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Manual for High Voltage Process Performance Motors

4 -

3BFP 000 063 R0101 REV D

7.3.1

Recommended maintenance program ..................................................... 49
7.3.1.1

General construction......................................................... 49

7.3.1.2

Stator and rotor ................................................................. 50

7.3.1.3

Auxiliaries ........................................................................ 50

7.3.1.4

Lubrication system and bearings ...................................... 51

7.4

Maintenance of general constructions...................................................................... 51
7.4.1

The tightness of fastenings...................................................................... 51

7.4.2

Vibration and noise ................................................................................. 52

7.4.3

Vibrations................................................................................................ 53
7.4.3.1

Measurement procedures and operational conditions ...... 53

7.4.3.2

Classification according to support flexibility ................. 54

7.4.3.3

Evaluation......................................................................... 54

7.5

Maintenance of bearings and lubrication system ..................................................... 55
7.5.1

Rolling bearings ...................................................................................... 56
7.5.1.1

Bearing construction......................................................... 56

7.5.1.2

Bearing plate..................................................................... 56

7.5.1.3

Re-greasing intervals ........................................................ 56

7.5.1.4

Re-greasing....................................................................... 57

7.5.1.5

Bearing grease .................................................................. 58

7.5.1.6

Bearing maintenance ........................................................ 59

7.6

Maintenance of stator and rotor windings................................................................ 59
7.6.1

Particular safety instructions for winding maintenance .......................... 60

7.6.2

The timing of the maintenance................................................................ 60

7.6.3

The correct operating temperature .......................................................... 61

7.6.4

Insulation resistance test ......................................................................... 61
7.6.4.1

Conversion of measured insulation resistance values ...... 61

7.6.4.2

General considerations ..................................................... 63

7.6.4.3

Minimum values for insulation resistance........................ 63

7.6.4.4

Stator winding insulation resistance measurement........... 63

7.6.5

Insulation resistance measurement for auxiliaries .................................. 64

7.6.6

The polarization index............................................................................. 65

7.6.7

Other maintenance operations................................................................. 65

7.7

Repairs, disassembly and assembly ......................................................................... 65

Chapter 8 - Trouble Shooting

8.1

Trouble shooting ...................................................................................................... 66
8.1.1

Mechanical performance ......................................................................... 67

8.1.2

Lubrication system and bearings............................................................. 68
8.1.2.1

Lubrication system and rolling bearings .......................... 68

8.1.3

Thermal performance .............................................................................. 69
8.1.3.1

Thermal performance, rib cooled ..................................... 69

8.2

Electrical performance, excitation, control and protection ...................................... 69
8.2.1

Protection trips ........................................................................................ 69

8.2.2

Pt-100 resistance temperature detectors.................................................. 70

Chapter 9 - After Sales Support and Spare Parts

9.1

After Sales ................................................................................................................ 72
9.1.1

Site Services ............................................................................................ 72

9.1.2

Spare Parts............................................................................................... 72

9.1.3

Support and Warranties........................................................................... 72

Summary of Contents for AMA

Page 1: ...Manual for High Voltage Process Performance Motors ABB ...

Page 2: ...count use degrees of protection IP23 outdoors Air cooled models are typically designed for ambient temperatures of 20 C up to 40 C and altitudes of 1000 m above sea level Ambient temperature for air water cooled models should be not less than 5 C for sleeve bearing machines see manufacturer s documentation By all means take note of deviating information on the rating plate Field conditions must co...

Page 3: ...e rating plate markings and connection diagram in the terminal box The connection must be made in a way that the permanent safe electrical connection is maintained Use appropriate cable terminals Establish and maintain safe equipotential bonding The clearances between uninsulated live parts and between such parts and earth must not be below the values of appropriate standards and values possibly g...

Page 4: ...is to equalise the potentials When the motor and the gearbox are mounted on a common steel fundament no potential equalisation is required To comply with EMC requirements use only cables and connectors approved for this purpose See instruction for frequency converters Additional Safety Instructions for Permanent Magnet Synchronous Machines Electrical connection and operation When the machine shaft...

Page 5: ... not belong to the machine and wastes must be removed from the interior of the machine NOTE Beware of magnetic stray fields and possible induced voltages when rotating the separate rotor of a permanent magnet synchronous machine as they may cause damage to surrounding equipment for example lathes or balancing machines Additional Safety Instructions for Electrical Motors for Explosive Atmosphere NO...

Page 6: ...nduction Machines sizes 315 to 450 Increased safety Ex e AMA Induction Machines sizes 315 to 500 AMB Induction Machines sizes 560 to 630 AMI Induction Machines sizes 560 to 630 HXR Induction Machines sizes 315 to 560 Pressurisation Ex pxe Ex pze Ex px Ex pz AMA Induction Machines sizes 315 to 500 AMB Induction Machines sizes 560 to 630 AMI Induction Machines sizes 560 to 630 HXR Induction Machines...

Page 7: ...Ex nA protection IEC 61241 0 Std concerning General Requirements for combustible dust IEC 61241 1 Std concerning combustible dust Ex tD protection NFPA 70 National Electric Code NEC C 22 1 98 Canadian Electrical Code Part I CE Code ABB machines valid only for group II can be installed in areas corresponding to following marking Atmosphere EN G explosive atmosphere caused by gases D explosive atmos...

Page 8: ...ing for advises from ABB Oy Be sure that air gap between rotor and stator is measured after any maintenance for the rotor or bearings The air gap shall be the same in any point between stator and rotor Centralize the fan to the center of the fanhood or the air guide after any maintenance The clearance shall be at least 1 of the maximum diameter of the fan and in accordance with standards Connectio...

Page 9: ...entilation Before starting check the need to purge the machine enclosure to make sure that the enclosure is free of flammable gases Based on the risk assessment the customer and or the local authorities will make the decision whether the customer needs to use the pre start ventilation or not NOTE If there are any conflicts between these safety instructions and the user manual these safety instruct...

Page 10: ...rning a vertically mounted machine 10 2 4 Checks upon arrival and unpacking 11 2 4 1 Check upon arrival 11 2 4 2 Check upon unpacking 11 2 5 Storage 11 2 5 1 Short term storage less than 2 months 11 2 5 2 Long term storage more than 2 months 12 2 5 3 Rolling bearings 13 2 5 4 Openings 14 2 6 Inspections records 14 Chapter 3 Installation and Alignment 3 1 General 15 3 2 Foundation design 15 3 2 1 G...

Page 11: ...levelling 24 3 6 3 Rough adjustment 24 3 6 4 Correction for thermal expansion 25 3 6 4 1 General 25 3 6 4 2 Thermal expansion upwards 26 3 6 4 3 Thermal axial growth 26 3 6 5 Final alignment 26 3 6 5 1 General 26 3 6 5 2 Run out of the coupling halves 27 3 6 5 3 Parallel angular and axial alignment 27 3 6 5 4 Alignment 28 3 6 5 5 Permissible misalignment 29 3 7 Care after installation 30 Chapter 4...

Page 12: ...ature detectors 38 5 5 3 3 Thermistors 38 5 5 4 Protection equipment 38 5 6 First test start 39 5 6 1 General 39 5 6 2 Precautions before first test start 39 5 6 3 Starting 39 5 6 3 1 Direction of rotation 39 5 7 Running the machine the first time 40 5 7 1 Supervision during the first run 40 5 7 2 Checks during running of the machine 40 5 7 3 Bearings 40 5 7 3 1 Machines with rolling bearings 40 5...

Page 13: ...ns for winding maintenance 60 7 6 2 The timing of the maintenance 60 7 6 3 The correct operating temperature 61 7 6 4 Insulation resistance test 61 7 6 4 1 Conversion of measured insulation resistance values 61 7 6 4 2 General considerations 63 7 6 4 3 Minimum values for insulation resistance 63 7 6 4 4 Stator winding insulation resistance measurement 63 7 6 5 Insulation resistance measurement for...

Page 14: ...different sets 74 9 2 5 1 Operational spare part package 74 9 2 5 2 Recommended spare part package 75 9 2 5 3 Capital spare parts 75 9 2 6 Order information 75 Chapter 10 Recycling 10 1 Introduction 76 10 2 Average material content 76 10 3 Recycling of packaging material 76 10 4 Dismantling of the machine 77 10 5 Separation of different materials 77 10 5 1 Frame bearing housing covers and fan 77 1...

Page 15: ... any improvement suggestions For contact information see Chapter 9 1 5 After Sales contact information NOTE These instructions must be followed to ensure safe and proper installation operation and maintenance of the machine They should be brought to the attention of anyone who installs operates or maintains this equipment Ignoring the instruction invalidates the warranty 1 2 Important note The inf...

Page 16: ...act information please see the back page of this User s Manual Please remember to provide the serial number of the machine when discussing machine specific issues 1 4 Documentation 1 4 1 Documentation of the machine It is recommended that the documentation of the machines is studied carefully before any actions are taken This manual and safety instructions are delivered with each machine and is lo...

Page 17: ...rial number of the machine Each machine is identified with a 7 digit serial number It is stamped on the rating plate of the machine as well as on the machine frame The serial number must be provided in any future correspondence regarding a machine as it is the only unique information used for identifying the machine in question 1 5 2 Rating plate A stainless steel rating plate is attached permanen...

Page 18: ... for direct on line machines manufactured according to IEC Figure 1 2 Rating plate for direct on line machines manufactured according to NEMA 1 Type designation 2 Manufacturing year 3 Duty 4 Insulation class 5 Machine weight kg or lbs 6 Degree of protection IP class 7 Space for additional information 8 Manufacturer ...

Page 19: ...10 Output kW or HP 11 Stator voltage V 12 Frequency Hz 13 Rotating speed rpm 14 Stator current A 15 Power factor cosf 16 Standard 17 Frame 18 Product code 19 Maximum mechanical rotating speed rpm 20 Bearing types 21 Designation for locked rotot kVA HP NEMA 22 Ambient temperature C NEMA 23 Service factor NEMA ...

Page 20: ...nt indicated on the bearing plate which is attached to the machine frame see Chapter 2 1 2 Bearing plate Machined metal surfaces such as the shaft extension are protected against corrosion with an anti corrosive coating In order to protect the machine properly against water salt spray moisture rust and vibration damages during loading sea transport and unloading of the machine the machine should b...

Page 21: ... end 3 Lubrication interval 4 Quantity of grease for D end bearing 5 Quantity of grease for ND end bearing 6 Type of grease delivered from factory 2 2 Lifting the machine Before the machine is lifted ensure that suitable lifting equipment is available and that the personnel is familiar with lifting work The weight of the machine is shown on the rating plate dimension drawing and packing list NOTE ...

Page 22: ...st not be used NOTE Lifting eyebolts must be tightened before lifting If needed the position of the eyebolt must be adjusted with suitable washers 2 2 1 Lifting a machine in a seaworthy package The seaworthy package is normally a wooden box which is covered with lamina paper on the inside The seaworthy package should be lifted by forklift from the bottom or by crane with lifting slings The sling p...

Page 23: ... 2 4 Lifting of horizontal and vertical machines on pallets or by forklift from the bottom of the pallet The machine is fixed to the pallet with bolts Figure 2 4 Lifting of horizontal and vertical machines on pallets 2 2 3 Lifting an unpacked machine Suitable lifting equipment must be used The machine should always be lifted by crane from the lifting eyes on the frame of the machine see Figure 2 5...

Page 24: ...s may be necessary to turn from vertical to horizontal position e g when changing the bearings and vice versa This is shown in Figure 2 6 Machine with turnable lifting eyes lifting and turning Avoid damaging the painting or any parts during the procedure Remove or install the bearing locking device only when the machine is in vertical position Figure 2 6 Machine with turnable lifting eyes lifting ...

Page 25: ...ing and disposal of the packaging material see Chapter 10 3 Recycling of packaging material 2 5 Storage 2 5 1 Short term storage less than 2 months The machine should be stored in a proper warehouse with a controllable environment A good warehouse or storage place has A stable temperature preferably in the range from 10ºC 50 F to 50ºC 120 F If the anti condensation heaters are energized and the su...

Page 26: ...on to the measures described with short term storage the following should be applied Measure the insulation resistance and temperature of the windings every three months see Chapter 7 6 Maintenance of stator and rotor windings Check the condition of the painted surfaces every three months If corrosion is observed remove it and apply a coat of paint again Check the condition of anti corrosive coati...

Page 27: ... storage Check the bearing locking device periodically Tighten the transport locking device according to the axially locating bearing type see Table 2 1 Tightening torque for horizontal machines lubricated screw NOTE A too high tightening torque on the transport locking device will damage the bearing NOTE The type of bearings used are found on the bearing plate see Chapter 2 1 2 Bearing plate and ...

Page 28: ...langes that are not connected to the piping they are to be sealed The coolers and the piping within the machine are to be cleaned and dried before they are sealed The drying is made by blowing warm and dry air through the pipes 2 6 Inspections records The storage period taken precautions and measurements including dates should be recorded For relevant check lists see Appendix COMMISSIONING REPORT ...

Page 29: ...tion must be strong rigid flat and free from external vibration The possibility of machine resonance with the foundation has to be verified In order to avoid resonance vibrations with the machine the natural frequency of the foundation together with machine must not be within a 20 range of the running speed frequency A concrete foundation is preferred however a correctly designed steel constructio...

Page 30: ...rease available is according to the specification on the bearing plate see Chapter 2 1 2 Bearing plate Additional recommended greases can be found in Chapter 7 5 1 5 Bearing grease Remove the anti corrosive coating on the shaft extension and machine feet with white spirit Install the coupling half as described in Chapter 3 3 4 Assembly of the coupling half Check that the drain plugs at the lowest ...

Page 31: ...NOTE The machine is not suitable for belt chain or gear connection unless it is specifically designed for such use The same applies for high axial thrust applications 3 3 4 Assembly of the coupling half 3 3 4 1 Balancing of coupling The rotor is dynamically balanced with half key as standard The way of balancing is stamped to the shaft end H half key and F full key The coupling half must be balanc...

Page 32: ...achines two drain plugs are fitted to the lower end shield The main terminal box has one drain plug at the lowest part of the box which has to be closed during operation 3 4 Installation on concrete foundation 3 4 1 Scope of delivery The machine delivery does not normally include installation shim plates mounting bolts foundation plate set or sole plate set These are delivered according to special...

Page 33: ... rinsed and thus free from pollution and dust Oil or grease must be removed by chipping away slices of the concrete surfaces Check that the position of the grouting holes and the height of the foundation agree with corresponding measurements on the drawing provided Attach a steel wire on the foundation to indicate the center line of the machine Mark also the axial position of the machine 3 4 3 2 F...

Page 34: ...ud assembly The tape will prevent the upper part of the bolt from being stuck in the concrete and enables it to be retightened after the concrete has set Fit the anchor bolt part 2 in the foundation plates part 1 or sole plates so that the top of the anchor bolts is 1 2 mm 40 80 mil above the upper surface of the nuts part 4 Fit the anchor flange part 3 and the lower nut part 4 to the anchor bolts...

Page 35: ...thin 2 mm 80 mil 3 4 5 Alignment The alignment is made as described in Chapter 3 6 Alignment 3 4 6 Grouting The grouting of the machine into the foundation is a very important part of the installation The instructions of the grouting compound supplier must be followed Please use high quality non shrinking grouting materials to avoid difficulties with the grouting in the future Cracks in the grouti...

Page 36: ...stallation shim plates or mounting bolts These are delivered according to special orders If new fixing holes need to be drilled please contact ABB to ensure suitability 3 5 2 Check of foundation Before lifting the machine onto the foundation the following checks should be made Clean the foundation carefully The foundations shall be flat and plain parallel within 0 1 mm 4 0 mil or better The founda...

Page 37: ...ces for future use 3 5 6 Installation of flange mounted machines on steel foundation The purpose of a mounting flange for vertically mounted machines is to enable an easy installation and coupling connection as well as an easy inspection of the coupling during operation In order to fit the ABB machines the mounting flanges shall be designed according to the IEC standard The mounting flange is not ...

Page 38: ...e alignment and enable the mounting of shims jacking screws are fitted to the feet of the machine see Figure 3 3 Vertical positioning of machine foot The machine is left standing on the jacking screws Note that the machine must stand on all four feet screws on a plain parallel within 0 1 mm 4 0 mil or better If this is not the case the frame of the machine will be twisted or bent which can lead to...

Page 39: ...ate NOTE Figure 3 5 Mounting of the bracket plate shows bracket plate mounted to concrete foundation place similar bracket plate on steel foundation 3 6 4 Correction for thermal expansion 3 6 4 1 General Running temperatures have a considerable influence on the alignment and should therefore be considered during the alignment The machine temperature is lower during erection than under operating co...

Page 40: ...d The expected axial thermal expansion of the rotor is proportional to the length of the stator frame and can be approximately calculated according to the formula L α T Lwhere L thermal expansion mm α 10 10 6 K 1 T 50 K for AMA AMB AMK AMI 80 K for AMH HXR M3BM M3GM L frame length mm NOTE Make sure that a continuous free axial movement is possible between the coupling halves excluding rigid coupli...

Page 41: ...g the run out at the coupling half 3 6 5 3 Parallel angular and axial alignment After the machine has been roughly positioned as described in Chapter 3 6 2 Rough levelling and Chapter 3 6 3 Rough adjustment the final alignment can start This step must be performed with great caution Failure to do so can result in serious vibrations and damage to both driving and driven machine The alignment is don...

Page 42: ...justment 3 Mount the alignment equipment If gauges are used it is practical to adjust the dial gauge in such way that approximately half of the scale is available in either direction Check the rigidity of the gauge brackets in order to eliminate the possibility of sag see Figure 3 8 Alignment check with gauges Figure 3 8 Alignment check with gauges 4 Measure and note readings for parallel angular ...

Page 43: ...tting sufficiently hard with a center punch 11 Dowel the feet of the machine for easy future re installation of the machine see Chapter 3 4 7 1 Dowelling of the machine feet 3 6 5 5 Permissible misalignment Definite alignment tolerances are impossible to state as too many factors have an influence Too large tolerances will cause vibration and may possibly lead to bearing or other damages Therefore...

Page 44: ...ings must be filled with oil If external vibration is present the shaft coupling should be opened and suitable rubber blocks should be placed under the feet of the machine NOTE External vibration will damage the bearing rolling surfaces and therefore shorter the bearing lifetime 100 250 mm 4 10 Rigid Flange 0 02 mm 0 8 mil 0 01 mm 0 4 mil 0 02 mm 0 8 mil Gear 0 05 mm 2 mil 0 03 mm 1 mil 0 05 mm 2 ...

Page 45: ... planned before taking any action The connection diagrams received with the machine have to be studied before starting the installation work It is important to verify that the supply voltage and the frequency are the same as the values indicated on the rating plate of the machine The network voltage and frequency should be within given limits according to the applicable standard Note rating plate ...

Page 46: ... is sufficient 4 2 4 1 Delivery without main terminal box If the machine is delivered without a main terminal box the stator connection cables have to be covered with earthed protective structure before commissioning The structure must have the same or higher enclosure classification and hazardous area certifications as the machine To avoid cable failure stator connection cables must be shortened ...

Page 47: ...eparated from the supply network and that the cables are connected to protective earth The stator terminals are marked with letters U V and W according to IEC 60034 8 or T1 T2 and T3 according to NEMA MG 1 The neutral terminal is marked with N IEC or with T0 NEMA Stripping splicing and insulating of the high voltage cables must be performed in accordance with instructions by the cable manufacturer...

Page 48: ...ower motor rating plate shows the voltage and frequency to be used The direction of rotation of the fan is indicated by an arrow plate on the flange of the main machine NOTE Check visually the direction of rotation of the external blower motor fan before starting the main machine If the blower motor is running in the wrong direction the phase sequence of the blower motor must be changed 4 2 8 Eart...

Page 49: ...ment EN 50081 2 For further information see ABB manual Grounding and cabling of the drive system 3AFY 61201998 R0125 REV A 4 2 9 2 Earthing of main cable The compliance with EMC directive requires high frequency earthing of the main cable This is achieved by a 360 earthing of the cable screens at the cable entries in both the machine and in the frequency converter The earthing at the machine is im...

Page 50: ... anchored to the foundation Check for cracks in the foundation and the general condition of the foundation Check the tightness of the mounting bolts Additional checks when applicable Check that the lubrication system is commissioned and is running before the rotor is turned If possible turn the rotor by hand and make sure that the rotor turns freely and that no abnormal sound can be heard Check th...

Page 51: ...ow as possible The level can be determined based on the test results or the noticed operating temperature The temperature alarm can be set 10K 20 F higher than the operating temperature of the machine during maximal load at highest ambient temperature If a two function temperature monitoring system is used the lower level is normally used as an alarm level and the higher as a trip level NOTE In ca...

Page 52: ...e the machine should be shut down immediately as the temperature rise might indicate a bearing failure 5 5 3 2 Resistance temperature detectors Recommended maximum temperature settings For determining the temperature settings see the Connection Diagram delivered with the machine It is recommended to apply the method described in Chapter 5 5 1 General when setting the temperature alarm 5 5 3 3 Ther...

Page 53: ...nnections and earthing devices are verified The starting control protection and alarm relays of each device are inspected The insulation resistance of the windings and other equipment verified The machine covers are assembled and the shaft seals are tightly fitted in The machine and the environment are cleaned 5 6 3 Starting The first start should last only about one 1 second during which the dire...

Page 54: ...g is recommended NOTE If resistance temperature detector RTD Pt 100 or equivalent is not available the surface temperature of the bearing area shall if possible be measured The bearing temperature is approximately 10 C 20 F higher than the surface temperature In case of any deviations from expected normal operation e g elevated temperatures noise or vibration shut down the machine and find the rea...

Page 55: ...ring will return to normal running temperature If available and after the machine has been running for several hours measure the vibrations or SPM values from the SPM nipples and record the values for future reference use 5 8 1 Vibrations For a comprehensive discussion on vibrations see Chapter 7 4 2 Vibration and noise 5 8 2 Temperature levels The temperatures of the bearings stator windings and ...

Page 56: ...larm and trip levels see main connection diagram and Chapter 7 4 3 3 Evaluation 5 9 Shut down The shutdown of the machine depends on the application but main guidelines are Reduce the load of the driven equipment if applicable Open the main breaker Switch possible anti condensation heaters on if not automatically done by switch gear ...

Page 57: ...ion conditions according to the IEC or NEMA standards customer specifications and internal ABB standards The operation conditions such as maximum ambient temperature and maximum operating height are specified in the performance data sheet delivered as a part of the project documentation The foundation shall be free from external vibration and the surrounding air shall be free of dust salt and corr...

Page 58: ...peratures and vibrations This data is useful basis for maintenance and service During the first period of operation 200 hours supervision should be intensive Temperatures of bearings and windings load current cooling lubrication and vibration shall be checked frequently During the following duty period 200 1000 hours a check up once a day is sufficient A record of supervision inspections should be...

Page 59: ...BFP 000 063 R0101 REV D 6 6 Shut down When the machine is not in operation anti condensation heaters have to be switched on where applicable This is to avoid condensation effect inside the machine NOTE Voltage may be connected to the terminal box for heating element ...

Page 60: ...f maintenance By intensifying maintenance and supervision activities the reliability of the machine and the long term availability will increase The data obtained during supervision and maintenance is useful for estimating and planning additional service In case some of this data indicates something out of the ordinary the trouble shooting guides in Chapter 8 Trouble Shooting will aid in locating ...

Page 61: ...en customized to match the machine it might contain references to accessories not available on all machines The maintenance program is based on four levels of maintenance which rotate according to operating hours The amount of work and down time vary so that level 1 includes mainly quick visual inspections and level 4 more demanding measurements and replacements More information about the spare pa...

Page 62: ...is maintenance is to repair encountered problems and replace parts subjected to wear The maintenance can be estimated to last approximately 16 40 hours depending on the type and installation of the machine and the amount of repairs and replacements to be done Tools for this maintenance include the same tools as for L2 and in addition an endoscope and an oscilloscope The preparations consist of ope...

Page 63: ...tenance intervals 7 3 1 1 General construction Main supply connection MAINTENANCE INTERVAL In equivalent operating hours or time period which ever comes first L1 L2 L3 L4 Maintenance object 4 000 Eq h 12 000 Eq h 20 000 Eq h 28 000 Eq h 8 000 Eq h 16 000 Eq h 24 000 Eq h 80 000 Eq h year Annual 3 5 years Overhaul Check Test Maintenance object L1 L2 L3 L4 Check Test Machine operation V T V T V T V ...

Page 64: ... coil over hangs V V V V Insulation damages Stator coil supports V V V V Insulation damages Stator slot wedges V V V V Movement tightness Stator terminal bars V V V V Fixing insulation Instrumentation V V V V Condition of cables and cable ties Rotor winding insulation V V T V T C V T C Wear cleanliness insulation resistance Rotor balancing weights V V V V Movement Shaft V V V V Crack corrosion Con...

Page 65: ...ghtness of all fastenings should be verified regularly Special focus should be given to the grouting the anchor bolts and the rotor parts which must remain correctly tightened at all times Loose fastening in these parts can lead to sudden and severe damage to the entire machine General values for tightening torques are presented in Table 7 2 General tightening torques Maintenance object L1 L2 L3 L...

Page 66: ... on the application type and foundation of the machine The vibration measurements and levels are discussed in detail in Chapter 7 4 3 Vibrations Some typical reasons that might cause high noise or vibration levels are Alignment see Chapter 3 Installation and Alignment Bearing wear or damage Vibration from connected machinery see Chapter 7 4 3 Vibrations Tightening torque in Nm pound feet Property ...

Page 67: ...elocity or combinations of these see ISO 10816 1 However for machines with speeds approaching or below 600 r min the lower limit of the flat response frequency range shall not be greater than 2 Hz Measurement locations Measurements will usually be taken on exposed parts of the machine that are normally accessible Care shall be taken to ensure that measurements reasonably represent the vibration of...

Page 68: ...hen the support system may be considered rigid in that direction All other support systems may be considered flexible 7 4 3 3 Evaluation ISO 10816 1 provides a general description of the two evaluation criteria used to assess vibration severity on various classes of machines One criterion considers the magnitude of observed broad band vibration the second considers changes in magnitude irrespectiv...

Page 69: ...rticular machine It is recommended that the ALARM value should be set higher than the baseline by an amount equal to 25 of the upper limit for zone B If the baseline is low the ALARM may be below zone C Setting of TRIPS The TRIP values will generally relate to the mechanical integrity of the machine and be dependent on any specific design features which have been introduced to enable the machine t...

Page 70: ...s found on the bearing plate NOTE Regardless of the re greasing interval the bearings need to be re greased at least once per year The re greasing intervals are calculated for an operating temperature of 70 C 160 F If the operating temperature is lower or higher than the assumed the re grease interval has to be altered accordingly Higher operating temperature decreases the re greasing interval NOT...

Page 71: ...ipped with a handle open it Press the specified amount and type of grease into the bearing Let the machine run 1 2 hours in order to ensure that all excess grease is forced out of the bearing The bearing temperature may temporarily increase during this time If equipped with a handle close it NOTE Beware of all rotating parts during the re greasing For the locations of the handles see Appendix Typi...

Page 72: ...base oil viscosity of 100 to 160 cSt at 40 C 105 F Have a consistency NLGI grade between 1 5 and 3 For vertically or in hot conditions mounted machines NLGI grade 2 or 3 is recommended Have a continuous temperature range between 30 C 20 F and at least 120 C 250 F Grease with the correct properties is available from all major lubricant manufacturers If the make of grease is changed and compatibilit...

Page 73: ...s and fitted by heating or using special tools for the purpose If there is a need to change bearings please contact ABB After Sales See After Sales contact information in Chapter 9 1 5 After Sales contact information 7 6 Maintenance of stator and rotor windings The windings of rotating electrical machines are subjected to electrical mechanical and thermal stresses The windings and insulation gradu...

Page 74: ... resin Adhesive resin epoxy resin NOTE There are special instructions for handling dangerous substances during maintenance work These instructions must be followed Some general safety measures during winding maintenance are as follows Avoid breathing air fumes ensure proper air circulation at the work site or use respiration masks Wear safety gear such as glasses shoes hardhat and gloves and suita...

Page 75: ...could be a sign of damage in the windings Make sure that the changes are not caused by the drifting of the measuring channel 7 6 4 Insulation resistance test During general maintenance work and before the machine is started up for the first time or after a long period of standstill the insulation resistance of stator and rotor windings must be measured The insulation resistance measurement provide...

Page 76: ... the temperature R Insulation resistance value at a specific temperature R40 Equivalent insulation resistance at 40 C R40 k x R Example R 30 MΩ measured at 20 C k 0 25 R40 0 25 x 30 MΩ 7 5 MΩ Table 7 4 Temperature values in degrees Celsius ºC and degrees Fahrenheit ºF C 0 10 20 30 40 50 60 70 80 90 100 110 F 32 50 68 86 104 122 140 158 176 194 212 230 ...

Page 77: ...erefore the following values can only be considered as guidelines The insulation resistance limits which are given below are valid at 40 C and when the test voltage has been applied for 1 minute or longer Rotor For induction machines with wound rotors R 1 10 min at 40 C 5 MΩ NOTE Carbon dust on slip rings and naked copper surfaces lower the insulation resistance values of the rotor Stator For new ...

Page 78: ...rame of the machine and one of the windings The frame and the two phases not measured are earthed see Figure 7 3 Connections of the stator windings for insulation resistance measurements When phases are measured separately all star points of the winding system must be removed If the star point of the component cannot be removed as in a typical tri phase voltage transformer the whole component must...

Page 79: ...fely started For the polarization index PI the values usually range between 1 and 4 Values close to 1 indicate that the windings are humid and dirty The minimum PI value for class F stator windings is more than 2 NOTE If the insulation resistance of the winding is in the range of several thousands of MΩ the polarization index is not a meaningful criterion of the condition of the insulation and it ...

Page 80: ...d rotating electrical machine The trouble shooting charts given below can aid in locating and repairing mechanical electrical and thermal problems and problems associated with the lubrication system The checks and corrective actions mentioned should always be conducted by qualified personnel If in any doubt the After Sales of ABB should be contacted for more information or technical assistance reg...

Page 81: ...r cooling system z z Machine misalignment Check machine alignment z z Rotor or shaft imbalance Rebalance rotor z z Vibration coming from connected machinery Check the balance of connected machinery and coupling type z z Axial load coming from connected machinery Check alignment and coupling function and type z z Faulty or incorrectly assembled coupling Check coupling function z Insufficient founda...

Page 82: ...rating and grease recommendations z z Excessive lubrication Clean bearing and add correct amount of lubricant z z Impurities in grease Change grease check bearing condition z z Bearing currents Check bearing and insulation condition z z Complete bearing failure Replace bearing z z Normal wearing Replace worn bearing parts z Faulty instrumentation Faulty temperature detector Check bearing temperatu...

Page 83: ... 8 2 1 Protection trips The machine needs to be protected with alarms and trips for abnormal running conditions both electrical and mechanical Some of these protections can be reset and the machine restarted directly as the fault is located Trouble shooting Thermal performance rib cooled Overload Control system setting Check machine controls eliminate overload Overspeed Check actual speed and ABB ...

Page 84: ...rotection system They are used to measure temperatures in the windings bearings and in the cooling air The Pt 100 detector uses a fine platinum filament for the temperature measurement which can be damaged e g by incorrect handling or excessive vibration The following symptoms might suggest a problem in a Pt 100 detector Infinite or zero resistance over the detector Disappearance of measurement si...

Page 85: ...7 22 71 60 135 46 92 197 60 161 79 162 323 60 109 35 24 75 20 136 22 94 201 20 162 53 164 327 20 110 12 26 78 80 136 98 96 204 80 163 27 166 330 80 110 90 28 82 40 137 74 98 208 40 164 02 168 334 40 111 67 30 86 00 138 50 100 212 00 164 76 170 338 00 112 45 32 89 60 139 26 102 215 60 165 50 172 341 60 113 22 34 93 20 140 02 104 219 20 166 24 174 345 20 113 99 36 96 80 140 77 106 222 80 166 98 176 ...

Page 86: ...ivered with the machine Sells genuine spare parts after the machines has been delivered For spare part packages see Chapter 9 2 Spare parts for rotating electrical machines 9 1 3 Support and Warranties The Support department Handles warranty issues under warranty period based on written claims Makes warranty determination Decides about corrective actions Provides technical support 9 1 4 Support fo...

Page 87: ...nel 9 2 2 Periodical part replacements There is always mechanical wear when two moving surfaces are in contact with each other In electrical machines most of the mechanical wear occurs between the rotating shaft and stationary parts The bearing parts such as rolling bearings bearing shells and oil rings in sleeve bearings will eventually wear out and need to be replaced even if correct lubrication...

Page 88: ...pare part packages The personnel best informed of the machine s operational conditions should select the most suitable package based on criticality of the application and on the financial risk related to the duration of downtime and loss of production Operational spare part package for commissioning and to ensure usability These are the most essential spare parts that should always be available Re...

Page 89: ...umber of the machine in question The serial number can be found either on the rating plate fixed to the machine frame or stamped on the machine frame In addition provide specific and detailed information about the parts ordered The contact information of ABB s After Sales organization can be found in Chapter 9 1 5 After Sales contact information Spare part Amount Operational spare part package 1 p...

Page 90: ...er s Manual Additional documentation will be found in the project documentation 10 2 Average material content The average material content used in the manufacturing of the electrical machine is as follows 10 3 Recycling of packaging material Once the machine has arrived on site the packaging material will need to be removed Any wood packaging can be burned For some countries the packaging used for...

Page 91: ...umber of machines All these components are in an inert stage once the manufacturing of the machine has been completed Some components in particular the stator and the rotor contain a considerable amount of copper which can be separated in a proper heat treatment process where the organic binder materials of the electrical insulation are gasified To ensure a proper burning of the fumes the oven sha...

Page 92: ...it it is recommended that the permanent magnets are demagnetized The demagnetization is done by heating the rotor in the oven until the permanent magnets reach a temperature of 300 C 572 F WARNING Magnetic stray fields caused by an open or disassembled permanent magnet synchronous machine or by a separate rotor of such a machine may disturb or damage other electrical or electromagnetic equipment a...

Page 93: ... 79 3BFP 000 063 R0101 REV D COMMISSIONING REPORT Rating plate information Serial no Manufacturer ABB Oy Address Telephone Fax P O Box 186 FIN 00381 HELSINKI FINLAND 358 0 10 22 11 358 0 10 22 22544 Customer Customer address Contact person Telephone Mobile phone Fax Email ...

Page 94: ... Accessories Spare parts tools Actions taken in response to damages Photographed Reported to the transportation company Reported to the supplier Reported to the insurance company Method of transportation Comments Railway Mail Airfreight Shipped by M S ___________ Truck Other no yes missing items no yes what kind of no yes what kind of no yes what kind of no yes date no yes to whom date no yes to w...

Page 95: ...rosive gases in the air Brushes are lifted up Machine documents are saved and protected for future use Comments no yes begin _______________end _____________________ no yes in packing case protected by a waterproof cover Daily temperature min max _______ _______ºC Humidity _______ indoors outdoors no yes no yes type ______________________________________ no yes voltage ____________________________...

Page 96: ...C ____________ D ____________ Axial position of the rotor ET 1 __________mm ET 2 __________mm Axial distance between shaft ends __________mm Rotor support distance Crankshaft deflection is checked Tapered guide pins are used to lock the position of the machine after alignment Foundations bolts are tightened with torque wrench Bolt lubrication Cooling water Cooling element piping Transport locking ...

Page 97: ... freely Bearing oil Manufacturer __________________ Type _________________________ The oil quality is the same as recommended Lubrication rings rotate freely Flood lubrication oil pressure ___________kPa Oil flow ___________liters min Rotation of the pumps checked Jack up pumps checked Oil filters checked Grease Manufacturer __________________ Type _________________________ The grease quality is t...

Page 98: ... ______ºC Exciter stator 1 min 500 VDC __________MΩ tested by________ kV winding temperature ______ºC Space heater __________MΩ 500 VDC Temperature detectors __________MΩ 100 VDC N end bearing insulation __________MΩ 100 VDC Stator 1 Pt 100 Stator 2 Pt 100 Stator 3 Pt 100 Stator 4 Pt 100 Stator 5 Pt 100 Stator 6 Pt 100 __________Ω __________Ω __________Ω __________Ω __________Ω __________Ω Bearing...

Page 99: ...g Earth fault setting Reverse power setting Differential protection setting Vibration monitoring Temperature monitoring in stator winding in bearing in ______________________________ Other protection units no yes setting no yes setting no yes setting no yes setting no yes alarm __________mm s trip ______________mm s no yes type no yes alarm __________ºC trip ______________ºC no yes alarm _________...

Page 100: ...otation viewed from D end Are there abnormal noises Are there abnormal noises Does the machine vibrate abnormally Bearing vibration level measured D end __________ mm s rms N end _________ mm s rms Running Time Bearing temperature Bearing vibration levels Stator Stator winding temperature D end N end D end mm s N end mm s Current Power Factor Excit Current U V W h min ºC ºC rms rms A cos φ A ºC ºC...

Page 101: ...Stator Stator winding temperature D end N end D end mm s N end mm s Current Power Factor Excit Current U V W h min ºC ºC rms rms A cos φ A ºC ºC ºC 0 00 Vibration spectrum attached Acceleration time __________ s Cooling air temperature Inlet __________ ºC Outlet __________ ºC Cooling water temperature Inlet __________ ºC Outlet __________ ºC Comments Machine approved for use Date Commissioning don...

Page 102: ...h Voltage Process Performance Motors Commissioning Report 88 3BFP 000 063 R0101 REV D Fax Cover Sheet Date To ABB Oy Telefax 358 0 10 22 22544 From Fax number Phone number Email Number of pages 1 9 _________ Message ...

Page 103: ...LATE OF THE MACHINE BEARING PLATE OF THE MACHINE ADDITIONAL PLATE MARKING PLATE FOR DIRECTION OF ROTATION HANDLE OF WASTE GREASE EXHAUST VALVE DIRECTION OF ROTATION SEEN FROM THE DRIVE END TOWARDS THE MACHINE CLOCKWISE COUNTER CLOCKWISE REVERSING OPERATION MACHINE ENDS D END N END DRIVE END NON DRIVE END 4 6 D END N END 5 3 2 5 1 4 D END N END 5 1 2 3 ...

Page 104: ...Manual for High Voltage Process Performance Motors Typical Main Power Cable Connections 90 3BFP 000 063 R0101 REV D Typical main power cable connections ...

Page 105: ...ABB Oy Machines P O Box 186 FIN 00381 HELSINKI FINLAND Telephone 358 0 10 2211 Telefax 358 0 10 22 22141 www abb com motors drives 3BFP 000 063 R0101 REV D ABB October 2006 ...

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