INITIAL INSPECTION REPORT – MOTOR DIVISION

Date December 22, 2018 Protection Type Ex nA S.O. # MT-00708

Customer K.O.K Tag No. 45-K-201 C
MACHINE DETAILS (AC MOTOR)
Make SCHORCH Gas Group II Sr. No. 44076332/1
Rating 580 KW Category --- RPM 3545
Voltage 4000 V Temperature Class T2 Current 100 A
INSPECTION SUMMARY: As received
1. MOTOR RECEIVED IN ASSEMBLED CONDITION WITH COUPLING HUB. 12. N.D.E TEMPERATURE GAUGE FOUND MISSED.
2. BODY FRAME FOUND DUSTY. 13. D.E EXTERNAL & INTERNAL FLOATING LABYRINTH SEALS FOUND
3. VISUALLY INSPECTED AND PHOTOGRAPHS TAKEN. RUBBING.

4. D.E JOURNAL SEAT, EXT. & INT. SEAL SEATS FOUND SEVERE RUBBING. 14. N.D.E SLEEVE BEARING ID SLIGHT MARKS.
5. D.E BEARING HOUSING ASSEMBLY FOUND BURNT CONDITION. 15. N.D.E EXTERNAL & INTERNAL SEAL SEATS FOUND SLIGHT MARKS.
6. D.E SLEEVE BEARING ID FOUND SEVERE RUBBING & BURNT CONDITION. 16. D.E INTERNAL GUARD SEAL SEATS FOUND RUBBING.
7. N.D.E BEARING HOUSING ASSEMBLY FOUND DIFFERENT UPPER & LOWER 17. D.E PROBE TRACK AREA FOUND DISCOLORATION & SLIGHT
INSULATIONS. MARKS.

8. D.E EXTERNAL DUST SEAL FOUND LIPS ID RUBBING. 18. D.E INTERNAL GUARD SEAL ID FOUND SEVERE RUBBING.
9. D.E PROBE TIPS (2 NOS.) FOUND DAMAGE. 19. N.D.E INTERNAL GUARD SEAL ID FOUND RUBBING MARKS.
10. D.E OIL RING (1 NO.) FOUND OVALITY & RUBBING MARKS. 20. STATOR FEET PADS FOUND SLIGHTLY RUSTY.
11. D.E TEMPERATURE GAUGE SENSOR FOUND MISSED. 21. HARDWARES & GASKETS FOUND NOT OK.

SCOPE OF WORK: As recommended

1. BASIC OVERHAULING OF THE MOTOR.
2. HARD CHROME PLATING:
a. COUPLING SEAT
3. FABRICATING OF THE D.E INTERNAL GUARD SEAL. (AS PER SAMPLE) (OUTSOURCED)
4. BURNISHING OF THE D.E & N.D.E PROBE TRACK AREAS.
5. SKIMMING OF THE N.D.E INTERNAL GUARD SEAL ID.
6. POLISHING: a. N.D.E SLEEVE BEARING ID
b. STATOR FEET PADS
c. N.D.E EXTERNAL & INTERNAL SEAL SEATS
7. DYNAMIC BALANCING OF THE ROTOR.
8. ASSEMBLY, TEST AND PAINT.
NOTE: 1. SINCE D.E SIDE OF THE ROTOR SHAFT HAVING SEVERE DAMAGE. ATS WILL NOT GIVE WARRANTY OF THE ROTOR SHAFT AFTER REPAIRING.
2. ELECTRICAL RUN OUT REPORT NOT PERFORMED DUE TO SEVERE DAMAGE ON THE D.E SIDE ROTOR SHAFT.
3. D.E PROBES TO BE PROVIDED BY CUSTOMER DURING NO LOAD RUN TEST.
4. N.D.E PROBES FOUND OK.

REPLACEMENT PARTS OR SPARES

1. D.E & N.D.E BEARING HOUSINGS ASSEMBLY AS PER SAMPLE
2. D.E SLEEVE BEARING TO BE PROVIDED BY CUSTOMER
3. D.E EXT. & INT. FLOATING LABYRINTH SEALS (ID-100 mm) – 2 SETS
4. D.E DUST SEALS (1 SET)
5. D.E OIL RING (1 NO.)
6. D.E & N.D.E TEMPERATURE GAUGES (2 NOS.)
7. D.E & N.D.E INTERNAL GLAND SEALS
8. GASKETS AS PER SAMPLE
9. HARD WARES
 INITIAL INSPECTION REPORT – MOTOR DIVISION

D.E PROBE TIPS-DAMAGE D.E JOURNAL SEAT, EXT. & INT. SEAL SEAT
(RUBBING)

D.E SLEEVE BRG.

D.E BRG.HSG.ASSY. N.D.E BRG.HSG.ASSY. (BURNT CONDITION & RUBBING ID)
(BURNT CONDITION & INS. (DAMAGE) (DIFFERENT INSULATION)

D.E BAKELITE SEALS-RUBBING

D.E INT.GUARD SEAL ID-DEEP RUBBING D.E EXT.DUST SEAL ID-RUBBING
D.E OIL RING-OVALITY & RUBBING MARKS

ATTACHMENTS
MOTOR EX nA REPAIR FORMS MECHANICAL MEASUREMENTS
INITIAL INCOMING INSPECTION RUN OUT CHECK
ELECTRICAL STATIC REPORTS
Prepared by: Angel Talon Approved by: Ayman Badawy
QC Engineer QC Manager
Accepted/ Witnessed by:
Remarks:
 alfanar Technical Services
ATF-QA-18/REW
Issue/Rev. 01/03
ELECTRICAL STATIC TEST RECORD - AC HT MOTORS Issued 04/03/2014
INITIAL INSPECTION
DATE: 19/12/2018
CLIENT : K.O.K S.O No.: MT-00708
MACHINE DETAILS:
MAKE : SCHORCH,GERMANY RATING : 580 KW SL. NO.: 44076332/1
OP. VOLTAGE: 4000 V FL AMPS : 100 A RPM : 3545
TAG NO. : 45-K-201 C MOUNTING TYPE: HORIZONTAL FREQUENCY: 60 HZ
TEST DETAILS RESULT
0
IR At 2500V DC Amb temp 28 C
Between U-G V-G W-G U-V U-W V-W U.V.W - G OK
IR in GΩ 35.1
WINDING RESISTANCE Amb temp 28 0 C
Phase reference UV VW WU OK
mΩ 385.8 385.7 384.7
SURGE COMPARISON TEST AT APPLIED VOLTAGE 4.00 KV
U-V V-W W-U

OK

POLARIZATION INDEX (PI): Applied Volts 2500 VDC

Time in Min. 1 2 3 4 5 6 7 8 9 10 OK
IR GΩ 35.1 61.0 80.9 100 111 123 141 152 155 168
PI: 4.80
CURRENT BALANCE TEST
Between Phases U-V V-W U-W
Voltage Applied 449 451 449 OK
Current Drawn 25.9 26.2 26.3
RTD RESISTANCE Amb temp
No. 6 Nos. BTD(DE) BTD (NDE) --
Ω 111.0 111.0 111.0 -- OK
SPACE HEATER
IR Value AT 250 VDC Resistance in Applied Voltage - 220 V OK
>2000 MΩ 157 Ω Current Drawn – 1.41 A
VISUAL INSPECTION
GROWLER TEST ROTOR OK Stator Core (Physically) OK
Wedges OK Rotor Core (Physically) OK
Terminal Leads (Stator) OK Number of Rotor Bars 36
Insulators / Terminal Block OK Number of Stator coils 48
Terminal Box OK Accessorie’s connectors --
SHAFT VIBRATION PROBES(4 NOS.) NOT OK
Remarks:
• Static electrical test results are satisfactory
• 2 Nos. shaft vibration probes Tip damaged,Recommends to replace.
• Received 1 no. Temp. Guage with out sensor.
TESTED BY: Datta Jakka Kiran APPROVED BY: Mariappan Nainar
 alfanar Technical Services
ATF-PD-25/REW
Issue/Rev. No 01/03
MECHANICAL MEASUREMENT RECORD Issue date: 3/8/2002
CUSTOMER: K.O.K SERVICE ORDER No.: MT-00708 Date: 19/12/2018
MACHINE DETAILS: Ex nA T2 TAG # 45-K-201 C
MAKE : SCHORCH KW 580 SL No.: 44076332/1
OP. VOLTAGE: 4000 V FL. AMPS.: 100 RPM : 3545
RECORD OF DIMENSIONS/CONDITION: (mm)
AS RECEIVED AS CORRECTED DURING ASSEMBLY
ITEM DE NDE DE NDE
Bearing No.
Bearing ID
FLOAT
Bearing OD NA
BRG
Bearing Seat OD
Bearing Housing ID
Bearing Journal Seat
Severe Damaged 89.865 (Slight marks)
OD
Bearing Journal ID 90.03
Severe Damage (Scouring & Slight marks)
SLEEVE
BRG Bearing Shaft Clearance
ND 0.16
[LEAD WIRE METHOD]
Brg. Housing Clearance ND 0.05
Bearing Thrust collar --- ---
100.06
Seal Ext. ID Severe rubbing (Slight marks)
99.93/99.95
Seal Seat Ext. OD (Rubbing) 99.93 (Slight marks)
Seal Int. ID Severe rubbing 100.09 (Slight marks)
Seal Seat Int. OD 99.93 (Rubbing) 99.935 (Slight marks)
Coupling Hub ID 90.03 (W/ Grub screw)
NA
Coupling Seat OD 90.03
Fan ID 91.03
NA
Fan Seat OD 91.02
Key Way Width 25.00 25.00
Key Way Height 14.00 9.00
Key Way Length 150.00 162.00
Key Width 25.00 22.00
Key Height 14.00 14.00
Key Length 150.00 40.00
Fan Cover NA OK
Circlips (Ext./Int.) NA NA
Locknut NA NA
Lock washer NA NA
Fan (Ext./Int.) OK (Int.) OK (Ext. & Int.)
Seals (Bakelite) OK–2 Sets Damage-2 Sets
V-Ring VS/VA NA NA
Total motor end float – 12.80 mm
AIR GAPS
VIEW FROM DE VIEW FROM NDE
As Recd. As Cor. A A As Recd. As Cor.
A 3.45 A 3.45
B 3.40 B 3.40
C 3.45 D B D B C 3.45
D 3.40 C C D 3.40
BEARING TYPE & ALIGNMENT SEQUENCE
BEARING MOUNTING ------ N/A
BEARING TYPE
DE NDE
Sleeve Bearings DF: DB: NORMAL: DF: DB: NORMAL:
Remarks:
RECORDED BY: Noel INSPECTED BY: Angel Talon APPROVED BY: Leji Alex
DATE: 19/12/2018 DATE: 19/12/2018 DATE: 19/12/2018
 alfanar Technical Services
ATF-PD -26/REW
Issue/Rev. No 01/03
RUN OUT CHECK RECORD – ROTOR Issue date: 3/8/2002
CUSTOMER: K.O.K SERVICE ORDER No.: MT-00708 Date: 19/12/2018
MACHINE DETAILS: Ex nA T2 TAG # 45-K-201 C
MAKE : SCHORCH KW 580 SL No.: 44076332/1
OP. VOLTAGE: 4000 V FL. AMPS.: 100 RPM : 3545
NOTE:
1. “Mike” all the measuring areas for ovality and/or taper prior to check run outs.
2. Object to be kept on V – Blocks on bearing seats.
3. Readings to be taken3/4 times for reference comparison
4. Refer attached sketch for readings obtained.
5. All measurements are in mm

00 900 1800 2700

LOCATION
Fan 0.000 ----- ----- -----
Fan Seat Ext. 0.000 0.000 -0.02 -0.01
Probe Track Area
0.000 0.000 0.000 0.005
Seal Area Ext. 0.000 0.000 0.000 0.005
Journal Seat 0.000 0.000 0.000 0.000
Bearing
0.000 ----- ----- -----
Shoulder(Axial)
Seal Area Int. 0.000 0.000 0.005 0.000
Rotor Core 0.000 ----- ----- -----

LOCATION 00 900 1800 2700

Rotor Core 0.000 ----- ----- -----
Int. Guard Seal Seat
0.000 0.000 0.01 0.005
Δ
Seal Area Int. 0.000 RUBBING
Bearing
0.000 ----- ----- -----
Shoulder(Axial)
Journal Seat
0.000 RUBBING
Seal Area Ext. 0.000 -0.02 0.04 0.06
Probe Track Area 0.000 RUBBING MARKS
Coupling Seat 0.000 - 0.05 - 0.2 - 0.10
Coupling Face(Axial) 0.000 ----- ----- -----
REMARKS: ٠ALL RUN - OUT READINGS FOUND WITHIN THE ACCEPTABLE LIMIT ON THE D.E SIDE HAVING RUBBING & HIGH RUN OUT.
RECORDED BY: Noel VERIFIED BY: Angel Talon APPROVED BY: Leji Alex
DATE: 19/12/2018 DATE: 19/12/2018 DATE: 19/12/2018