Motors Rewinding Services [PDF]

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OUR VISION To be a world class and highly preferred electro-mechanical service partner in Asia



OUR MISSION We strive to provide the highest quality of services and exceed customer satisfaction. Focus on Quality and Delivery. Efficient Processes and Procedures. Continuous development of People and Facilities. Our customers are central to everything that we do.



CORE VALUES Competence Professionalism Teamwork Integrity Consistency



OUR OBJECTIVES To show Newton’s improvements along the years in terms of: Quality Delivery Customer service



Technical People



To share Newton’s expertise to our partners. To exchange ideas with our partners. To understand the NEEDS of our Partners.



GREAT THINGS START WITH SIMPLE BEGINNINGS…



1969 NEC



2001 NCR



2003 NISSC



2005 TCGS



NEECO



Newton Engineering Corporation was founded by Engr. Joseph Tan Lee and Engr. Reynaldo Rillo. Engaged in Electro-mechanical service with major works such as Rewinding, Reconditioning, Re-design and rebuilding of Electric Motors and Generators. Organized affiliate companies and changed company names such as Newton Consolidated Resources, Newton Industrial Sales and Service Corporation and Finally Newton Electrical Equipment Co., Inc.



New leadership under Engr. Anthony Lee and international affiliation with TurboCare Generator Services.



OUR SERVICES COMPLETE SERVICES FOR: Turbine and Hydro Generators Diesel Generators Large AC Motors Large DC Motors Excitation System Vibration Analysis Precision Balancing Power and Distribution Transformers



OUR SERVICES MECHANICAL SERVICES: Manufacturing of shafts Rebarring / Restacking Manufacturing of Commutator and Collector Rings State-of-the-art Laser Alignment



OUR SERVICES SPECIALIZED TESTING FOR: 40KV Surge Testing Power Factor and Dissipation Test Computerized Wedge Tightness Test EL-CID (Electro Magnetic Core Imperfection Detection Test) CORONA Activity Analysis (Corona Camera) Thermography ( Thermal Imaging Camera) Bore Scope Examination Transformer Oil Vacuum Purification



SPECIALIZED TESTING SERVICES



40kV Surge Testing Checks the winding for phase symmetry and turn to turn insulation integrity



Power Factor & Dissipation Test Non-destructive AC test to detect insulation contamination



SPECIALIZED TESTING SERVICES



Computerized Wedge Tightness Test Wedge testing to check for looseness



EL-CID (Electro Magnetic Core Inspection Detection Test) Measures current between laminations, high current indicates shorted lamination.



SPECIALIZED TESTING SERVICES



Corona Activity Analysis (Corona Camera) A special camera used to check for corona activity in the stator.



Thermography (Thermal Imaging Camera) Camera used to detect hotspots



NEWTON’S ORGANIZATION CUSTOMER



CUSTOMER SERVICE (Sales & Mktg.)



OPERATIONS Field Service Engineering Support Service Rewinding Mechanical



BUSINESS SUPPORT Quality Assurance HRAD Purchasing Warehouse Logistics Accounting



NEWTON’S AFFILIATES AND MEMBERSHIP



SOME ACCOMPLISHED PROJECTS



CBK Power Co. Ltd. Rewinding of Main Stator 150MW, Hydro Generator



Luzon Hydro Rewinding of Main Stator 44MVA Generator



SOME ACCOMPLISHED PROJECTS



Toledo Power Company Rewinding of Turbine Generator Rotor



COVANTA (Quezon Power Phils.) Rewinding of Stator 2-units, 7,600HP, 3,600RPM, 13,200 Volts, SCIM



SOME ACCOMPLISHED PROJECTS



CBK Power Co. Ltd. Reconditioning of Motors 10,000HP, Pony Motor



SOME ACCOMPLISHED PROJECTS Name of Power Plant: Carmen Diesel (Subsidiary of Toledo Power Company) Nature of Work: Rewinding of Main Stator Capacity: 1-unit, 12MW, 600RPM, 13,800RPM, Diesel Generator *************** Name of Power Plant: Energy Development Corporation Nature of Work: Rewinding of Stator Capacity: 2-units, 4,500kW, 13,800 Volts, 1,800RPM, Steam Driven Generator **************** Name of Power Plant: Masinloc Power Partners Co., Ltd. (Formerly National Power Corp.) Nature of Work: Rewinding of Stator Capacity: 1-unit, 4,850kW, 1,792RPM, 7,200 Volts, SCIM



NEWTON ENSURES QUALITY WORK



PROCESS FLOW



RECEIVING



Actions: • Issuance of job order number • Visual inspection • Recording of nameplate details • Preparation of job card Equipment Required: Digital Camera Job Card



DISMANTLING AND INITIAL INSPECTION



Actions: • Mechanical and electrical inspection • No-load test if necessary Equipment Required: Dial indicator Megohmmeter Inside and outside micrometer Clamp meter Tachometer Microlog Feeler gauges High-potential tester Surge Test Thermal scanner



BURN-OUT AND STRIPPING OF WINDINGS



Action: • Heating of the stator/rotor to a temperature of 300 °C using a temperature controlled burn-out oven • Pulling out of coils using coil puller • Careful scrapping to remove insulating materials and other debris left in the slots • Sandblasting was done if needed to clean the rotor/stator and to remove rusted parts Equipment Required: Burn-out oven Sandblasting equipment



CORE TESTING



Actions: • Loop core testing. Newton is using the Stator Core Test Form developed by EASA which provides a step-by-step procedure for calculating the number of turns and cable size required for a loop test.



Equipment Required Thermal imaging camera



REWINDING



Operations: Redesign Rewinding of stator/rotor Wind coils Install new leads/ renew leads



Equipment Required: Winding machine High potential tester Megohmmeter Surge tester



VARNISH DIPPING AND OVEN BAKING



Actions: • Preheating after steam washing, the stator/rotor is preheated at less than 100 °C • Preheating to remove moisture, the stator/rotor is preheated at 150 °C • Dip varnishing of the rotor/stator • Baking to cure varnish at 150 °C



Types of Varnish Used: Hi Therm BC-346-A- Baking varnish Hi Therm BC352- Clear Baking Varnish Synthite AC41- Air Drying Varnish Synthite AC43- Clear Air Drying Varnish) Dolph-Spray ER41- Red Air Dry Polyurethane Spray Dolph-Spray ER-44- Air Dry Polyurethane Varnish



VARNISH DIPPING AND OVEN BAKING Mechanical Operations: • Tig welding • Arc welding • Sleeving of DE and NDE • Metalizing of housing/shaft• Fabrication of shaft • Re-baring of rotor • Repair of end rings • Re-stacking • Repair of rings • Dynamic balancing-



VARNISH DIPPING AND OVEN BAKING



Operations: • Re-assembly • Rebuilding of brush holders • Replacement of slip rings • Replacement of seals and terminal leads



FINAL INSPECTION AND TESTING Actions: • Electrical and mechanical testing • No-load testing



Equipment Required: Megohmmeter Microlog High-potential tester Thermal scanner Clamp meter Dial indicator Tachometer



CLEANING AND PAINTING



Operations: • Cleaning and painting of parts • Cleaning of stator/rotor • Sand blasting of parts



Detergent Used: Vergo-LDS 225 Liquid Detergent Soap Degreaser Used: (material will not cause surface corrosion, erosion or acid attack) Fast Dry Non-Flammable Safety Solvent Degreaser



PREPARATION FOR SHIPMENT



Actions: • The unit will be packed in a manner suitable for the form of transport to be used • Unit to be shipped will be correctly identified, marked and recorded on the appropriate documentation. • Where jurisdiction requirements apply, all necessary permits, licenses and authorizations will be obtained to allow proper delivery to the consignee.



THANK ENDYOU



SM PRIME HOLDINGS INC. January 10, 2013



BASIC PARTS OF AN INDUCTION MOTOR



REACTIVE MAINTENANCE also referred to as breakdown maintenance, is the most common form of equipment maintenance practiced in the industry today.



PREVENTIVE MAINTENANCE Is a program of routine equipment inspections, maintenance task and repairs which are scheduled to ensure that degradation of equipment is minimized.



PREDICTIVE MAINTENANCE Is the technique of regularly monitoring selected parameters of equipment operation to detect and correct a potential problem before it causes a failure



Why Maintenance Is So Important? A maintenance program ensures continuity of operation and lessens the danger of unplanned outages. Planned shutdowns take place during periods of inactivity or least usage, and as a result, troubles can be detected in the early stages and corrective action taken before extensive damage is done.



Causes Of Electrical Failure Dust And Dirt Accumulation Presence of Moisture Loose Connection Friction



List of all the Motors at your Facility Type Size and Application of each motor. Age Maintenance and Repair History Operating Conditions and Environment Annual Energy Cost (Hours of Operation)



Motor Insulation Predictive



MAINTENANCE TESTING INSULATION RESISTANCE TEST DIELECTRIC ABSORPTION TEST POLARIZATION INDEX TEST



SURGE COMPARISON TEST



Winding Rated Voltage (V)



Insulation Resistance Test Direct Voltage (V)



12,000



5000-10,000



Maximum Insulation Resistance



Test Specimen



IR1min=kV + 1



For most windings made before about 1970, all field windings, and others not described below.



IR1min = 100



IR1min = 5



For most DC armature and AC windings built after about 1970(form-wound coils) For most machines with randomwound stator coils and formwound coils rated below 1 kV.