Abstract technology of repair and maintenance of an asynchronous motor with a squirrel-cage rotor. Technological map of repair of windings of an induction motor Technological map of repair of an induction motor

Tool used

In the process of servicing and repairing an asynchronous squirrel cage motor, the following tool is used:

Reconciliation ruler

Staples and strings

Rulers for pulleys of different widths.

Spanners 6 - 32 mm - 1 set.

Files - 1 set.

Head set - 1 set.

Metal brush - 1 pc.

Plumber's knife - 1 pc.

Screwdriver set - 1 set.

Bench screwdriver - 1 pc.

Dies 4 - 16 mm - 1 set.

Taps 4 - 16 mm - 1 set.

Drill set 3 - 16 mm - 1 set.

Crowbar - 1 pc.

Pliers - 1 pc.

Chisel - 1 pc.

Drill - 1 pc.

Kern - 1 pc.

Flat brush - 2 pcs.

Hammer - 1 pc.

Shovel - 1 pc.

Broom brush - 1 pc.

Technological map of repair and maintenance of an asynchronous motor with a squirrel-cage rotor

Name and content of works	Equipment and fixtures	Technical requirements
External inspection of the electrical machine, including control systems, protection, ventilation and cooling.	Compliance with technical data sheets for operation and electrical circuits.
Visual check of the condition of the grounding conductor; checking the condition of the ground loop.	Hammer, shovel	Lack of anti-corrosion coating, loosening of fastening, mechanical damage are not allowed.
Check for extraneous noise.	Extraneous noise is not allowed.
Cleaning accessible parts from dirt and dust.	White spirit, rags, metal brush, broom brush.
Inspection of the elements of the connection between the engine and the driven mechanism.	Cracks at the seams, breaks, distortions, loosening of threaded connections are not allowed.
Checking the connection and the reliability of the sealing of the supplied cables, the technical condition and tightness of the lead-in boxes and couplings of the sealed lead-in; checking the condition of seals, surfaces and parts that ensure explosion protection; explosion proof of cable and wire entries.	A set of locksmith probes No. 1 A set of tools a set of screwdrivers A set of heads.	Roughness of the working surface Rd no more than 1.25 microns.
Checking the fastening of the electric drive to the frame (valve).	Set of tools. Set of heads.	Loosening of the fastening is not allowed.
Inspection of the state of the start-up control equipment (PRA).
Blowing out the stator and rotor with compressed air.	Compressor.
Insulation resistance test of windings; drying if necessary.	Megohmmeter with a voltage of 500V.	Insulation resistance should not be less than 0.5 MΩ.
Checking the mating of parts that ensure tightness.	A set of locksmith probes No. 1. A set of tools, a set of screwdrivers. Set of heads, sealant.	The clearances are indicated in the instruction manual.
Checking the presence of grease in the bearings of the electric motor (if there is a press oiler, replenishment).	CIATIM-221 grease, grease press-in gun.

	Set of tools. Screwdriwer set.
	Brush, paint (plate).
Inspection, cleaning and tightening of contact connections.	Set of tools. Cloth abrasive paper in accordance with GOST 5009-82.	Distortions, the presence of oxide, loosening of contact connections are not allowed.
Revision of automatic circuit breaker assemblies.	Set of tools. Screwdriwer set.
Checking the presence of cable markings, inscriptions and markings on the casing, restoration if necessary.	Brush, paint (plate).	The absence of markings and inscriptions is not allowed.

Security measures

The electric motor must be de-energized, disconnected AB, installed grounding, posted posters. Apply portable grounding to the lead-in ends of the motor cable. Protect the place of work. Work with PPE. Work with verified devices and tested power tools and devices.

The composition of the brigade

An electrician for the repair of electrical equipment with an electrical safety group of at least the third. Electrician for the repair of electrical equipment with the third group of electrical safety.

Technological (map) process during the repair of a high-voltage synchronous electric motor weighing 2 tons. Outfit, turning off the electric motor, taking out for repair, using lifting mechanisms, slinging scheme, rigging to the repair site

Architecture, design and construction

If work on an electric motor or a mechanism driven by it is associated with touching live and rotating parts, the electric motor must be turned off with the implementation of the provided technical measures to prevent its erroneous activation. Work that is not associated with touching live or rotating parts of the electric motor and the mechanism driven by it can be performed on a running electric motor. When working on an electric motor, it is allowed to install grounding on any section of the cable line ...

If work on an electric motor or a mechanism driven by it is associated with touching live and rotating parts, the electric motor must be turned off with the implementation of the provided technical measures to prevent its erroneous activation. In this case, for a two-speed electric motor, both power circuits of the stator windings must be disconnected and disassembled.

Work that is not associated with touching live or rotating parts of the electric motor and the mechanism driven by it can be performed on a running electric motor.

It is not allowed to remove the guards of the rotating parts of the operating electric motor and mechanism.

When working on an electric motor, it is allowed to install grounding on any section of the cable line connecting the electric motor to the switchgear section, shield, assembly. If work on the electric motor is designed for a long period of time, is not performed or interrupted for several days, then the cable line disconnected from it must also be grounded on the motor side. In cases where the cross-section of cable conductors does not allow the use of portable grounding, for electric motors with voltages up to 1000 V, it is allowed to ground the cable line with a copper conductor with a cross-section of at least the cross-section of the cable conductor, or to connect the cable conductors together and isolate them. Such grounding or connection of cable cores should be taken into account in the operational documentation along with portable grounding.

Before being allowed to work on electric motors capable of rotating due to mechanisms connected to them (smoke exhausters, fans, pumps, etc.), the handwheels of shut-off valves (valves, valves, gates, etc.) must be locked. In addition, measures have been taken to brake the rotors of electric motors or disengage couplings.

The necessary operations with shut-off valves must be agreed with the shift supervisor of the technological shop, section with an entry in the operational log.

The voltage must be removed from the circuits of manual remote and automatic control of electric drives of shut-off valves, guide vanes. On the steering wheels of valves, gates, valves, posters should be posted "Don `t open! People work ", and on the keys, control buttons for electric drives of shut-off valves - "Do not turn on! People work "... On electric motors of the same type or similar in size, installed next to the engine on which the work is to be performed, posters should be posted“Stop! Voltage"regardless of whether they are in operation or stopped.

Admission to all pre-prepared workplaces, one at a time on electric motors of the same voltage, is allowed to be performed simultaneously, registration of a transfer from one workplace to another is not required. At the same time, testing or putting into operation any of the electric motors listed in the order until the complete completion of work on others is not allowed.

The order of turning on the electric motor for testing should be as follows:the contractor removes the team from the place of work, draws up the completion of the work and hands over the outfit to the operational personnel;

operating personnel removes the installed grounding, posters, assembles the circuit.

After testing, if it is necessary to continue working on the electric motor, the operating personnel again prepares the workplace and the team, along with it, is again allowed to work on the electric motor.

Work on a rotating electric motor without contact with live and rotating parts can be carried out by order.

Maintenance of the brush set on a running electric motor is allowed by order of an employee trained for this purpose, having group III, subject to the following precautions:

work with the use of face and eye protection, in buttoned overalls, being careful not to be caught by rotating parts of the electric motor;

use dielectric galoshes, carpets;

do not touch with your hands simultaneously live parts of two poles or live and grounding parts.

The rotor rings are allowed to be ground on a rotating electric motor only with the help of pads made of insulating material.

The labor protection instructions of the relevant organizations should detail the requirements for the preparation of the workplace and the organization of safe work on electric motors, taking into account the types of electrical machines used, the features of ballasts, the specifics of mechanisms, technological schemes, etc.

Organizational measures to ensure the safety of work in electrical installations are:

registration of work by order, order or list of work performed in the order of current operation;

admission to work;

supervision during work;

registration of a break in work, transfer to another place, completion of work.

Responsible for the safe conduct of work are:

issuing an order, giving orders, approving a list of works performed in the order of current operation;

responsible work manager;

admitting;

work manager;

watching;

members of the brigade.

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3.11 Technological map of current repair of asynchronous electric motors 6kV PEN.

	Name of operations	NTD (drawings etc.)	Control operations					Note
	Name of operations	NTD (drawings etc.)		Criteria				Note
3.11.1 Disassembly of the electric motor.
	Remove the stator terminal cover, disconnect the power cable and RTD wires, disconnect the ground	OVK.412.106 TO		Clean surface of terminals, Integrity of insulators and thread of studs, tight fit of lugs on cables	hot-smoked 12x13 sandpaper, gasoline, soldering iron	Oxidation of terminal surfaces, cracking of insulators, thread stripping on pins, loss of fastening of lugs on cables	Grind the surface of the terminals, rinse with gasoline, if necessary replace the insulators, solder the tips
	Disconnect and remove diffusers from the ED.	OVK.412.106 TO
	Remove air filter, blow out and dry	OVK.412.106 TO			Blower device, gasoline B-70, g / c 10x12
3.11.2 Revision of the stator.
	Check the fastening (from the outside) of the stator ventilation spacers	OVK.412.106 TO	OK by tapping with a hammer	Uniform, dull sound and no rattling	Hammer 0.2 kg	Loose mount	Weld up defective spacers
	Remove dust, dirt, oil and inspect the stator winding frontal parts	OVK.412.106 TO		Contamination-free, tight banding and spacer fit		Loose bands and struts	Re-band the winding ends, install spacers
3.11.3 Assembling the electric motor.
	Install diffusers on ED.	OVK.412.106 TO
	Install the air filter.	OVK.412.106 TO
	Connect the power cable, RTD wires, connect the ground, close the cover of the stator terminals,	OVK.412.106 TO					Clean the surface of the terminals, rinse with gasoline, replace the insulators if necessary, solder the tips

After assembly, make a control measurement of the motor insulation resistance and absorption coefficient with a 2500V megohmmeter. The insulation resistance must be at least 40 megohms, the absorption coefficient must be at least the value specified in paragraph 1.3.2.

3.12 Technological map of current repair of asynchronous electric motors 6kV TsN.

	Name of operations	NTD (drawings etc.)	Control operations		Fixtures, tools, equipment	Possible defects, malfunctions		Note
	Name of operations	NTD (drawings etc.)		Criteria	Fixtures, tools, equipment	Possible defects, malfunctions		Note
3.12.1 Disassembly of the electric motor.
	Remove the stator terminal cover, disconnect the power cable and RTD wires, disconnect the ground			Clean surface of terminals, Integrity of insulators and thread of studs, tight fit of lugs on cables	hot-smoked, sandpaper, gasoline, soldering iron	Oxidation of terminal surfaces, cracking of insulators, thread stripping on pins, loss of fastening of lugs on cables	Grind the surface of the terminals, rinse with gasoline, if necessary replace the insulators, solder the tips
	Measure the air gap between stator and rotor				Set of test leads		Make a decision to transfer the engine to KR to set the required air gap.
3.12.2 Revision of the stator.
	Clean the ventilation ducts, bores, winding ends, stator housing from dirt and blow out with compressed air				Air blower, lint-free cloth
				Contamination-free, tight banding and spacer fit	Bandage needle, bandage tape		Re-band the winding ends, install spacers
3.12.3 Assembling the electric motor.
	Measure the air gap between stator and rotor			Compliance of the clearances with the requirements (Table 4.1).	Set of test leads	Inconsistency of the air gap with the required values	Make a decision to transfer the engine to KR to set the required air gap.
	Connect the power cable, RTD wires, connect the ground, close the cover of the stator terminals,			Clean surface of terminals, Integrity of insulators and thread of studs, tight fit of lugs on cables	hot-smoked, sandpaper, gasoline, soldering iron	Oxidation of terminal surfaces, cracking of insulators, thread stripping on pins, loss of fastening of lugs on cables	Clean the surface of the terminals, rinse with gasoline, replace the insulators if necessary, solder the tips

a) clean the oil indicators from external contamination;

b) unscrew the damping bolt from the oil gauge, clean the inner cavity of the damping chamber of the oil gauge and the damping bolt from dirt; install a new gasket for the damping bolt head and screw the bolt back. It is allowed, if necessary, to lubricate the sealing gasket of the head of the soothing bolt with a thin layer of oil-resistant sealant KLT-75;

c) check that there is no plaque on the inner surfaces of the glass that impedes the visual control of the oil level, mechanical damage in the form of cracks and chips; clean the "breathing" hole in the upper cover of the oil indicator with a soft wire;

d) blow out the oil indicators with compressed air at a pressure of no more than 2 kg / cm 2 to check the passability of the oil indicator with control by the pressure of the air coming out through the "breathing" hole;

If traces of oil drips through the seals of the oil indicator, deposits on the inner surface of the glass that impede visual inspection of the oil level, foreign particles (residues of sealant, etc.) or other defects are found, the oil indicator is completely disassembled and the defects are eliminated with subsequent assembly. The damping bolt is then screwed into place last, after the glass sealant has hardened. After assembly, the oil indicator is installed on the oil bath with the inspection hole of the low indicator housing in the direction opposite to the electric motor housing, after which the oil indicator is checked again according to item d).

When installing the bottom half of the upper part of the body and connecting bridges between the bottom bars, use a sealant (paint) as a locking measure in the threaded connection of the bars.

3.13 Technological map of the current repair of asynchronous electric motors 6kV (NR).

	Name of operations	NTD (drawings etc.)	Control operations		Fixtures, tools, equipment	Possible defects, malfunctions		Note
	Name of operations	NTD (drawings etc.)		Criteria	Fixtures, tools, equipment	Possible defects, malfunctions		Note
3.13.1 Disassembly of the electric motor.
	Remove the stator terminal cover, disconnect the power cable, ground	IAEG.528122.002 TO		Clean surface of terminals, Integrity of insulators and thread of studs, tight fit of lugs on cables		Oxidation of terminal surfaces, cracking of insulators, thread stripping on pins, loss of fastening of lugs on cables	Grind the surface of the terminals, rinse with gasoline, if necessary replace the insulators, solder the tips
	Remove the shroud and cooler fan	IAEG.528122.002 TO			hot-smoked 14х17, center punch, sledgehammer 3kg, assembly crowbar
	Remove outer bearing caps (flanges)	IAEG.528122.002 TO
3.13.2 Revision of the stator.
	Remove dust, dirt, oil and inspect the stator winding frontal parts	IAEG.528122.002 TO		Contamination-free, tight banding and spacer fit	Bandage needle, bandage tape	Loose bands and struts	Re-band the winding ends, install spacers
3.13.3 Inspection of bearings.
	Remove old grease	IAEG.528122.002 TO			Parts washing bath, gasoline B-70
	Inspect the bearing	IAEG.528122.002 TO		No visible defects		Holes, chipping, wear marks, matt tracks on rolling surfaces, deformation of balls or rollers	Replace bearing	If replacement is necessary, issue a Fault Detection Report
3.13.4 Revision of the cooler.
	Remove dirt and blow dry air from the coolant tubes	IAEG.528122.002 TO			Air blower, lint-free rags, cleaning rod
3.13.5 Assembling the electric motor.
	Install both shields on the motor	IAEG.528122.002 TO			Crane-beam, stands, torque gauge 17x19, center punch, sledgehammer 3kg.
	Install the outer bearing caps	IAEG.528122.002 TO
	Install the cooler fan and shroud.	IAEG.528122.002 TO
	Connect the power cable, ground. Close the cover of the stator terminal box,	IAEG.528122.002 TO		Clean lead surface, integrity of insulators and stud threads, tight fit of cable lugs	hot-smoked 14х17, sandpaper, gasoline, soldering iron	Oxidation of terminal surfaces, cracking of insulators, thread stripping on pins, loss of fastening of lugs on cables	Clean the surface of the terminals, rinse with gasoline, if necessary replace the insulators, solder the tips

3.14 Flow chart of current repair of the backup exciter DAZ-18-10-6 (U3), GSP-2000-1000.

	Name of operations	NTD (drawings etc.)	Control operations		Fixtures, tools, equipment	Possible defects, malfunctions		Note
	Name of operations	NTD (drawings etc.)		Criteria	Fixtures, tools, equipment	Possible defects, malfunctions		Note
3.14.1 Disassembly of the exciter.
	Remove cable covers and disconnect power cables			Clean surface	hot-smoked 17х19, glass paper	Oxidation of leads	Grind the surfaces of the terminals, rinse with gasoline
	Disconnect the cables of the bearing temperature sensors	6BS. 345.030.036		Clean surface	hot-smoked 17х19, glass paper	Oxidation of leads	Grind the surfaces of the terminals, rinse with gasoline
	Disconnect the cables from the generator control panel	1BS. 217.038.039		Clean surface	hot-smoked 17х19, glass paper	Oxidation of leads	Grind the surfaces of the terminals, rinse with gasoline
3.14.2 Inspection of the generator stator.
	Inspect stator leads			Clean tip surface, No tears or cracks in the insulation	Glass paper, fiberglass, electrical tape	Oxidation of tips, damage to insulation	Grinding, tinning of tips, insulating leads
	Tighten threaded connections		VK, test tightening	Tight tightening of threaded connections	Set of wrenches	Loosening of threaded connections	Tighten loose screw connections
3.14.3 Assembling the exciter.
	Connect the cables to the generator control panel	1BS. 217.038.039		Clean surface	hot-smoked set, glass paper	Oxidation of leads
	Connect the cables of the bearing temperature sensors	6BS. 345.030.036		Clean surface	hot-smoked set, glass paper	Oxidation of leads	Clean the surfaces of the terminals, rinse with gasoline
	Install the cable covers and connect the power cables			Clean surface	hot-smoked set, glass paper	Oxidation of leads	Clean the surfaces of the terminals, rinse with gasoline

When replacing a bearing, it must be pressed off the shaft using a screw puller. The new bearing is washed from conservation grease in B-70 gasoline. Heat the bearing in an oil bath or inductor to a temperature of 90 ° C and press it onto the shaft. Bearing installation recommendations are given in Appendix 20. The shaft fits snugly. Then the bearing is filled with grease (LITOL-24, SVEM, TsIATIM-201). After assembly, make a control measurement of the motor insulation resistance and absorption coefficient with a 2500V megohmmeter. The insulation resistance must be at least 40MΩ, the absorption coefficient must be at least the value specified in clause 1.3.2.

I offer an example of a flow chart for the current repair of 0.4 kV asynchronous electric motors with a power of 0.5 - 1.5 kW.

Security measures.

The composition of the brigade.

Electrician for the repair of electrical equipment with at least 3 gr. on electrical safety. Electrician for the repair of electrical equipment with 3 gr. on electrical safety.

Tool.

Spanners 6 - 32 mm - 1 set.

Files - 1 set.

Head set - 1 set.

Metal brush - 1 pc.

Plumber's knife - 1 pc.

Screwdriver set - 1 set.

Bench screwdriver - 1 pc.

Dies 4 - 16 mm - 1 set.

Taps 4 - 16 mm - 1 set.

Drill set 3 - 16 mm - 1 set.

Crowbar - 1 pc.

Pliers - 1 pc.

Chisel - 1 pc.

Drill - 1 pc.

Kern - 1 pc.

Flat brush - 2 pcs.

Hammer - 1 pc.

Shovel - 1 pc.

Broom brush - 1 pc.

Devices, devices, mechanisms, protective equipment.

Microohmmeter - 1 pc.

Megohmmeter 500 V -1 pc.

Micrometric level - 1 pc.

Soldering tool - 1 pc.

A set of probes - 1 set.

Vernier caliper - 1 pc.

Safety helmets - individually.

Voltage indicator (380v).

First aid kit - 1 pc.

Mittens - 2 pairs.

Safety glasses - 2 pcs.

Materials and spare parts.

Solder POS - 0.02 kg

Copper-phosphorus solder - 0.02 kg

Alcohol - 0.05 kg

Sealant - oil resistant gasket - 50 ml

Glass tape - 0.150 kg

Electrical insulating varnish - 0.4 kg

Emery paper - 0.5 m

Cleaning materials - 0.5 kg

PVC tape - 0.05 kg

Rosin - 0.005 kg

Kiper tape - 0.5 m

CIATIM grease - 221 - 0.3 kg

White spirit - 0.3 l

Sequence of operations.

P / p No.	Name and content of works	Equipment and fixtures	Technical requirements
1	External inspection of an electrical machine, including systems control, protection, ventilation and cooling.		Compliance with technical data sheets for operation and electrical circuits.
2	Visual check of the condition of the grounding conductor; checking the condition of the ground loop.	Hammer, shovel	Lack of anti-corrosion coating, loosening of fastening, mechanical damage are not allowed.
3	Check for extraneous noise.		Extraneous noise is not allowed.
4	Cleaning accessible parts from dirt and dust.	White spirit, rags, metal brush, broom brush.
5	Inspection of the elements of the connection between the engine and the driven mechanism.		Cracks at the seams, breaks, distortions, loosening of threaded connections are not allowed.
6	Checking the connection and tightness of the supplied cables, technical condition and tightness of lead-in boxes and sealed bushing couplings; checking the condition of seals, surfaces and parts that ensure explosion protection; explosion proof of cable and wire entries.	A set of locksmith probes No. 1 A set of tools a set of screwdrivers A set of heads.	Roughness of the working surface Rd no more than 1.25 microns.
7	Checking the fastening of the electric drive to the frame (valve).	Set of tools. Set of heads.	Loosening of the fastening is not allowed.
8	Inspection of the state of the start-up control equipment (PRA).
9	Blowing out the stator and rotor with compressed air.	Compressor.
10	Insulation resistance test of windings; drying if necessary.	Megohmmeter with a voltage of 500V.	Insulation resistance should not be less than 0.5 MΩ.
11	Checking the mating of parts that ensure tightness.	A set of locksmith probes No. 1. A set of tools, a set of screwdrivers. Set of heads, sealant.	The clearances are indicated in the instruction manual.
12	Checking the presence of grease in the bearings of the electric motor (if there is a press oiler, replenishment).	CIATIM-221 grease, grease press-in gun.
13	Inspection, cleaning and tightening of contact connections.	Set of tools. Cloth abrasive paper in accordance with GOST 5009-82.	Distortions, the presence of oxide, loosening of contact connections are not allowed.
14	Revision of automatic circuit breaker assemblies.	Set of tools. Screwdriwer set.
15	Checking the presence of cable markings, inscriptions and markings on the casing, restoration if necessary.	Brush, paint (plate).	The absence of markings and inscriptions is not allowed.

Additionally, it is possible to indicate in the table the labor intensity, labor costs, and other necessary information applicable to your conditions.