etc.) to permit the
moisture to escape and for clean, dry air to enter.
Measure the temperature using the built-in resistance thermometers (slot
thermometers) if possible. In addition, in the case of running machines measure
the inlet and outlet (cold and hot air) temperatures are not provided and, in any
case, with stationary machines. install alcohol thermometers on the winding
overhangs if possible. The most important measurement is the temperature at the
highest point. Mercury thermometers should not be used beacuse of the danger
of breakage and also beacuase if incorrect readings resulting from AC induced
eddy currents. Wind aluminium foil around the lower end of the thermometers to
improve the thermal contact and cover with felt of cotton wadding to reduce the
effects of cooling. Do not assume the temperature of the housing of machines is
also the temperature of the winding. The rise in temperature above the ambient
temperature of machines without resistance thermometers should be calulated
from the increase in the measured winding resistance.

Rule or thumb: For every 10 K temperature rise the resistance of copper rises by
4%. After completing the drying process the machine should be loaded as soon
as possible to prevent moisture from being re-absorbed. Where anticondensation
heating is provided, this should naturally be put back into service after drying.
The windings of generators should preferably
be dried with the machine running on short circuit to prevent hot spots being
formed by heat accumulation.

The three-phase short-circuit link should be designed so that the rated current of
the machine does not cause the link to be noticeably heated (typical value
1A/MM2). Connect the short-circuit link as close as possible to the generator
terminals. If circuit breakers or isolating breakers are in circuit between the
generator and the ; short-circuit link, measures must be taken to ensure that they
cannot be opened during the drying process. If this did occur, voltage would
immediately appear at the generator terminals. Voltage transformers or
capacitors in the region of the short-circuited winding should be disconnected
since they introduce errors into the insulation resistance measurement.
During the short-circuit drying of windings the following whoa A be observed.

Switch the voltage regulator changeover switch to "Maunal". With Transipol

excitation each phase of the secondary winding of the air-gap reactor is
individually short-circuited. Break the connection between the excitation
transformer higher-voltage winding and the air-gap reactors and feed the
secondary winding of the excitation transformer from an external system. Beware
danger of feed-back voltage.

In the first 6 to 8 hours (depending on the size of the machine) increase the stator
current from about 0.5/N to a value such that the winding temperature does not
exceed 60C. Set the cooling-water flow accordingly .

Do not exceed the rated current energize the over-current protection including the
de excitation equipment. If the short circuit is in the zone of the differential
protection, short-circuit the current circuit of the current transformers Record the
slot temperature, inlet and outlet temperatures and the generator current eve
hour.

Monitor the progress of the drying process by repeated measurement of the

insulation resistance-three phases to earthed frame-while observing the winding
temperature (see example Fig. 1)

1. For this measurement the winding must be isolated.

Drying with welding sets

If m.g: welding sets are to be used for drying machine windings certain
precautions must be taken before connecting them in parallel. Measure the open
circuit DC voltages to ensure that they are all equal. Connect the excitation
windings F, - FZof all the welding sets required to operate in parallel through an
additional switch. This allows all the field windings to be switched on or off
together depending on wheather the three-phase motors of the m.g. sets have
been started or stopped.

Because there is no ventilation, adjust the maximum permissible current per

winding phase to 50% of the rated current. Measure the current and voltage of
each m.g. set (observe permissible limits). Connect the individual phases of the
winding either in series or parallel. With series connection connect the individual
phases unsymmetrically je.g. plus to U1, U2 to V1, V2 to W1, W2 to minus) in
order to keep the axial magnetic fux in the shaft low. Where the neutral point is
not brought out, two phases must inevitably be paralleled and connected in series
to the third phase. Change the connection order about every hour so that the
winding is evenly heated. With the neutral point open, measure the insulation
resistance of each phase to earth hourly.

Before switching off a direct current the current should be gradually reduced
otherwise the winding inductance will cause heavy arcing. Since the temperature
distribution of a machine at standstill is different from that in the running condition,
a winding temperature of 60C must not be exceeded. If the rotor is in position,
turn it by 90 every hour.

If methods 1 and 2 cannot be applied, the machine must be dried with hot air
produced from an external heat source. This method of drying is usually adopted
for synchronous motors and DC motors where direct heating by means of current
losses is not possible or when an m.g. welding set cannot be used. The heaters
should be arranged so that by means of suitable winding being heated is in the
hot-air stream without concentrating the heat to the extent that excessive
temperatures are reached. This requires that a continuous circulation and
replacement of the airtakes place.

The air inlet temperature should not exceed 80C an d the outlet tempereature
should be at least 10k above the ambient air temperature. Do not allow the air
temperature within the machine to drop below the dew point i.e. there must be no
moisture condensation forming at the outlet.

Because of the risk of fire this method of drying requires constant monitoring to a
much larger extent than the other two methods. This method also requires that
the rotor should be turned by 90 about every hour.
Anti Condensation Heating
Instructions Module No. ME:FES:197-9
Description

Application

Anti condensation heaters fitted in electrical machine warm the air inside the
stationary machine above that of the surroundings, thus effectively preventing
moisture condensation.

1. Heater
2.Machine Frame

Fig. 1
Anti-condensation heating (example) for totally enclosed fan cooled three-phase
AC motor.

Installation

Depending on the size and type of the machine the anti-condensation heater
consists of two or more heating tubes connected together. They are combined to
form units which are normally built into the stator frame on the drive and non drive
ends.
Fig. 2
Anti-condensation heating (example) for enclosed self ventilated three phase AC
motors

The following types are generally available to suit the various machine designs :
- Heating tubes fiixed in the stator frame on welded on support bracket
(Fig.1) Immersion heater screwed into the stator
frame so as to be accessible from the outside (Fig. 2).

Heating tubes

The heating tubes have a, heating conductor which is embedded in insulating

material and arraged inside a corrosion-rsistant metal tube. The tube ends are
sealed to prevent the ingress of moisture.
The anti-condensation heating of machines of "increased safety" and
"pressurised enclosure" types of protection used in hazardous locations
corresponds to the "Special type of protection" to VIDE 0171. The heating tubes
or the heating tube units are equipped with special ends. The heating tubes of
one unit, are soldered to one another and rigidly jointed by means of soldering
bushes. The heating power is rated by the corresponding connection of the
heating tubes or heating tube units in such a manner that the permissible
temperature of the heater surface must not be exceeded corresponding to the
certified ignition temperature group.

Installation

Connecting

The heater connections are brought to terminals which are located in the main
terminal box of low-voltage machines or a separate terminal box in special cases
and in the case of high-voltage machines.
Connection must be made in accordance with the diagram shown in the terminal
box. Examine the rating plate or the text of the dimension drawing to see that the
voltage and the power of the heating agree with the mains 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.
In the case of machines used in hazardous ` locations according to VIDE 0171
the main' connection may be made without cable lugs. Adhere to VIDE 01 65.

Maintenance

Important

When the machine has come to a standstill the anti-condensation heating is

switched on. Therefore the heating must also be switched off

before the maintenance begins inside the machine.

Cleaning

The maintenance is limited to the cleaning ' corresponding to the normal

maintenance of the machine and to the replacement of damaged parts.

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.
In the case of machines-used in hazardous locations, the heating tube units
soldered to one another must be replaced in complete sets,and obtained in
preformed condition. If repair work and modifications to machine models covered
by the certificate are not made in the works of BHEL, an acceptance inspection
by an authorized engineer is necessary. If modifications not covered by the
certificate are made, the machine must be newly certified. Equipment intended for
use in explosive atmosphere is subject to the "Regulations for electrical systems
in locations subject to explosion hazards."
.
Spare Parts

When ordering spare heating tubes or spare heater units please state the type
and the serial number of the machine as shown on the rating plate. At the same
time it is recommended that an enquiry be made about the 'int6rconriection of the
heating tubes or heater units.
Fault diagnosis Chart
Instruction Module No.:ME:FES :197-10

General

The Chart lists general faults due to mechanical and electrical factors.
Bearing faults are dealt with in supplementary instructions for bearings.
Safety Precaution
Instruction Module No. ME: FES :197-11

1.0 When operating the motor, the following basic safety precautions must be
observed.
1.1 No work shall be carried on running motor.
1.2 In order to carry out any work on motor or driven unit, the motor must be
disconnected from the mains and fool proof protection be provided to avoid any
possibility of accidental switching on of the motor or of rotor revolving from the
driven end side.
1.3 Motor frame, main terminal box and sheath armour of the cable must be
reliably earthed.
1.4 Rotating parts such as driving end of the motor shaft or coupling must be
provided with a trustworthy guard to protect the servicing personnel or people
passing close by.
1.5 If the feeding cables are to be disconnected from the motor, the cables
ends must be short circuited.
1.6 When working on high voltage starting equipment, all safety rules
pertaining to high voltage installation should be observed.
2.0 When handling the motor or sub assemblies, it is necessary to take all the
safety precautions, a few of which are listed below.
2.1 All lifting equipment and attachments should be in good condition, tested
and properly selected.
2.2 Ascertain the weight of the load prior to lifting it and remove all loose items
lying on it.
2.3 When lifting the motor and other parts by the lifting bars, hooks of eye
bolts, these should be carefully examined.
2.4 Put paddings of soft materials at places where the slings touch the stator
frame.
2.5 All manipulation should be done carefully without jerks.
3.0 While handling the rotor, the followings must be strictly observed.
3.1 Do not let the ropes touch the journal surface of the shaft.
3.2 While lifting the motor do not apply force to the parts of the shaft between
the extreme ends upto the surfaces under, the bearings including journals.
3.3 Do not support the motor on rotor overhang and fans.
3.4 Do not support the motor on parts of the shaft between the extreme ends
upto the surfaces under the bearing including journals.
3.5 Any equipment connected/coupled on the NDF- side the motor, provided
with bearing insulation, must be thoroughly, insulated from machine/earth to
prevent flow of shaft current in the motor.
3.6 In no case shall any part of rotor touch the winding overhang during
insertion or removal of rotor from stator. It is desirable to cover the winding
overhangs on both the ends by thick presspahn or leartheroid or Elephantide
paper as a protection.

NOTE : The safety precautions mentioned in the modules, should also be

followed while attending to motor sub-assembly.
Environmental Guide Lines

Instructions Module No. : ME:FES:197-12

SAFE DISPOSAL OF AC & DC MACHINES ITEMS

(After expiry of useful life)

HEEP, BHEL Hardwar has adopted an Environmental Policy and pledged to fulfill
its responsibility of protecting and conserving the environment on account of its
product.

Items/materials of AC & DC machines, served their useful life are to be disposed

off in an environment friendly way to protect our resources and control,
environmental pollution. ("Guidelines furnished below lead to a long way in
planning activity for scrapping the above effectively in an echo-friend!,, manner.

AC & DC machines are basically manufactured by using the following :

01- Metals.
02- Non Metals
03- Lubricating oils.

These iteins should be disposed off/recycled/re-used as per current

environmental laws of the Country.

METALS (Structural Steel, Coper, Aluminium etc.) :

These may be sold as scrap metal for recycling and re-use

NON METALS (Insulating Materials (Mica, Glass, Nomex, Epoxy/

PolysterlSilicone based bonding materials), Rubber (Synthetic/ Natural)
Grease etc.) :

Big pieces & useable lengths of insulating materials may be salvaged for re-using
as insulation in smaller & lower voltage rating electrical equipment. Materials unfit
for economic salvaging, should be stored in an isolated space for further safe
disposal.

LUBRICATION OILS :

Oils should be recycled after cleaning and when become unserviceable, may be
disposed off to rerefiners for lower end use as low-grade lubricating oil.