OVERVIEW OF THE
ELECTRIC REPAIR
SHOP
• K. Madhu Arya • D. Pavan Kumar
• J. Pavan Kalyan • B. Harshith
• B. Tapan Kumar • K. Manikyam Mani
• P. Keerthi
• S. Deepika
• G. Neelaveni
The Sections at ERS
• Planning
• Small Motor Division
• Assembling/Dismantling
• Pre- Rewinding Activities
• Rewinding Section
• Varnishing Section
• Machine and Magnet Section
• Testing Section
Planning Section
• The motors used in the Vizag Steel
Plant which are complained to be
working improperly or facing faults,
then they are brought to the Electric
Repair Shop (ERS).
• The data regarding the name plate
details, working conditions and
information about the parts of the
motor is tabulated and is further sent to
the Assembling and Dismantling
Section.
Small Motor Division
• The motors that are less than 15KW
rating are sent to this division where
they are dismantled and faults are
determined (whether electrical or
mechanical) and then are sent to the
PRA and later to Rewinding sections.
• SMD is very similar to Assembling
and Dismantling if not for the
difference in the ratings of motors
that are worked on.
Assembling/ Dismantling
Section
• The motors along with the data is
sent to this section where there is a
team of engineers who dismantle
the faulty motors after classifying it
with Non-Drive and Drive ends.
• After Dismantling, the FDR (First
Dismantling Report) is tabulated
based on the motor parts and then
the fault is identified to be
electrical (windings) using a
Megger or mechanical (bearings).
Pre Rewinding Activities Section
(PRA)
• If in case the fault is identified to be
about the windings i.e short circuited,
then the stator/field or rotor/armature is
sent to the PRA.
• The windings are cut and removed from
the core and placed separately to
determine various parameters, such as:
slots, conductors, coil series, poles, type
of connection etc.
• This data is filled in a ‘Data Sheet’ and
the empty core is sent to the Rewinding
Section.
Rewinding Section
There are two works that
need to be done before
inserting new windings
into the core slots. They
are:
1. Coil making
2. Insulation making
1. Coil Making
• Based on the Data Sheet that is
received, a Super Enameled
Copper(SEC) conductor coil of
required SWG is taken.
• The coil making is mainly done using
the machine that is shown in the fig.
• Depending on the coil pitch, the
machine is adjusted and the wheel is
rotated to form the rectangular shaped
coils with required number of turns and
coil series.
• Three sets are done for three phase
motors and kept aside until the
insulation is done.
2. Insulation Making
• As much as the conductors are insulated
by enamel, it is still important that the
stator/rotor core slots needs to be
insulated. For that purpose, we mainly
used these materials.
1. Nomex (H class Insulation paper)
2. Mililex (B class Insulation sheet)
3. Wedge (Textilide Material)
4. Sleeve ( Vinyl cloth)
5. Tapes
1. PVC Tape
2. Mica Tape
3. Terlin Tape
• After the coils and insulation
materials are made ae as fit for the
stator/rotor core, each slot is filled
with a layer of nomex and on it, the
windings are mounted.
• The milinex is placed on the windings
and wedges are placed on milinex.
Therefore, the slots of the core are
mounted with coils as per data sheet.
• Now that the windings is finished, the
ends of the coils are brought out and
series joints and line joints are made
and connected to the line terminals.
• After the Rewinding is successfully
finished, the stator/rotor is sent to
the Vanishing Section.
Varnishing Section
• After the windings are finished, it is
mandatory that the motor to be
insulated overall.
• Hence, the motor is sent to the
Varnishing Section.
• The Varnish is a resin like liquid material
used as insulation to avoid chances of
conduction between conductor to
conductor and conductor to core.
• The Varnish is sprayed all over the
inside of the core, covering the entire
apparatus of slots, coils and insulation.
OVENS
ENAMEL
COATIN
G
Testing Section
• After the Varnishing is done,
the stator/rotor is taken to this
section to run test to find out
whether the present values
matches with original values or
not.
• Mainly, 3 tests are conducted.
1. Primary Test
. Only surge test is conducted
on the motor. This is to find out
the characteristics of the motor
during surge conditions.
2. Intermediate Test
In this test, we will being determining
two values. They are
• We measure the Insulation Resistance(Ir)
by using the megger between the
terminals, terminals to body and body to
body. If the measure Ir is as we require
them it is sent for the next test.
• Now we Measure the Resistance value of
the Stator/Rotor.
If the machine has passed all of the above
tests, then it will be eligible for the Final
Test. If not, then it is sent back to
Rewinding section for rectification of the
problem.
3. Final Test
• After the Intermediate test is
finished, the motor is sent forward for
the Final test where the voltage (V)
and current (I) values are measured
and checked.
• Now that the values are perfectly
matched with the desired values the
motor is labelled as “Tested OK” and
carried to the Assembling Section
where the motor is assembled to its
original form without causing any
damage in the process.
Magnet and Machine Section
• Here the motors that are
received are of very high
ratings or heavy rating motors
that are powered by
permanent magnets or high
ratings copper strips
• Here the magnets are
replaced by new permanent
magnets and tested before
being dispatched.
Dispatch
• After the successfully tested
motor has been neatly
assembled, the motor is then
sent to the Dispatch area
• Here, the motor is loaded into
a truck and sent back to
where it was received.
• The job is now considered
finished.
