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CHANCADOR TRAYLOR

MANUAL DE INSTALACION, OPERACION Y MANTENIMIENTO

MANUAL DE INSTALACION,
OPERACION Y MANTENIMIENTO DE
1525mm x 2870mm (60x113)
TIPO NT
CHANCADOR GIRATORIO TRAYLOR
VOLUMEN 3 of 3 (ELECTRICIDAD)
SOCIEDAD MINERA
CLIENTE:
CERRO VERDE S.A.A.
UBICACION PLANTA : AREQUIPA, PERU
ORDEN DE COMPRA NO.: A1WF-59-001-PO
FFEM CONTRATO NO.: 04-31645-720
EQUIPO NO.: C-3110-CR-001
COPYRIGHT FFE Minerals USA Inc. 2004

COVER PAGE - VOLUME 3


Manual Volume 3 Manual Section Preface ai Contract No. 04-31645-720
Prep. by SRH Date 11/21/2005 FFEM DWG. No. 5.401478
App by MDS Date 11/21/2005 Rev. 0 Page 1 of 1
CHANCADOR TRAYLOR
MANUAL DE INSTALACION, OPERACION Y MANTENIMIENTO

FFE MINERALS USA., INC.


HOJA DE REGISTRO DE DISTRIBUCION y REVISION
PARA
1525 X 2870 (60x113) TIPO NT
CHANCADOR GIRATORIO TRAYLOR
MANUAL DE INSTALACION,
OPERACION Y MANTENIMIENTO
CLIENTE: SOCIEDAD MINERA
CERRO VERDE S.A.A.

Volumen COMENTARIOS REV. POR FECHA


Manual No. TRANSMISION
3 MANUAL - CERTIFICADO 0 S.R. HARRIS 12/22/2005
3 MANUAL ELECTRONICO - CERTIFICADO 0 S.R. HARRIS 12/22/2005

Distribucion: Cliente : 6 Copias & 3 Copias Electronica


FFEM Ingeniera CHQ : 1 Copias & 3 Copias Electronica
FFEM Chile : 3 Copias & 3 Copias Electronica

DISTRIBUTION AND REVISION RECORD


Manual Volume 3 Manual Section Preface aii Contract No. 04-31645-720
Prep. by SRH Date 11/21/2005 FFEM DWG. No. 5.401479
App. by MDS Date 12/12/2005 Rev 1 Page 1 of 1
CHANCADOR TRAYLOR
MANUAL DE INSTALACION, OPERACION Y MANTENIMIENTO

RENUNCIA

El presente manual es un servicio de FFE Minerals U.S.A. Inc. A pesar de


nuestros mejores esfuerzos, cierta informacin en este manual puede quedar
obsoleta con l. FFE Minerals U.S.A. Inc. no acepta responsabilidad por la
exactitud, la integridad o el uso de, ni ninguna otra responsabilidad en la puesta
al da de la informacin contenida en el presente manual. Estos materiales se
entregan TAL COMO SON, SIN GARANTA DE NINGN TIPO, NI EXPRESA
NI IMPLCITA, INCLUYENDO, AUNQUE NO LIMITADO A, LAS GARANTAS
INVOLUCRADAS RELATIVAS AL COMERCIO, OPORTUNIDAD PARA UN
PROPSITO PARTICULAR O DE NO TRANSGRESIN, UD. ASUME LA
COMPLETA RESPONSABILIDAD Y RIESGO POR EL USO DE ESTE
MATERIAL. Algunas jurisdicciones no permiten la exclusin de las garantas
implicadas, por lo que las exclusiones establecidas anteriormente, podran no
aplicarse a Ud.

FFE MINERALS U.S.A. INC., SUS AGENTES, REPRESENTANTES Y


EMPLEADOS, NO SON RESPONSABLES NI IMPUTABLES POR CUALQUIER
DAO DIRECTO, INDIRECTO, INCIDENTAL, CONSECUENCIAL, ESPECIAL,
EJEMPLAR, PUNITIVO U OTROS, QUE SURGIERAN DE O SE RELACIONEN
DE ALGUNA MANERA CON EL PRESENTE MANUAL Y/O SU CONTENIDO,
TRADUCCIN, NI LA INFORMACIN DENTRO DEL MANUAL. SU NICO
ACTO DE INSATISFACCIN RESPECTO DE ESTE MANUAL ES DEJAR DE
UTILIZARLO.

Todos los contenidos dentro de este manual, incluyendo, aunque no limitado a,


su texto, logos e imgenes, son de propiedad de FFE Minerals U.S.A. Inc.
Ninguna porcin de los materiales de estas pginas puede ser reimpreso o
republicado de ninguna forma sin la expresa autorizacin por escrito de FFE
Minerals U.S.A. Inc.

AL USAR ESTE MANUAL UD RECONOCE HABER LEIDO, COMPRENDIDO Y


EST DE ACUERDO CON LOS TRMINOS PARA SU USO.

DISCLAIMER
Manual Volume all Manual Section preface Contract ALL
Orig. by J. Anthony Date 1/22/2003 FFEM DWG. No. 7.500267
Rev. by M. Solomon Date 5/14/2004 Rev. 1 Page 1 of 1
CHANCADOR TRAYLOR
MANUAL DE INSTALACION, OPERACION Y MANTENIMIENTO

SEGURIDA

SE ESTABLECEN EN EL PRESENTE MANUAL REGLAS


BSICAS RELATIVAS A LA SEGURIDAD DENTRO Y
CERCA DE UNA PLANTA CHANCADORA EN LA SECCIN
1.2, PROCEDIMIENTO DE TRABAJO SEGURO.
LA SEGURIDAD DE UN OPERADOR Y LA DE LOS DEMS
DEPENDE DEL CUIDADO Y JUICIO RAZONABLES EN LA
OPERACIN DE ESTE CHANCADOR. UN OPERADOR CUIDADOSO
ES UN BUEN SEGURO CONTRA ACCIDENTES.
LA MAYORA DE LOS ACCIDENTES, SIN IMPORTAR
DONDE OCURREN, SON CAUSADOS POR FALLAS AL
OBSERVAR Y RESPETAR REGLAS O PRECAUCIONES
SIMPLES Y FUNDAMENTALES. POR TAL RAZN, LA
MAYORA DE LOS ACCIDENTES PUEDEN PREVENIRSE
RECONOCIENDO PELIGROS Y SIGUIENDO PASOS PARA
EVITARLOS ANTES QUE OCURRA UN ACCIDENTE.
SIN DESMEDRO DEL CUIDADO QUE SE HA TENIDO EN
EL DISEO Y CONSTRUCCIN DE ESTE TIPO DE
EQUIPOS, EXISTEN CONDICIONES QUE NO PUEDEN SER
COMPLETAMENTE SALVAGUARDADAS, SIN INTERFERIR
CON UN ACCESO RAZONABLE Y UNA OPERACIN
EFICIENTE. SE INCLUYEN ADVERTENCIAS EN EL
PRESENTE MANUAL DE INSTRUCCIONES PARA
RESALTAR DICHAS CONDICIONES.

SAFETY STATEMENT
Manual Volume all Manual Section prefac Contract ALL
Orig. by J. Anthony Date 1/22/2003 FFEM DWG. No. 7.500268
Rev. by M. Solomon Date 5/14/2004 Rev. 1 Page 1 of 1
TRAYLOR CRUSHER
CHANCADOR TRAYLOR
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
MANUAL DE INSTALACION, OPERACION Y MANTENIMIENTO

A Spanish translation of this Installation, Maintenance and


Operation manual has been provided. The Spanish translation was
prepared by an outside service. FFE Minerals USA, Inc. cannot
guarantee or warrant the accuracy of the translation, and therefore
the English version of this manual shall be the official manual for all
purposes.

In the event of any inconsistency or conflict between the English and


Spanish version, or in the event that the Spanish version omits or
fails to accurately state in Spanish what is stated in English, the
English version shall prevail.

*******************************************************

Se ha hecho llegar una versin en Espaol para el Manual de


Instalatcin, Mantencin y Operacin. Esta versin fue realizada
por servicios externos a nuestra compaia. Aunque fue FFE
Minerals USA, Inc. No se hace responsable ni garantiza su exacto
traduccin, este manual se considerar como el documanto oficial
para cualquier propsito.

En la eventualidad de existir alguna disconformidad o mala


interpretacin de la traduccin Ingls al Espaol, o que su versin
omita o no corresponda con lo indicado en Ingls, prevalecer e
trmino en Ingls

TRANSLATION WARNING
Manual Volume all Manual Section prefac Contract ALL
Orig. by SRH Date 08/19/2004 FFEM DWG. No. 7.500433
Rev. by MDS Date 08/19/2004 Rev. 0 Page 1 of 1
CHANCADOR TRAYLOR
MANUAL DE INSTALACION, OPERACION Y MANTENIMIENTO

INFORMACION ACERCA ESTE MANUAL

ESTE MANUAL CONSTA DE 3 VOLUMENES.

CADA VOLUMEN CONTIENE ESTA DESCRIPCIN & UNA TABLA


DE CONTENIDOS DEL VOLUMEN.

EL CONTENIDO DE LOS VOLUMENES ES:

VOLUMEN 1: INSTRUCCIONES DE INSTALACIN, OPERACIN


& MANTENCIN MECANICAS & PLANOS FFEM
MECANICOS

VOLUMEN 2: PLANOS E INSTRUCCIONES DE


SUMINISTRADORES

VOLUMEN 3: ELECTRICIDAD

ABOUT THIS MANUAL


Manual Volume all Manual Section preface Contract 04-31645-720
No.
Prep. by SRH Date 11/21/2005 FFEM DWG. No. 5.401468
App by MDS Date 11/21/2005 Rev. No. 0 Page 1 of 1
CHANCADOR TRAYLOR
MANUAL DE INSTALACION, OPERACION Y MANTENCION
TABLA DE CONTENIDOS
VOLUMEN 3
SECCION TITULO Plano No. Rev
(o pgina No.)

ai Cubierta 5.401478 0
aii Registro de Distribucin y Revisin 5.401479 0
aiii Exencin de Responsabilidad 7.500267 1
aiv Declaracin de Seguridad 7.500268 1
av Algunos datos sobre este manual 7.500433 0
avi Acerca de este Manual 7.500468 0
INDICE TABLA DE CONTENIDOS 5.401480 0
1 DIATRAMAS DE CONTROL & INSTRUMENTOS
1 Hoja con texto 1 8.500980-1 0
2 Hoja con texto 2 8.500980-2 0
3 Hoja con texto 3 8.500980-3 0

4 Aspectos Generales del Chancador 8.500980-4 3


Sistema Hidrulico de Lubricacin con Aceite del
5 8.500980-5 3
Chancador
Sistema de Lubricacin del Buje de la Araa del
6 8.500980-6 3
Chancador
Patn de Lubricacin del Sistema de Lubricacin
7 8.500980-7 3
con Aceite del Chancador
2 LISTA DE CARGA ELECTRICA 8.500983 2
3 LISTADO DE INSTRUMENTOS DE TERRENO 8.500981 2
4 LISTADO I/O (ENTRADA/SALIDA) 8.500982 2
5 ESPECIFICACION FUNCIONAL 8.500985 1
6 MOTOR DE ACCIONAMIENTO DEL CHANCADOR

TABLA DE CONTENIDOS
Vol. Manual 3 Seccin INDICE Contrato No. 04-31645-720

Prep. por SRH Fecha 12/12/2005 PLANO FFEM No. 5.401480


Aprobado por MDS Fecha 12/12/2005 Rev. 0 Pag. 1 de 2
CHANCADOR TRAYLOR
MANUAL DE INSTALACION, OPERACION Y MANTENCION
1 Plano General del Motor 6.506964 2
2 Placa-marca 6.506948 2
3 Caja Terminal Principal 6.506949 1
4 Caja Terminal Calentador de Espacio 6.506950 2
5 Caja Terminal RTD del Estator 6.506951 1
6 Plano del Eje 6.506952 1
7 Curva Caracterstica de Arranque 6.506991 0
8 Curva Trmica 6.506992 0
9 Especificaciones del Motor 6.506997 0
10 Manual de Instalacin y Mantencin - Ingles EME000077-D

11 Manual de Instalacin y Mantencin Espaol EME300051-a

TABLA DE CONTENIDOS
Vol. Manual 3 Seccin INDICE Contrato No. 04-31645-720

Prep. por SRH Fecha 12/12/2005 PLANO FFEM No. 5.401480


Aprobado por MDS Fecha 12/12/2005 Rev. 0 Pag. 2 de 2
I/O SIGNAL LIST
CRUSHER
CERRO VERDE PROJECT

PERU, S. AMERICA
CONTRACT NO. 04-31645-720

FFE MINERALS USA INC.


A MEMBER OF THE F.L. SMIDTH-FULLER ENGINEERING GROUP
3235 SCHOENERSVILLE ROAD
P.O. BOX 810
BETHLEHEM, PA 18016-0810
TEL. 610-264-6900
FAX. 610-264-6996

Revision 30 JULY 05 JYY JYY MDS


Original 30 JULY 05 JYY JYY MDS
Scale: Sign. Sign. Sign
Date
NONE Drawn Chkd. Appr.

I/O SIGNAL LIST


CRUSHER
CERRO VERDE PROJECT
PERU, S. AMERICA

The information transmitted by this document is proprietary and

No.: 8.500982 2
confidential property of FFE MINERALS and may not be duplicated
FFE MINERALS USA INC.
disclosed or utilized without written consent from FFE MINERALS.
DOCUMENT NO. 8.500982

INPUT/OUTPUT SIGNAL LIST REV. 2


CRUSHER 30 JULY 05
CERRO VERDE PROJECT
PERU, S. AMERICA

R C&ID I/O DESCRIPTION SIGNAL RANGE

E SOURCE 8.500980 I/O TYPE @ SIGNAL ENGR.


V TAG NUMBER SHEET NO. DEVICE AI AO DI DO EQUIPMENT OR SYSTEM SUBSYSTEM MEASURED VARIABLE STATE STATUS UNITS MIN. MAX. COMMENTS
31 TE-0140A 4 ELEMENT RTD PT100 1 CRUSHER COUNTERSHAFT INBOARD BEARING TEMPERATURE
31 TE-0140B 4 ELEMENT RTD PT100 1 CRUSHER COUNTERSHAFT OUTBOARD BEARING TEMPERATURE
31 HS-6507A 4 PUSH BUTTON 1 CRUSHER HYDRAULIC MANTLE PUSH BUTTON RAISE
31 HS-6507B 4 PUSH BUTTON 1 CRUSHER HYDRAULIC MANTLE PUSH BUTTON LOWER
31 ZE-0118 4 POSITION SENSING ELEMENT 1 CRUSHER HYDRAULIC MANTLE POSITION
31 ZIT-0118 4 INDICATING TRANSMITTER CRUSHER HYDRAULIC MANTLE POSITION 4 WIRE TRANSMITTER
31 ZY-0118 4 CONVERTER CRUSHER HYDRAULIC MANTLE POSITION
31 FISL-0141 4 INDICATING SWITCH 1 CRUSHER LUBRICATION INNER ECCENTRIC SUPPLY LINE OIL FLOW LOW
31 FISL-0142 4 INDICATING SWITCH 1 CRUSHER LUBRICATION OUTER ECCENTRIC SUPPLY LINE OIL FLOW LOW
31 FISL-0143 4 INDICATING SWITCH 1 CRUSHER LUBRICATION COUNTERSHAFT SUPPLY LINE OIL FLOW LOW
31 TE-0111A 4 ELEMENT RTD PT100 1 CRUSHER MOTOR BEARING TEMPERATURE HARDWIRED TO MOTOR PROTECTION RELAY
31 TE-0111B 4 ELEMENT RTD PT100 1 CRUSHER MOTOR BEARING TEMPERATURE HARDWIRED TO MOTOR PROTECTION RELAY
31 TE-0112A 4 ELEMENT RTD PT100 1 CRUSHER MOTOR WINDING TEMPERATURE HARDWIRED TO MOTOR PROTECTION RELAY
31 TE-0112B 4 ELEMENT RTD PT100 1 CRUSHER MOTOR WINDING TEMPERATURE HARDWIRED TO MOTOR PROTECTION RELAY
31 TE-0112C 4 ELEMENT RTD PT100 1 CRUSHER MOTOR WINDING TEMPERATURE HARDWIRED TO MOTOR PROTECTION RELAY
31 TE-0112D 4 ELEMENT RTD PT100 1 CRUSHER MOTOR WINDING TEMPERATURE HARDWIRED TO MOTOR PROTECTION RELAY
31 TE-0112E 4 ELEMENT RTD PT100 1 CRUSHER MOTOR WINDING TEMPERATURE HARDWIRED TO MOTOR PROTECTION RELAY
31 TE-0112F 4 ELEMENT RTD PT100 1 CRUSHER MOTOR WINDING TEMPERATURE HARDWIRED TO MOTOR PROTECTION RELAY
31 XY-6507A 5 SOLENOID VALVE 1 CRUSHER HYDRAULIC OIL DIRECTION VALVE MANTLE RAISE COMMAND
31 XY-6507B 5 SOLENOID VALVE 1 CRUSHER HYDRAULIC OIL DIRECTION VALVE MANTLE LOWER COMMAND
31 HS-6505A 5 PUSH BUTTON 1 CRUSHER HYDRAULIC MAIN OIL PUMP PUSH BUTTON START

31 HS-6505B 5 PUSH BUTTON 1 CRUSHER HYDRAULIC MAIN OIL PUMP PUSH BUTTON STOP

31 HS-6510A 5 PUSH BUTTON 1 CRUSHER HYDRAULIC STANDBY OIL PUMP PUSH BUTTON START

31 HS-6510B 5 PUSH BUTTON 1 CRUSHER HYDRAULIC STANDBY OIL PUMP PUSH BUTTON STOP

31 LSL-6511 5 SWITCH 1 CRUSHER HYDRAULIC RESERVOIR OIL LEVEL LOW

31 LSLL-6511 5 SWITCH 1 CRUSHER HYDRAULIC RESERVOIR OIL LEVEL LOW-LOW

31 PDSH-6506 5 DIFF PRESS SWITCH 1 CRUSHER HYDRAULIC OIL FILTER DIFFERENTIAL PRESSURE HIGH

31 YS-6601 6 RELAY OUTPUT 1 SPIDER LUBRICATION LOCAL CONTROLLER REMOTE RUN COMMAND
31 FQS-6603 6 CYCLE SWITCH SPIDER LUBRICATION SUPPLY LINE GREASE FLOW FIELD SWITCH WIRED TO CONTROLLER
31 XA-6602 6 RELAY 1 SPIDER LUBRICATION LOCAL CONTROLLER SYSTEM FAULT
31 HS-6705A 7 PUSH BUTTON 1 CRUSHER LUBRICATION MAIN OIL PUMP PUSH BUTTON START
31 HS-6705B 7 PUSH BUTTON 1 CRUSHER LUBRICATION MAIN OIL PUMP PUSH BUTTON STOP
31 HS-6710A 7 PUSH BUTTON 1 CRUSHER LUBRICATION STANDBY OIL PUMP PUSH BUTTON START
31 HS-6710B 7 PUSH BUTTON 1 CRUSHER LUBRICATION STANDBY OIL PUMP PUSH BUTTON STOP
31 LSL-6721 7 SWITCH 1 CRUSHER LUBRICATION RESERVOIR OIL LEVEL LOW

31 LSLL-6721 7 SWITCH 1 CRUSHER LUBRICATION RESERVOIR OIL LEVEL LOW-LOW

31 PDSH-6719 7 SWITCH 1 CRUSHER LUBRICATION OIL SUPPLY FILTER DIFFERENTIAL PRESSURE HIGH
31 TE-6718 7 ELEMENT RTD PT100 1 CRUSHER LUBRICATION LUBE OIL COOLER OUTLET OIL TEMPERATURE
31 TE-6722 7 ELEMENT RTD PT100 1 CRUSHER LUBRICATION RETURN OIL LINE OIL TEMPERATURE CONTROL HEATERS
31 TE-6723 7 ELEMENT RTD PT100 1 CRUSHER LUBRICATION RESERVOIR OIL TEMPERATURE
31 ZSC-6716 7 CLOSED LIMIT SWITCH 1 CRUSHER LUBRICATION OIL COOLER DRAIN DRAIN VALVE CLOSED
31 ZSC-6717 7 CLOSED LIMIT SWITCH 1 CRUSHER LUBRICATION LUBE OIL FILTER DRAIN VALVE CLOSED
31 ZSO-6716 7 OPEN LIMIT SWITCH 1 CRUSHER LUBRICATION OIL COOLER DRAIN DRAIN VALVE OPEN

8500982B.xls PAGE 2 PRINT DATE: 8/1/2005


DOCUMENT NO. 8.500982

INPUT/OUTPUT SIGNAL LIST REV. 2


CRUSHER 30 JULY 05
CERRO VERDE PROJECT
PERU, S. AMERICA

R C&ID I/O DESCRIPTION SIGNAL RANGE

E SOURCE 8.500980 I/O TYPE @ SIGNAL ENGR.


V TAG NUMBER SHEET NO. DEVICE AI AO DI DO EQUIPMENT OR SYSTEM SUBSYSTEM MEASURED VARIABLE STATE STATUS UNITS MIN. MAX. COMMENTS
31 ZSO-6717 7 OPEN LIMIT SWITCH 1 CRUSHER LUBRICATION LUBE OIL FILTER DRAIN VALVE OPEN
NOTE 1 MOTOR CONTROL IO NOT INCLUDED
NOTE 2 IO FOR LOCAL PB STATION
BY OTHERS NOT INCLUDED

8500982B.xls PAGE 3 PRINT DATE: 8/1/2005


Functional Specification
for Electrical Control of a
Gyratory Crusher

Prepared for:

CERRO VERDE PROJECT


Gyratory Crusher
PERU, S. AMERICA

FFE Minerals Contract No. 04-31645-720


Prepared by:

FFE Minerals USA Inc.


3235 Schoenersville Road
Bethlehem, PA 18017-2103
USA
Tel. (610) 264-6900

Rev. Date Designed Checked Approved Description


:

01 16SEP05 JYY JYY MDS REVISED PER CUSTOMER COMMENTS


00 30JULY05 JYY JYY MDS

FFE Minerals Document No. 8.500985


FILENAME: 8500985.doc
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

Table of Contents
1 About This Document ................................................................................... 4
Equipment ....................................................................................................... 4
Normal Startup Sequence ............................................................................... 4
Normal Operation............................................................................................ 4
Normal Shutdown Sequence........................................................................... 5
Abnormal and Emergency Shutdowns ............................................................ 5
HMI Control Summary..................................................................................... 5
Alarms ............................................................................................................. 5
Interlocks......................................................................................................... 6

2 Overview ........................................................................................................ 8
A. Function Groups ........................................................................................ 8
B. System Startup Sequence ......................................................................... 8
C. System Shutdown Sequence..................................................................... 8
D. Equipment/Device Descriptions ................................................................. 9
E. Equipment/Device Parameter Descriptions ............................................. 13
F. Reference Documents ............................................................................. 15

3 Crusher Lubrication Group ........................................................................ 16


A. Equipment................................................................................................ 16
B. Normal Startup Sequence........................................................................ 19
C. Normal Operation .................................................................................... 20
D. Normal Shutdown Sequence ................................................................... 20
E. Abnormal and Emergency Shutdowns..................................................... 20
F. HMI Control Summary ............................................................................. 21
G. Alarms...................................................................................................... 22
H. Interlocks ................................................................................................. 23

4 Crusher Hydraulic Adjustment Group....................................................... 26


A. Equipment................................................................................................ 26
B. Normal Startup Sequence........................................................................ 29
C. Normal Operation .................................................................................... 29
D. Normal Shutdown Sequence ................................................................... 30
E. Abnormal and Emergency Shutdowns..................................................... 30
F. HMI Control Summary ............................................................................. 30
G. Alarms...................................................................................................... 31
H. Interlocks ................................................................................................. 32

5 Crusher Spider Bushing Lubrication Group............................................. 33


A. Equipment................................................................................................ 33
B. Normal Startup Sequence........................................................................ 34
C. Normal Operation .................................................................................... 35

Page 2
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

D. Normal Shutdown Sequence ................................................................... 35


E. Abnormal and Emergency Shutdowns..................................................... 35
F. HMI Control Summary ............................................................................. 36
G. Alarms...................................................................................................... 36
H. Interlocks ................................................................................................. 36

6 Crusher Dust Seal Air Group ..................................................................... 37


A. Equipment................................................................................................ 37
B. Normal Startup Sequence........................................................................ 37
C. Normal Operation .................................................................................... 37
D. Normal Shutdown Sequence ................................................................... 38
E. Abnormal and Emergency Shutdowns..................................................... 38
F. HMI Control Summary ............................................................................. 38
G. Alarms...................................................................................................... 39
H. Interlocks ................................................................................................. 39

7 Crusher Main Drive Motor .......................................................................... 40


A. Equipment................................................................................................ 40
B. Normal Startup Sequence........................................................................ 42
C. Normal Operation .................................................................................... 43
D. Normal Shutdown Sequence ................................................................... 43
E. Abnormal and Emergency Shutdowns..................................................... 43
F. HMI Control Summary ............................................................................. 44
G. Alarms...................................................................................................... 45
H. Interlocks ................................................................................................. 46

Page 3
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

1 About This Document


The purpose of this functional specification is to describe the system control phi-
losophy in a user-friendly, yet practical approach. It is intended to provide guid-
ance to the control system programmers and to plant operators. With this in
mind, this document provides the following major headings for each function
group:

Equipment
This section lists and describes the equipment included in each function group,
including a description of the auxiliary devices associated with the equipment.
Equipment and devices will be identified by their descriptive name, which can be
used to cross-reference the corresponding tag numbers, listed in the Equip-
ment/Device Descriptions section (Section D of Chapter 2), for use with other
FFE Minerals documents.

Normal Startup Sequence


This section describes the function groups startup sequence. If the group has
an automatic start sequence, time delays between equipment will also be listed
(if required). Any group preconditions required prior to startup are also listed
herein. However, interlocks required for individual or predefined groups of
equipment are listed in the Interlocks section (Section H of the same chapter).

Normal Operation
This section describes the function groups normal operation, including operator
functions (if any). There are three modes of operation, as described below:

Operation Auto: Operation Auto mode is when the different function


groups are controlled by the Control system. Process set points are moni-
tored by the control system and are used to automatically control equip-
ment. All Safety, Start and Process interlocks (Section H of the same
chapter) must be met in order to operate.

Operation Manual: Operation Manual mode is when the different func-


tion groups are controlled by the operator. All Safety interlocks (Section H
of the same chapter) must be met in order to operate.

PAGE 4
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

Maintenance: Maintenance mode is when the individual equipment


within each function group can be controlled separately by the operator (or
maintenance personnel). All Safety interlocks (Section H of the same
chapter) must be met in order to operate.

Normal Shutdown Sequence


This section describes the function groups shutdown sequence. If the group has
an automatic shutdown sequence, time delays to allow for equipment cleanout or
deceleration will also be listed (if required).

Abnormal and Emergency Shutdowns


This section describes abnormal shutdown conditions caused by isolated proc-
ess or equipment abnormalities or activation of individual equipment safety de-
vices. It also describes emergency shutdowns due to automatic activation of
personnel safety systems or field emergency stop push buttons.

HMI Control Summary


This section describes how the HMI shall be programmed for the associated
function group. Requirements include any special pop-up windows or HMI but-
tons and a list of all process values, which are displayed on the HMI graphics
screen(s) and the controller faceplates.

Alarms
This section describes alarm messages and alarm conditions/parameters for all
equipment or devices within the function group.

Some alarms are debounced using timers of various durations to help prevent
nuisance chatter or spikes. Non-debounced alarms are generated without a time
delay from the control system, to immediately begin the Abnormal and Emer-
gency Shutdown process (Section E of the same chapter).

As a general rule, alarms will be disabled when equipment is not operating.

PAGE 5
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

Interlocks
The Interlocks section describes all interlocks for the individual equipment or
function groups of equipment within the associated software function group. In-
terlock is defined herein as an input/output signal or a PLC/DCS internal logic
condition, which automatically prevents the operation of an individual or function
group of equipment from the control system Human Machine Interface (HMI).
That is, only PLC/DCS software interlocks are listed in the interlock table. Hard-
wired interlocks (not through the PLC/DCS) are NOT listed in the interlock table.
Interlocks are defined in the condition or state which permits operation, so loss of
this signal or logic condition inhibits operation. When the condition of an interlock
or interlocks is such that operation of a related piece of equipment or an equip-
ment group is permitted, the interlock is defined as being satisfied. Interlocks
consist of three types and are described in detail below:

Safety interlocks: Safety interlocks are those interlocks which prevent


damage to that associated piece of equipment. As a result, safety inter-
locks apply when operating in REMOTE AUTO, REMOTE HAND and
MAINTENANCE modes.

Example
Safety interlock for a fan or pump would be no high-high bearing
temperature.

Safety interlock for a belt conveyor would be no zero speed.

Safety interlocks for every motor will also include the MCC/motor
ready signal and receipt of a run confirmation from the motor con-
tactor after a run command is sent. These interlocks apply to all
motors and are not listed in the interlock table for this reason.

Start interlocks: Start interlocks are those interlocks which prevent an in-
dividual or function group of equipment from being started in Operation
Auto mode only (not Operation Manual or Maintenance mode). Once
the individual or function group of equipment is running, the start interlock
will no longer inhibit operation.

Example
A start interlock for a fixed speed fan with automatic damper would
be that the damper be closed (limit switch or position transmitter)
prior to starting.

PAGE 6
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

Process interlocks: Process interlocks are those interlocks which prevent


an individual or function group of equipment from starting or running in
Operation Auto mode only (not in Operation Manual or Maintenance
mode). The term process is commonly used because these interlocks
are often dependent on another individual or function group of equipment
within the process.

Example
A process interlock for a belt conveyor would be that the down-
stream conveyor is running.

The following table summarizes the modes of operation for the three types of in-
terlocks defined above:

INTERLOCK MODES OF OPERATION

Mode Selector Operator Control Station Interlock Type


Switch Component Mode Selection
Safety Start Process

MAINTENANCE --- X --- ---

OPERATION
MANUAL X --- ---

AUTO X X X

PAGE 7
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

2 Overview
This functional specification is for the Electrical Control of a Gyratory Crusher
and its auxiliary components for the Cerro Verde Project.

A. Function Groups
The following function groups combine to deliver a complete Gyratory
Crusher control and operating system. Details for FFEM-supplied function
groups are described in each groups relevant chapter:

3. Crusher Lubrication Group


4. Crusher Hydraulic Adjustment Group
5. Crusher Spider Bushing Lubrication Group
6. Crusher Dust Seal Air Group
7. Crusher Main Drive Motor

B. System Startup Sequence


When starting the Crusher from a total shutdown, refer to the Contract In-
struction Manual for the Gyratory Crusher. For details of individual subgroups,
refer to the appropriate chapters of this document.

C. System Shutdown Sequence


When a system shutdown is required, refer to the Contract Instruction Manual
for the Gyratory Crusher. For details of individual subgroups, refer to the ap-
propriate chapters of this document.

PAGE 8
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

D. Equipment/Device Descriptions
Note: All instrument tags are prefixed by 31.
Equipment/Device Tag Equipment/Device Description

M-1.0 CRUSHER MAIN DRIVE MOTOR

H-10.0 CRUSHER MAIN DRIVE MOTOR HEATER

M-7.0 CRUSHER SEAL AIR BLOWER

CRUSHER INNER ECCENTRIC BUSHING LUBE OIL SUPPLY LINE


FISL-0143
FLOW SWITCH
CRUSHER OUTER ECCENTRIC BUSHING LUBE OIL SUPPLY LINE
FISL-0141
FLOW SWITCH
CRUSHER COUNTERSHAFT BEARING LUBE OIL SUPPLY LINE
FISL-0142
FLOW SWITCH
CRUSHER MAIN DRIVE MOTOR INBOARD BEARING TEMPERA-
TE-0111A
TURE ELEMENT
CRUSHER MAIN DRIVE MOTOR OUTBOARD BEARING TEMPERA-
TE-0111B
TURE ELEMENT
CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE
TE-0112A
ELEMENT
CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE
TE-0112B
ELEMENT
CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE
TE-0112C
ELEMENT
CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE
TE-0112D
ELEMENT
CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE
TE-0112E
ELEMENT
CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE
TE-0112F
ELEMENT
CRUSHER COUNTERSHAFT INBOARD BEARING TEMPERATURE
TE-0140A
ELEMENT
CRUSHER COUNTERSHAFT OUTBOARD BEARING TEMPERATURE
TE-0140B
ELEMENT

ZE-0118 CRUSHER MANTLE POSITION SENSING ELEMENT

ZY-0118 CRUSHER MANTLE POSITION CONVERTER

ZIT-0118 CRUSHER MANTLE POSITION-INDICATING TRANSMITTER

M-3.0 CRUSHER LUBE OIL MAIN SUPPLY PUMP

M-4.0 CRUSHER LUBE OIL STANDBY SUPPLY PUMP

H-11.0 CRUSHER LUBE OIL RESERVOIR HEATER 1

PAGE 9
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

Equipment/Device Tag Equipment/Device Description

H-12.0 CRUSHER LUBE OIL RESERVOIR HEATER 2

H-13.0 CRUSHER LUBE OIL RESERVOIR HEATER 3

H-14.0 CRUSHER LUBE OIL RESERVOIR HEATER 4

LSL-6721 CRUSHER LUBE OIL RESERVOIR LOW LEVEL SWITCH

LSLL-6721 CRUSHER LUBE OIL RESERVOIR LOW-LOW LEVEL SWITCH

TE-6722 CRUSHER LUBE OIL RETURN LINE TEMPERATURE ELEMENT

TE-6723 CRUSHER LUBE OIL RESERVOIR TEMPERATURE ELEMENT

TI-6706 CRUSHER LUBE OIL RESERVOIR TEMPERATURE GAUGE

HV-6717 CRUSHER LUBE OIL FILTER DRAIN VALVE

LG-6704 CRUSHER LUBE OIL RESERVOIR LEVEL GAUGE

PI-6703 CRUSHER LUBE OIL PUMPS DISCHARGE OIL PRESSURE GAUGE

CRUSHER LUBRICATION MAIN OIL PUMP DISCHARGE OIL PRES-


PSV-6701
SURE RELIEF VALVE
CRUSHER LUBRICATION STANDBY OIL PUMP DISCH. OIL PRES-
PSV-6702
SURE RELIEF VALVE
CRUSHER LUBE OIL FILTER DRAIN VALVE OPEN POSITION LIMIT
ZSO-6717
SWITCH
CRUSHER LUBE OIL FILTER DRAIN VALVE CLOSED POSITION
ZSC-6717
LIMIT SWITCH
CRUSHER LUBE OIL SUPPLY FILTER DIFFERENTIAL PRESSURE
PDSH-6719
SWITCH
CRUSHER LUBRICATION RETURN LINE OIL TEMPERATURE
TI-6707
GAUGE

M-5.0 CRUSHER LUBE OIL COOLER #1 FAN

M-6.0 CRUSHER LUBE OIL COOLER #2 FAN

HV-6716 CRUSHER LUBE OIL COOLER DRAIN VALVE

CRUSHER LUBE OIL COOLER DRAIN VALVE CLOSED POSITION


ZSC-6716
LIMIT SWITCH
CRUSHER LUBE OIL COOLER DRAIN VALVE OPEN POSITION LIMIT
ZS0-6716
SWITCH

PI-6709 CRUSHER LUBE OIL FILTER OUTLET OIL PRESSURE GAUGE

PI-6712 CRUSHER LUBE OIL COOLER OUTLET OIL PRESSURE GAUGE

PAGE 10
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

Equipment/Device Tag Equipment/Device Description

TE-6718 CRUSHER LUBE OIL COOLER OUTLET TEMPERATURE ELEMENT

TI-6708 CRUSHER LUBE OIL FILTER OUTLET OIL TEMPERATURE GAUGE

TI-6711 CRUSHER LUBE OIL COOLER OUTLET OIL TEMPERATURE GAUGE

PSV-6713 CRUSHER LUBE OIL COOLER PRESSURE RELIEF VALVE

M-2.0 CRUSHER HYDRAULIC OIL MAIN SUPPLY PUMP

M-9.0 CRUSHER HYDRAULIC OIL STANDBY SUPPLY PUMP

CRUSHER MANTLE RAISE/LOWER HYDRAULIC OIL CONTROL


XV-6507
VALVE

LG-6501 CRUSHER HYDRAULIC OIL RESERVOIR LEVEL GAUGE

LSL-6511 CRUSHER HYDRAULIC OIL RESERVOIR LOW LEVEL SWITCH

LSLL-6511 CRUSHER HYDRAULIC OIL RESERVOIR LOW-LOW LEVEL SWITCH

CRUSHER HYDRAULIC OIL FILTER DIFFERENTIAL PRESSURE


PDSH-6506
SWITCH

PI-0102 CRUSHER HYDRAULIC ACCUMULATOR OIL PRESSURE GAUGE

PI-6504 CRUSHER HYDRAULIC PUMP DISCHARGE PRESSURE GAUGE

PSV-0103 CRUSHER HYDRAULIC OIL PRESSURE RELIEF VALVE

CRUSHER HYDRAULIC PUMP DISCHARGE OIL PRESSURE RELIEF


PSV-6503
VALVE

CP1 CRUSHER SPIDER BUSHING GREASE LUBRICATION CONTROLLER

M-8.0 CRUSHER SPIDER BUSHING GREASE PUMP

CRUSHER SPIDER BUSHING GREASE SUPPLY LINE FLOW CYCLE


FQS-6603
SWITCH

HS-6507A CRUSHER HYDRUALIC MANTLE RAISE PUSH BUTTON

HS-6507B CRUSHER HYDRUALIC MANTLE LOWER PUSH BUTTON

HS-6505A CRUSHER HYDRUALIC MAIN OIL PUMP START PUSH BUTTON

HS-6505B CRUSHER HYDRUALIC MAIN OIL PUMP STOP PUSH BUTTON

HS-6510A CRUSHER HYDRUALIC STANDBY OIL PUMP START PUSH BUTTON

HS-6510B CRUSHER HYDRUALIC STANDBY OIL PUMP STOP PUSH BUTTON

PAGE 11
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

Equipment/Device Tag Equipment/Device Description

HS-6705A CRUSHER LUBRICATION MAIN OIL PUMP START PUSH BUTTON

HS-6705B CRUSHER LUBRICATION MAIN OIL PUMP STOP PUSH BUTTON

HS-6710A CRUSHER LUBRICATION STANBY OIL PUMP START PUSH BUTTON

HS-6710B CRUSHER LUBRICATION STANDBY OIL PUMP STOP PUSH BUTTON

CRUSHER HYDRUALIC MAIN OIL PUMP RUNNING INDICATION


YL-6505
LIGHT
CRUSHER HYDRUALIC MAIN OIL PUMP RUNNING INDICATION
YL-6505
LIGHT
CRUSHER LUBRICATION MAIN OIL PUMP RUNNING INDICATION
YL-6705
LIGHT
CRUSHER LUBRICATION MAIN OIL PUMP RUNNING INDICATION
YL-6710
LIGHT

PAGE 12
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

E. Equipment/Device Parameter Descriptions


In the sections that follow, specific control system signals and set points are
printed in bold italics. The definitions and/or values of these signals and set
points are defined in the table below.

Signal / Set point Description Type Value

Lube Oil Reservoir Low


Low alarm/interlock reservoir level. Constant 2/3 FULL
Level
Lube Oil
Low-low alarm/interlock oil reservoir level
Reservoir Low-Low Constant 1/3 FULL
(* must be above tank discharge line).
Level
Lube Oil
Low oil reservoir temperature alarm set
Reservoir Low Constant
point.
Temperature
Lube Oil Low oil reservoir temperature heater con-
Constant <90 DEGF
Reservoir Heater On trol set point.
Lube Oil High oil reservoir temperature heater con-
Constant >100 DEGF
Reservoir Heater Off trol set point.
Lube Oil
High oil reservoir temperature alarm set
Reservoir High Constant
point.
Temperature
Low Lube Oil Cooler Outlet Temperature
Lube Oil Cooler Main
Moving Average Main Cooler Fan OFF Constant <90 DEGF
Fan Off
control set point.
High Lube Oil Cooler Outlet Temperature
Lube Oil Main Cooler
Moving Average Main Cooler Fan ON Constant >105 DEGF
Fan On
control set point.
Low Lube Oil Cooler Outlet Temperature
Lube Oil Cooler
Moving Average Standby Cooler Fan Constant <105 DEGF
Standby Fan Off
OFF control set point.
High Lube Oil Cooler Outlet Temperature
Lube Oil Cooler
Moving Average Standby Cooler Fan ON Constant >115 DEGF
Standby Fan On
control set point.
Lube Oil Cooler Outlet The average Lube Oil Cooler Outlet Tem-
Temperature Moving perature continuously calculated over a Variable Calculated
Average selected time interval.
Lube Oil Cooler Outlet The adjustable time interval over which
Temperature Moving the Lube Oil Cooler Outlet Temperature Adjustable 2-5 minutes
Average Interval Moving Average is calculated.
Lube Oil High Return
High alarm oil reservoir return line tem-
Line Constant
perature.
Temperature
Lube Oil High-High Re-
High-high alarm/interlock oil reservoir re-
turn Line Constant
turn line temperature.
Temperature
Lube Oil Filter High Pressure at or above this value is alarmed
Constant
Differential Pressure indicating filter is dirty or clogged.
Inner Eccentric
Low alarm/interlock for lube oil flow to
Bushing Lube Oil Low Constant 34 GPM
Inner Eccentric Bushing.
Flow
Outer Eccentric
Low alarm/interlock for lube oil flow to
Bushing Lube Oil Low Constant 34 GPM
Outer Eccentric Bushing.
Flow

PAGE 13
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

Signal / Set point Description Type Value

Countershaft Bearings Low alarm/interlock for lube oil flow to


Constant 2 GPM
Lube Oil Low Flow Countershaft Bearings.
Countershaft Inboard
Bearing High Tempera- High alarm/interlock bearing temperature. Constant
ture
Countershaft Inboard
High-high alarm/interlock bearing tem-
Bearing High-High Constant
perature.
Temperature
Countershaft Outboard
Bearing High Tempera- High alarm/interlock bearing temperature. Constant
ture
Countershaft Outboard
High-high alarm/interlock bearing tem-
Bearing High-High Constant
perature.
Temperature
Hydraulic Oil Reservoir
Low alarm/interlock reservoir level. Constant 2/3 FULL
Low Level
Hydraulic Oil Reservoir Low-low alarm/interlock reservoir level
Constant 1/3 FULL
Low-Low Level (* must be above tank discharge line).
Crusher Mantle
Position (elevation) of the crusher mantle. Analog Varies
Position
Hydraulic Oil Filter High Pressure at or above this value is alarmed
Differential Pressure Constant
Set Point indicating filter is dirty or clogged.
50mm above
Crusher Mantle Low
Low alarm/interlock mantle position. Constant minimum point
Position
of travel
25mm below
Crusher Mantle High
High alarm/interlock mantle position. Constant maximum point
Position
of travel
Minimum duration Crusher Main Drive Provided by
Crusher Main Drive Mo-
Motor must run prior to adjusting mantle Constant Motor Manufac-
tor Minimum Run Time
position. turer
Minimum duration from when the Crusher Provided by
Crusher Main Drive Mo-
Main Drive Motor is stopped to when it Constant Motor Manufac-
tor Minimum Stop Time
may be restarted. turer
Crusher Main Drive Mo-
tor Winding High Tem- High alarm/interlock winding temperature. Constant 135 DEGC
perature
Crusher Main Drive Mo-
High-high alarm/interlock winding tem-
tor Winding High-High Constant 145 DEGC
perature.
Temperature
Crusher Main Drive Mo-
tor Inboard Bearing High alarm/interlock bearing temperature. Constant 90 DEGC
High Temperature
Crusher Main Drive Mo-
High-high alarm/interlock bearing tem-
tor Inboard Bearing Constant 100 DEGC
perature.
High-High Temperature
Crusher Main Drive Mo-
tor Outboard Bearing High alarm/interlock bearing temperature. Constant 90 DEGC
High Temperature
Crusher Main Drive Mo-
High-high alarm/interlock bearing tem-
tor Outboard Bearing Constant 100 DEGC
perature.
High-High Temperature

PAGE 14
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

F. Reference Documents
FFE Doc./Dwg. Number Document/Drawing Description

CONTROL AND INSTRUMENTATION DIAGRAM,


8.500980, SHT. 1
LEGEND SHEET 1
CONTROL AND INSTRUMENTATION DIAGRAM,
8.500980, SHT. 2
LEGEND SHEET 2
CONTROL AND INSTRUMENTATION DIAGRAM,
8.500980, SHT. 3
LEGEND SHEET 3
CONTROL AND INSTRUMENTATION DIAGRAM,
8.500980, SHT. 4
CRUSHER OVERVIEW
CONTROL AND INSTRUMENTATION DIAGRAM,
8.500980, SHT. 5
CRUSHER HYDRAULIC OIL SYSTEM
CONTROL AND INSTRUMENTATION DIAGRAM,
8.500980, SHT. 6
CRUSHER SPIDER BUSHING LUBE SYSTEM
CONTROL AND INSTRUMENTATION DIAGRAM,
8.500980, SHT. 7
CRUSHER LUBE OIL SYSTEM

8.500981 FIELD INSTRUMENT LIST

8.500982 INPUT/OUTPUT SIGNAL LIST

8.500983 ELECTRICAL LOAD LIST

PAGE 15
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

3 Crusher Lubrication Group


The Crusher Lubrication Group provides pressurized lubricating oil to the
Crusher components, such as the countershaft bearings and the inner eccen-
tric and outer eccentric bushings. Refer to FFE Minerals Control and Instru-
mentation Diagrams 8.500980 Sheets 4 and 7 for details.

A. Equipment
This group consists of the following equipment, which is monitored and con-
trolled by the Control system:

A1. Crusher Lubrication System Reservoir


A2. Crusher Lubrication Supply Circuit
A3. Crusher Countershaft Bearing Temperature Elements

A1. Crusher Lubrication System Reservoir

The Crusher Lubrication System and Crusher Hydraulic System share one
common reservoir with an internal sealed partition. The Crusher Lubrica-
tion System Reservoir has the following devices associated with it:

1. Level Switches

There are two (2) oil level switches 31-LSL-6721 and 31-LSLL-
6721located in the lubrication system reservoir. The level switches share
a common housing. The level switch contacts for Lube Oil Reservoir
Low Level and Lube Oil Reservoir Low-Low Level are wired to the
Control system for alarming and interlocking.

2. Temperature Elements

Three (3) temperature elements are provided as part of the Crusher Lu-
brication System; one (1) element 31-TE-6723 is located in the lube oil
reservoir, one (1) element 31-TE-6718 is located in the Crusher lube oil
system cooler outlet line, and one (1) 31-TE-6722 is located in the
Crusher lube oil system return line.

The temperature element 31-TE-6723 located in the lube oil reservoir is


wired to the control system. For indicating temperature and controlling the
cycling of the reservoir heaters in response to the Lube Oil Reservoir
Heater On and Lube Oil Reservoir Heater Off set points.

PAGE 16
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

The element located in the cooler outlet line is wired to the Control system
and its signal is used to generate the Lube Oil Cooler Outlet Tempera-
ture Moving Average 31-TY-6718 . The Lube Oil Cooler Outlet Tem-
perature 31-TE-6718 Moving Average is compared to the Lube Oil
Cooler Main Fan Off 31-TCLL-6718, Lube Oil Cooler Main Fan On
TCH-6118, Lube Oil Cooler Standby Fan Off 31-TCL-6718and the Lube
Oil Cooler Standby Fan On 31-TCHH-6718 set points to cycle the cooler
fans on and off to control the temperature of the lube oil supply to the
Crusher. The moving average is continuously calculated over an operator
selected time period called the Lube Oil Cooler Outlet Temperature
Moving Average Interval to smooth out transient temperature swings
that might cause rapid on-off cycling of the Lube Oil Cooler fans. The best
setting of this interval is determined empirically in the field during actual
operation of the crusher.

The element located in the Crusher lube oil system return line 31-TE-6721
is wired to the Control system. Its signal is compared to the Lube Oil High
Return Line Temperature and Lube Oil High-High Return Line Tem-
perature set points for alarming and interlocking.

3. Heaters

Four (4) oil immersion heaters are located in the reservoir. The ON-OFF
cycling of the reservoir heaters is done through the control system in re-
sponse to the signal from the temperature element 31-TE-6723described
above.

A2. Crusher Lubrication Supply Circuit

The Lubrication Supply Circuit has the following devices associated with it:

1. Lube Oil Pumps

There are two (2) Lube Oil pumps. In normal operation only one of the
pumps is running and the other is standby. Each pump has inlet and out-
let isolation valves for maintenance.

2. Lube Oil Pump Pressure Relief Valve

Each Lube Oil Pump is protected by a pressure relief valve 31-PSV-6701,


31-PSV-6702in its discharge piping. The relief valve outlets are piped
back to the Lube Oil Reservoir.

PAGE 17
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

3. Oil Filter with Differential Pressure Switch

There is one (1) oil filter with a differential pressure switch 31-PDSH-6719.
If the filter is dirty, as indicated by an input to the control system from its
differential pressure switch, when the pressure exceeds the Lube Oil Fil-
ter High Differential Pressure set point, an alarm is generated. The dirty
filter should be manually taken out of service and cleaned or replaced.

4. Flow-Switches

Three (3) flow switches monitor the oil flow rate to the countershaft bear-
ings and the inner eccentric and outer eccentric bushings. Each flow
switch is wired to the Control system for alarming and interlocking when
the lube oil flow is below the Inner Eccentric Bushing Lube Oil Low
Flow 31-FISL-0143 , Outer Eccentric Bushing Lube Oil Low Flow 31-
FISL-0141, or the Countershaft Bearings Lube Oil Low Flow 31-FISL-
0142 set points as applicable.

5. Lube Oil Cooler (Oil Cooling Fans)

The Lube Oil Cooler consists of two (2) heat exchangers (radiators), each
with its own cooling fan for controlling the temperature of the lube oil sup-
ply to the Crusher.

6. Lube Oil Supply Pressure Relief Valve

One (1) pressure relief valve 31-PSV-6713 is provided to bypass lube oil
flow around the Lube Oil Cooler assembly in the event of a blockage or
inadvertent closure of individual cooler isolation valves.

7. Automatic Oil Drain Valves

Two (2) normally closed motorized valves 31-HV-6716 & 31-HV-6717 are
provided to automatically drain oil from the coolers and filters to the reser-
voir, when the Lubrication System is not in operation. These valves are
wired to the Control system for automatic lube oil draining.

8. Other Local Instruments

Other local instruments, such as pressure gauges, temperature gauges,


level indicators etc. are identified on the Control and Instrumentation Dia-
grams and in the Field Instrument List.

A3. Countershaft Bearing Temperature Elements

PAGE 18
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

1. Temperature Elements

Two (2) temperature elements monitor the countershaft (inboard and out-
board) bearings temperature. The signal from the countershaft inboard
bearing is compared to the Countershaft Inboard Bearing High Tem-
perature 31-TAH-0111A and Countershaft Inboard Bearing High-High
Temperature 31-TAHH-0111A set points for alarming and interlocking.
The signal from the countershaft outboard bearing is compared to the
Countershaft Outboard Bearing High Temperature 31-TAH-0111B
and Countershaft Outboard Bearing High-High Temperature 31-
TAHH-0111B set points for alarming and interlocking.

B. Normal Startup Sequence


Prior to starting the Crusher Lubrication Group, the operator should first per-
form the following actions:

1. Verify that the Crusher Lube System Oil Reservoir is not at the Lube Oil
Reservoir Low Level 31-LAL-6721.

2. Verify that the Crusher Lubrication System Reservoir heaters are in


AUTO. (31-XS-6725) A/M STATION

3. Verify that the desired lube oil supply pumps inlet and outlet isolation
valves are fully open.

After the operator has performed the actions listed above, the normal order of
starting the Crusher Lubrication Group is as follows:

1. Place cooler drain valve in AUTO mode A/M STATION 31-XS-6717, 31-
XS-6716, so that they may open (pump off) and close (pump on) auto-
matically as determined by the status of the lube oil supply pumps.

2. The reservoir heaters start automatically as determined by the Crusher


lube oil reservoir temperature element 31-TE-6723.

3. Place the cooling fans in AUTO 31-XS-6715 and 31-XS-6716 run mode,
so that they may start automatically as determined by the Crusher supply
line lube oil temperature element 31-TE-6718.

4. Start the desired lube oil supply pump. The pump cannot start unless the
reservoir temperature is above the Lube Oil Reservoir Low Tempera-
ture 31-TCL-6723 set point. Once started, this temperature may drop
momentarily while the lube circuit heats up. If after 15 minutes the
temperature is not above the Lube Oil Reservoir Low Temperature set
point, an alarm is initiated 31-TAL-6723.

PAGE 19
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

C. Normal Operation
Once the Crusher Lubrication Group is started, normal operation simply con-
sists of ensuring that lubricating oil is steadily supplied to the receiving points.
Also, normal operation ensures that the required function group interlocks
(listed in Section H of this chapter) are satisfied.

The reservoir heaters will automatically operate as required, maintaining the


oil temperature in the reservoir between the Lube Oil Reservoir Heater On
set point 31-TCL-6723 and Lube Oil Reservoir Heater Off set point 31-TCH-
6723. An ON-OFF controller in the Control system will control the operation
of the reservoir heaters.

The Lube Oil Cooler Fans will automatically cycle on and off as required to
maintain the lube oil supply temperature at or below the Lube Oil Supply
Standby Cooler Fan On set point 31-TCHH-6718.

D. Normal Shutdown Sequence


The normal order for short-term shutdown of the Crusher Lubrication Group is
as follows:

1. After the Crusher has come to a complete stop, stop the operating lube oil
supply pump. If desired (i.e., to lower the lube oil temperature), the lube
oil pump can be allowed to run continuously even after the Crusher has
stopped.

2. If the cooling fans are running, allow them to first lower the return line oil
temperature to the coolers OFF temperature setting 31-TCL-6718. These
motors may then be taken out of AUTO" mode by the operator.

3. The cooler drain valves may then be taken out of AUTO mode by the
operator.

E. Abnormal and Emergency Shutdowns

1. Abnormal Shutdown, Lube Oil Supply Pump Trips

If the Crusher Lubrication Group is operating and the running lube oil sup-
ply pump trips, the Control system will provide an alarm 31-XA-6705
(MAIN), 31-XA-6710 (STANDBY) to the operator. The remainder of the
Crusher Lubrication Group (Crusher lubrication oil cooling system) will
continue to operate unless shutdown by the operator or other required in-
terlocks (see Section H of this chapter).

PAGE 20
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

2. Abnormal Shutdown, Cooling Oil Fan Trips

If the Crusher Lubrication Group is operating and either of the lube oil
cooling fans trip, the Control system will provide an alarm 31-XA-6715
(MAIN) 31-XA-6720 (STANDBY) to the operator. The remainder of the
Crusher Lubrication Group (Crusher lubrication oil supply system) will con-
tinue to operate unless shutdown by the operator or other required inter-
locks (see Section H of this chapter).

3. Emergency Shutdowns

If the emergency stop push button(s) (by others) is depressed while the
Crusher Lubrication Group is running all function group motors will imme-
diately and simultaneously stopped. Furthermore, all motors associated
with the Crusher Lubrication Group are prohibited from restarting until the
emergency stop push button(s) is reset.

F. HMI Control Summary


The following signals are displayed on the Owners operator control stations:

1. Lube Oil Reservoir Low Level. (31-LAL-6721)


2. Lube Oil Reservoir Temperature. (31-T1-6723)
3. Status of each Lube Oil Supply Pump Motor (ready, running, stopped
or tripped). (31-XL-6705) (31-XL-6710)
4. Lube Oil Filter High Differential Pressure. (31-PDAH-6719)
5. Status of each Lube Oil Cooler Cooling Fan Motor (ready, running,
stopped or tripped). (31-XL-6715) (31-XL-6720)
6. Lube Oil Cooler Outlet Temperature Moving Average. (31-TI-6718)
7. Crusher Countershaft Bearings Oil Low Flow. (31-FAL-0142)
8. Crusher Inner Eccentric Bushing Oil Low Flow. (31-FAL-0143)
9. Crusher Outer Eccentric Bushing Lube Oil Low Flow (31-FAL-0141)
10. Crusher Return Line Lube Oil Temperature. (31-TI-6722)
11. Crusher Inboard Countershaft Bearing Temperature. (31-TI-0140A)
12. Crusher Outboard Countershaft Bearing Temperature. (31-TI-0140B)
13. Status of the Lube Oil Cooler Drain Valve (open or closed). (31-ZLO-
6716) (31-ZLC-6716)
14. Status of the Lube Oil Filter Drain Valve (open or closed). 31-ZLO-
6717) (31-ZLC-6717)

PAGE 21
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

G. Alarms
Debounced Alarms
Alarm Tag Alarm Text

LAL-6721 LUBE OIL RESERVOIR LOW LEVEL

LALL-6721 LUBE OIL RESERVOIR LOW-LOW LEVEL

TAL-6723 LUBE OIL RESERVOIR LOW TEMPERATURE

TAH-6723 LUBE OIL RESERVOIR HIGH TEMPERATURE

PDAH-6719 CRUSHER LUBE OIL FILTER DIRTY

FAL-0142 CRUSHER INNER ECCENTRIC BUSHING LUBE OIL LOW FLOW

FAL-0141 CRUSHER OUTER ECCENTRIC BUSHING LUBE OIL LOW FLOW

FAL-0143 CRUSHER COUNTERSHAFT BEARINGS LUBE OIL LOW FLOW

TAH-6722 LUBE OIL HIGH RETURN LINE TEMPERATURE

TAHH-6722 LUBE OIL HIGH-HIGH RETURN LINE TEMPERATURE

TAH-0140A CRUSHER COUNTERSHAFT INBOARD BEARING HIGH TEMPERATURE

TAH-0140B CRUSHER COUNTERSHAFT OUTBOARD BEARING HIGH TEMPERATURE

TAHH-0140A CRUSHER COUNTERSHAFT INBOARD BEARING HIGH-HIGH TEMPERATURE

TAHH-0140B CRUSHER COUNTERSHAFT OUTBOARD BEARING HIGH-HIGH TEMPERATURE

Non-debounced Alarms
Alarm Tag Alarm Text
31-XA-6705 CRUSHER MAIN LUBE SUPPLY PUMP TRIP
(If trips on run command)

31-XA-6710 CRUSHER STANDBY LUBE SUPPLY PUMP TRIP


(If trips on run command)
31-XA-6715 CRUSHER LUBE OIL COOLER COOLING FAN A TRIP
(If trips on run command)
31-XA-6720 CRUSHER LUBE OIL COOLER COOLING FAN B TRIP
(If trips on run command)

PAGE 22
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

H. Interlocks
Equipment or Interlock Type
Control System Signals Safety Start Process
Permissive
LUBE OIL LUBE OIL RESERVOIR TEMPERATURE
RESERVOIR NOT HIGH (below the Lube Oil Reservoir X
HEATERS High Temperature)
LUBE RESERVOIR OIL LEVEL NOT LOW-
LOW (below the Lube Oil Reservoir Low- X
Low Level)
MAIN LUBE OIL RESERVOIR LEVEL NOT LOW-
LUBE OIL LOW (below the Lube Oil Reservoir Low- X
SUPPLY PUMP Low Level)
LUBE RESERVOIR OIL TEMPERATURE
NOT LOW (below the Lube Oil Reservoir X X
Low Temperature
STANDBY LUBE OIL SUPPLY PUMP NOT
RUNNING X X
STANDBY LUBE OIL RESERVOIR LEVEL NOT LOW-
LUBE OIL LOW (below the Lube Oil Reservoir Low- X
SUPPLY PUMP Low Level)
LUBE OIL RESERVOIR TEMPERATURE
NOT LOW (below the Lube Oil Reservoir X X
Low Temperature
MAIN LUBE OIL SUPPLY PUMP NOT RUN-
NING X X
LUBE OIL LUBE OIL COOLER OUTLET TEMPERA-
COOLER FAN A TURE MOVING AVERAGE NOT LOW (below X
the Lube Oil Cooler Main Fan Off)
MAIN OR STANDBY LUBE OIL PUMP RUN-
NING X X
LUBE OIL COOLER OUTLET TEMPERA-
LUBE OIL
COOLER FAN B
TURE MOVING AVERAGE NOT LOW (below X
the Lube Oil Cooler Standby Fan Off)
MAIN OR STANDBY LUBE OIL PUMP RUN-
NING X X
LUBE OIL
COOLER DRAIN
ANY ONE (1) OIL LUBE PUMPS RUNNING
(CLOSE VALVE) X
VALVE
BOTH OIL LUBE PUMPS NOT RUNNING
(OPEN VALVE) X

PAGE 23
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

H. Interlocks (contd)
Equipment or Interlock Type
Control System Signals Safety Start Process
Permissive
LUBE OIL START
PERMISSIVE FOR
LUBE RESERVOIR OIL LEVEL NOT LOW
(below the Lube Oil Reservoir Low Level) X
THE CRUSHER
MAIN DRIVE MO- COUNTERSHAFT BEARINGS OIL FLOW
TOR NOT LOW (below the Countershaft Bearings X
Lube Oil Low Flow)
C1LBSTART INNER ECCENTRIC BUSHING OIL FLOW
(SEE CHAPTER 7,
SECTION H)
NOT LOW (below the Inner Eccentric Bush- X
ing Lube Oil Low Flow)
OUTER ECCENTRIC BUSHING OIL FLOW
NOT LOW (below the Outer Eccentric Bush- X
ing Lube Oil Low Flow)
LUBE OIL RETURN LINE TEMPERATURE
NOT HIGH (below the Lube Oil High Return X
Line Temperature)
COUNTERSHAFT INBOARD BEARING TEM-
PERATURE NOT HIGH (below the Counter-
shaft Inboard Bearing High Temperature) X
COUNTERSHAFT OUTBOARD BEARING
TEMPERATURE NOT HIGH (below the
Countershaft Outboard Bearing High Tem- X
perature)

PAGE 24
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

H. Interlocks (contd)

COUNTERSHAFT INBOARD BEARING TEM-


LUBE OIL
30-SECOND DE-
PERATURES NOT HIGH-HIGH (below the
Countershaft Inboard Bearing High-High X
LAYED STOP IN- Temperature)
TERLOCKS FOR
THE CRUSHER COUNTERSHAFT OUTBOARD BEARING
MAIN DRIVE MO-
TOR
TEMPERATURES NOT HIGH-HIGH (below
the Countershaft Outboard Bearing High- X
High Temperature)
C1LBSTOP
(SEE CHAPTER 7, COUNTERSHAFT BEARING OIL FLOW NOT
SECTION H) LOW (below the Countershaft Bearings X
Lube Oil Low Flow)
OUTER ECCENTRIC BUSHING OIL FLOW
NOT LOW (below the Outer Eccentric Bush- X
ing Lube Oil Low Flow)
LUBE RESERVOIR OIL LEVEL NOT LOW
(below the Lube Oil Reservoir Low Level) X
RETURN LINE OIL TEMPERATURE NOT
HIGH-HIGH (below the Lube Oil Reservoir X
High-High Temperature)
INNER ECCENTRIC BUSHING OIL FLOW
NOT LOW (below the Inner Eccentric Bush- X
ing Lube Oil Low Flow)

PAGE 25
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

4 Crusher Hydraulic Adjust-


ment Group
The Crusher Hydraulic Adjustment Group provides high pressure oil to lift the
Crusher main shaft (mantle) to maintain it at a certain vertical elevation.

The Crusher mantle is supported by a volume of oil between the piston and the
cylinder cover. This volume of oil supports the mantle and all crushing loads.
The volume of this oil is intentionally varied, in order to change the vertical posi-
tion of the shaft and to thereby adjust the Crusher open-side setting (material
discharge size setting).

Refer to FFE Minerals Control and Instrumentation Diagrams 8.500980 Sheets 4


and 5 for details.

A. Equipment

This group consists of the following equipment, which is monitored and controlled
by the Control system:

A1. Crusher Hydraulic Oil Reservoir


A2. Crusher Hydraulic Oil Supply Circuit
A3. Crusher Hydraulic Adjustment Mechanisms

A1. Crusher Hydraulic Oil Reservoir

The Crusher Hydraulic System and Crusher Lubrication System share one
common reservoir with an internal sealed partition. The Crusher Hydraulic Oil
Reservoir has the following devices associated with it:

1. Level Switches

There are two (2) oil level switches 31-LSL-6511 & 31-LSLL-6511 located in
the oil reservoir. The level switches share a common housing. The level
switch contacts for Hydraulic Oil Reservoir Low Level and Hydraulic Oil
Reservoir Low-Low Level are wired to the Control system for alarming and
interlocking.

PAGE 26
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

2. Other Local Instruments

Other local instruments, such as temperature gauges and level indicators etc.
are identified on the Control and Instrumentation Diagrams and the Field In-
strument List.

A2. Crusher Hydraulic Oil Supply Circuit

The Crusher Hydraulic Oil Supply Circuit has the following devices associated
with it:

1. Hydraulic Oil Pump

There are two (2) high pressure hydraulic oil pumps. In normal operation only
one of the pumps is running and the other is standby. Each pump has an inlet
and an outlet isolation valve for maintenance.

2. Hydraulic Oil Pump Pressure Relief Valve and Gauge

The Hydraulic Oil Pumps are protected by a pressure relief valve at the
discharge piping. The relief valve outlet is piped back to the Hydraulic Oil
Reservoir. A local pressure gauge is also provided.

3. Oil Filter with Differential Pressure Switch

There is a hydraulic oil filter with a differential pressure switch 31-PDSH-


6506. If the filter in service is dirty, as indicated by an input to the control
system from its differential pressure switch, when the pressure exceeds the
Hydraulic Oil Filter High Differential Pressure set point listed, the control
system generates an alarm 31-PDAH-6506. The dirty filter should then be
manually taken out of service and cleaned or replaced.

4. Dual Solenoid Directional Control Valve

A four way, solenoid operated, spring return directional control valve is pro-
vided and is used to control the direction of high pressure oil flow. The sole-
noids of the directional control valve are wired to the Control system. The
function of the directional control valve is described in Section C of this chap-
ter.

PAGE 27
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

A3. Crusher Hydraulic Adjustment Mechanisms

The Hydraulic Adjustment Mechanisms include the following devices:

1. Hydraulic Accumulator

The hydraulic accumulator receives pressurized fluid from the pumping sys-
tem and provides local pressure accumulation. The accumulator is of the hy-
dro-pneumatic type, with an integral gas bladder. Before operating the
Crusher, the customer must pre-charge the gas bladder as stated in the
FFEM Installation, Operation and Maintenance Manual for the Gyrator Crush-
ers (see the Contract Instruction Manual).

2. Hydraulic Oil Supply Pressure Relief Valve

One (1) pressure relief valve 31-PSV-0103 is provided to protect the accumu-
lator and other hydraulic adjustment group components from excessive pres-
sure. The relief valve outlet is piped back to the hydraulic oil reservoir

3. Hydraulic Oil Supply Pressure Gauge

One (1) pressure gauge 31-PI-6504 is provided to monitor the hydraulic oil
supply pressure.

4. Crusher Hydraulic Cylinder

The hydraulic cylinder contains a volume of fluid. As the volume of fluid be-
low the piston is varied, the vertical position of the Crusher mantle is
changed.

5. Crusher Mantle Position Transmitter

Crusher Mantle Position is monitored by a position transmitter. Vertical


movement of the mantle positively displaces the core of a differential trans-
former. Flux change is converted to a signal proportional to the position 31-
ZY-0118, which is wired to a local position-indicating transmitter 31-ZIT-0118.
The transmitter then converts this signal to a 4-20mADC Crusher Mantle Po-
sition signal, which is wired to the Control system, where it is used to derive
the Crusher Mantle Low Position 31-ZAL-0118 and Crusher Mantle High
Position 31-ZAH-0118 set points for alarming and interlocking.

PAGE 28
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

B. Normal Startup Sequence


Prior to starting the Crusher Hydraulic Adjustment Group, the operator should
first perform the following actions:

1. Verify that the Crusher Hydraulic Oil Reservoir is not at the Hydraulic Oil
Reservoir Low Level 31-LAL-6511.

2. Verify that the hydraulic oil pump'


s inlet and outlet isolation valves are fully
open.

After the operator has performed the actions listed above, the normal order of
starting the Crusher Hydraulic Adjustment Group is as follows:

Place the hydraulic oil supply pump in AUTO.

C. Normal Operation
Once the Crusher Hydraulic Adjustment Group is operating, normal operation
simply requires periodic adjustment of the volume of oil in the hydraulic cylinder,
in order to maintain the mantle elevation (position) at the desired point for crush-
ing operations. Also, normal operation ensures that the required function group
interlocks (listed in Section H of this chapter) are satisfied.

When the operator presses the MANTLE RAISE button 31-HS-6507A, the hy-
draulic oil supply pump automatically starts (if it is not already running), the
LOWER solenoid S2 remains de-energized and the RAISE solenoid S1 is ener-
gized. Oil is then ported towards the hydraulic cylinder. Simultaneously, a thirty
(30) minute run timer begins timing out. When the run timer expires, the hydrau-
lic oil supply pump is automatically stopped. The function of the run timer is to
allow the hydraulic oil to circulate through the filter.

When the operator presses the MANTLE LOWER button 31-HS-6507B, the hy-
draulic oil supply pump automatically stops (if it is running), the RAISE S1
solenoid remains de-energized and the LOWER solenoid S2 is energized.
Hydraulic oil from the main piston then drains back to the reservoir.

When the RAISE and LOWER solenoids are both de-energized, hydraulic oil in
the main piston is blocked off at the solenoid valve port to maintain mantle posi-
tion. Oil from the hydraulic oil supply pump is ported back to the reservoir.

The Control system shall ensure that the hydraulic pump is not started dur-
ing the mantle lowering operation.

PAGE 29
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

D. Normal Shutdown Sequence

The normal order for short-term shutdown of the Crusher Hydraulic Adjustment
Group is as follows:

After the Crusher has come to a complete stop, the hydraulic oil supply pump (if
operating) will automatically stop. If the run timer is still timing, the pump will
automatically stop after the timer times out.

Operate the LOWER push button 31-HS-6507B, to lower the mantle elevation to
the zero point (fully-lowered point of travel).

E. Abnormal and Emergency Shutdowns

1. Hydraulic Oil Pump Trip

If the Crusher is operating and the operating hydraulic oil pump trips, the Con-
trol system will provide an alarm to the operator. The Crusher will continue to
operate until shutdown by the operator.

2. Emergency Shutdowns

If the emergency stop push button(s) (by others) is depressed while the
Crusher Hydraulic Adjustment Group is running all function group motors
must be immediately and simultaneously stopped. Furthermore, all motors
associated with the Crusher Hydraulic Adjustment Group are prohibited from
restarting until the emergency stop push button(s) is reset.

F. HMI Control Summary


The following signals are displayed on the operator control stations:

1. Status of the Hydraulic Oil Reservoir level (within normal limits or alarm states
31-LAL-6511, 31-LALL-6511.
2. Status of Hydraulic Pump Motor ready, running, stopped (31-XL-6505 or
tripped 31-XA-6505)
3. Crusher Mantle Position 31-ZI-0118

PAGE 30
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

G. Alarms
Debounced Alarms
Alarm Tag Alarm Text
LAL-6511 CRUSHER HYDRAULIC TANK LOW LEVEL

LALL-6511 CRUSHER HYDRAULIC TANK LOW-LOW LEVEL

PDAH-6506 CRUSHER HYDRAULIC OIL FILTER DIRTY

ZAL-0118 CRUSHER MANTLE LOW POSITION


(*low alarm to be set at or below the lowest normal recommended operating point.
This point shall be field set at 50mm above the zero point of travel)
ZAH-0118 CRUSHER MANTLE HIGH POSITION
(*high alarm to be set at or above the highest normal recommended operating point.
This point shall be field set at 25mm below the maximum point of travel)

Non-debounced Alarms
Alarm Tag Alarm Text
31-XA-6505 CRUSHER HYDRAULIC MAIN OIL PUMP TRIP
(If trips on run command)
31-XA-6510 CRUSHER HYDRAULIC STANDBY OIL PUMP TRIP
(If trips on run command)

PAGE 31
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

H. Interlocks
Equipment or Interlock Type
Control System Signals
permissive Safety Start Process

HYDRAULIC OIL HYDRAULIC RESERVOIR OIL LEVEL NOT


PUMP LOW (below the Hydraulic Oil Reservoir Low
Level)
X
HYDRAULIC RESERVOIR OIL LEVEL NOT
LOW-LOW (below the Hydraulic Oil Reservoir X
Low-Low Level)
MANTLE LOWER CRUSHER MANTLE POSITION NOT LOW
SOLENOID
VALVE
(below the Crusher Mantle Low Position)
X
MANTLE RAISE CRUSHER MANTLE POSITION NOT HIGH
SOLENOID
VALVE
(below the Crusher Mantle High Position) X
HYDRAULIC HYDRAULIC RESERVOIR OIL LEVEL NOT
START PERMIS- LOW-LOW (below the Hydraulic Oil Reservoir X
SIVE FOR THE Low-Low Level)
CRUSHER MAIN
DRIVE MOTOR MANTLE POSITION NOT LOW (BELOW MINI-
MUM NORMAL RECOMMENDED OPERATING X
C1HYSTART POINT)
(SEE CHAPTER 7, MANTLE POSITION NOT HIGH (ABOVE
SECTION H) MAXIMUM NORMAL RECOMMENDED OPER- X
ATING POINT)
HYDRAULIC DE- HYDRAULIC RESERVOIR OIL LEVEL NOT
LAYED STOP IN- LOW-LOW (below the Hydraulic Oil Reservoir
TERLOCKS FOR Low-Low Level)
THE CRUSHER
MAIN DRIVE MO-
TOR X
C1HYSTOP
(SEE CHAPTER 7,
SECTION H)

PAGE 32
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

5 Crusher Spider Bushing Lu-


brication Group
The Crusher Spider Bushing Lubrication Group provides a supply of grease to
lubricate the spider bushing at the top of the Crusher. Refer to FFE Minerals
Control and Instrumentation Diagram 8.500980 Sheets 4 and 6 for details.

A. Equipment
The Crusher Spider Bushing Lubrication Group consists of the following compo-
nents:

A1. Grease Pump


A2. Grease Supply Line Components
A3. Local Timer/Controller Panel

A1. Grease Pump

The Grease Pump is a rotary driven electric pump that pumps the grease out
of a refinery drum (by others) to the supply line divider valve when the Pump
is energized by the Local Timer/Controller Panel.

A2. Grease Supply Line Components

The Grease Supply Line Components are as follows:

1. Divider Valve

The divider valve is a manifold proportioning device, which delivers a metered


amount of lubricant to the Spider Bushing. The divider valve has a progres-
sive design requiring each valve piston to complete its stroke before the next
downstream piston is activated. Each valve port has a built-in outlet check
valve. The divider valve should be installed in the grease delivery line, within
3 feet of the Crusher spider grease connection and protected from falling rock
material.

PAGE 33
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

2. Cycle Switch

The cycle switch is a proximity switch, which electronically gives assurance


that the divider valve is operating. The cycle switch is activated (pulse output)
when the final valve piston reaches the end of its travel, confirming that one
(1) lubricating cycle is complete. The cycle switch must be wired to the Local
Timer/Controller Panel, which will provide monitoring and interlocking.

3. Other Local Instruments

Other local instruments are identified in the Lincoln Lube Controller Manual.

A3. Local Timer/Controller Panel

The Modular Lube Controller controls and supervises all components of the
Spider Lubrication Group. It is a microprocessor-based unit and includes the
following functions:

1. Control Timers

Internal timers are provided to control the frequency and the duration of the
grease pump.

2. Flow Counter

An internal counter receives the signals from the cycle switch and counts the
number of pulses (cycles). If the required number of pulses (cycles) are not
counted within a preset and adjustable time, a fault is annunciated.

3. Manual Push button

When pressed, the local MANUAL RUN button (in the controller) forces the
grease pump to perform a grease injection for the preset duration.

4. Indicating LEDs

LEDs are located on the panel for POWER ON, PUMP ON, and FAULT
local indication.

B. Normal Startup Sequence


Prior to the normal startup of the Crusher Spider Bushing Lubrication Group, the
operator shall perform the following actions:

PAGE 34
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

1. Ensure that the fuses in the Local Timer/Controller Panel are installed and are
in satisfactory condition.

2. Ensure that the Local Timer/Controller Panel has been programmed from the
front display panel per Modular Lube Controller instructions and the FFEM In-
stallation, Operation and Maintenance Manual for the Gyrator Crushers (see
the Contract Instruction Manual).

The normal order of starting the Crusher Spider Bushing Lubrication Group is as
follows:

1. Based on the signal that Crusher Main Drive Motor is running, the customer
control system should close a contact, which applies external power to the
Modular Lube Controller Local Timer/Controller Panel. This POWER ON sig-
nal should be maintained at all times when the Crusher Main Drive Motor is
running.

The Modular Lube Controller Local Timer/Controller should be configured for


time-based programming operation. This will allow the Timer/Controller to begin
its operation once the POWER ON signal is received from the Control system.

The Spider Lubrication Group is now in automatic, timed operation.

C. Normal Operation
The frequency and duration of the grease pump operation are automatically con-
trolled by the Modular Lube Controller Local Timer/Controller Panel, based upon
programmed settings.

Modular Lube Controller Local Timer/Controller Panel will determine the ON-OFF
cycling of the Grease Pump.

D. Normal Shutdown Sequence

The normal order of shutdown of the Crusher Spider Bushing Lubrication Group
is as follows:

Based on the signal that the Crusher Main Drive Motor is stopped (off), the
POWER ON signal from the Control system is turned off and the external power
will thereby be removed from the Modular Lube Controller Local Timer/Controller
Panel. The reason for power-off is to prevent unnecessary injection of grease
when the Crusher is not operating.

E. Abnormal and Emergency Shutdowns

PAGE 35
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

1. Lubrication Timer Panel Fault

If, while operating normally, insufficient cycles are detected by the Local
Timer/Controller, a fault has occurred in the lubrication system (e.g., grease
drum exhausted, blocked lines, broken lines, etc.). The local fault-indicating
light is energized and a fault alarm signal is sent to the Control system. The
Crusher will continue to operate unless shutdown by the operator.

F. HMI Control Summary

The following signals are displayed on the operator control station graphics
screen:

1. Status of the Local Timer/Controller (normal or fault state)

G. Alarms
Debounced Alarms
Alarm Tag Alarm Text
XA-6602 CRUSHER SPIDER BUSHING LUBRICATION CONTROLLER FAULT
STOP FEED TO CRUSHER (20 MINUTES)
XA-6602 CRUSHER SPIDER BUSHING LUBRICATION CONTROLLER FAULT
TRIP CRUSHER (30 MINUTES)

H. Interlocks
Equipment or Interlock Type
control system
permissive Signals Safety Start Process
SPIDER LU- CRUSHER MAIN DRIVE MO-
BRICATION TOR RUNNING
POWER-ON X X
SIGNAL

SPIDER LU- C1SBLSTOP CRUSHER SPIDER GREASE


BRICATION CONTROLLER NO FAULTS.
DELAYED
STOP INTER-
LOCKS FOR
THE CRUSHER X
MAIN DRIVE
MOTOR
SEE CHAPTER
7, SECTION H)

PAGE 36
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

6 Crusher Dust Seal Air Group

The Crusher Dust Seal Air Blower Group pressurizes the outer eccentric bushing
to prevent the ingress of dust. Refer to FFE Minerals Control and Instrumenta-
tion Diagram 8.500980 sheet 4 for details.

A. Equipment
The Crusher Dust Seal Air Blower Group consists of the following compo-
nents:

1. Dust Seal Air Blower

There is one (1) dust seal air blower supplying air to the outer ec-
centric bushing.

B. Normal Startup Sequence


Prior to starting the Crusher Dust Seal Air Blower Group, the operator should first
perform the following actions:

1. Using the operator control stations, place all function group motors in AUTO
mode (by others).

After the operator has performed the actions listed above, the normal order of
starting the Crusher Dust Seal Air Blower Group is as follows:

1. Start the dust seal air blower and allow it to run continuously.

C. Normal Operation
Once the Crusher Dust Seal Air Group is operating, normal operation simply con-
sists of ensuring that air is steadily supplied to the receiving points. Also, normal
operation ensures that the required function group interlocks (listed in Section H
of this chapter) are satisfied.

PAGE 37
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

D. Normal Shutdown Sequence


The normal order of shutdown of the Crusher Dust Seal Air Blower Group is as
follows:

1. Based on the signal that the Crusher Main Drive Motor is stopped (off), the
operator may stop the operating dust seal air blower.

E. Abnormal and Emergency Shutdowns


1. Dust Seal Air Blower Trips

If the Crusher Dust Seal Air blower group is operating and the running dust
seal air blower trips, the Control system will provide an alarm to the operator.
If the Crusher Main Drive Motor is already running, it will continue to operate
unless shutdown by the operator.

2. Emergency Shutdowns

If the emergency stop push button(s) (by others) is depressed while the
Crusher Dust Seal Air Blower Group is running all function group motors must
be immediately and simultaneously stopped. Furthermore, all motors associ-
ated with the Crusher Dust Seal Air Blower Group are prohibited from restart-
ing until the emergency stop push button(s) is reset.

F. HMI Control Summary


The following signals are displayed on the operator control station graphics
screen by others.

1. Status of dust seal air blower motor ready, running, stopped (31-XL-0110 or
tripped 31-XA-0110).

PAGE 38
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

G. Alarms
Non-debounced Alarms
Alarm Tag Alarm Text

31-XA-0110
DUST SEAL AIR BLOWER TRIPPED (If trips on run command)

H. Interlocks
Interlock Type
Equipment Signals
Safety Start Process

DUST SEAL AIR


BLOWER
STOP PUSH BUTTON NOT
DEPRESSED X
DUST SEAL AIR C1SBSTART DUST SEAL BLOWER MOTOR
BLOWER RUNNING
START PER-
MISSIVE FOR
THE CRUSHER X X
MAIN DRIVE
MOTOR
(SEE CHAPTER
7, SECTION H)

PAGE 39
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

7 Crusher Main Drive Motor


The Crusher Main Drive Motor is supplied by FFE Minerals. This chapter serves
to identify the alarms and interlocks for the Crusher Main Drive Motor. Refer to
FFE Minerals Control and Instrumentation Diagram 8.500980 sheet 4.

A. Equipment
This group consists of the following equipment, which is monitored and controlled
by the Control system:

Crusher Main Drive Motor

The Crusher Main Drive Motor has the following devices associated with it:

1. Temperature Elements

Six (6) motor winding temperature elements are used for monitoring Crusher
Main Drive Motor Winding High Temperature 31-TAH-0112 and Crusher
Main Drive Motor Winding High-High Temperature 31-TAHH-0112 and
two (2) motor bearing temperature elements are used for monitoring Crusher
Main Drive Motor Inboard Bearing High Temperature 31-TAH-0111A,
Crusher Main Drive Motor Inboard Bearing High-High Temperature
31-TAHH-0111A, Crusher Main Drive Motor Outboard Bearing High Tem-
perature 31-TAH-0111B, Crusher Main Drive Motor Outboard Bearing
High-High Temperature 31-TAHH-0111B These temperature elements are
wired to the Owners Motor Protection Relay.

2. Motor Protection Relay (by others)

From the Owners Motor Protection Relay, the following status and Crusher
Main Drive Motor parameters are wired to the Control system:

Status/Alarm Alarm Text


Tag

UA-0105 MOTOR PROTECTION RELAY FAULT

XA-0105 MOTOR PROTECTION RELAY TRIP

CRUSHER MAIN DRIVE MOTOR INBOARD BEARING HIGH TEMPERA-


TAH-0111A TURE

PAGE 40
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

Status/Alarm Alarm Text


Tag
CRUSHER MAIN DRIVE MOTOR INBOARD BEARING HIGH-HIGH TEM-
TAHH-0111A PERATURE
CRUSHER MAIN DRIVE MOTOR OUTBOARD BEARING HIGH TEMPERA-
TAH-0111B TURE
CRUSHER MAIN DRIVE MOTOR OUTBOARD BEARING HIGH-HIGH TEM-
TAHH-0111B PERATURE
CRUSHER MAIN DRIVE MOTOR HOTTEST WINDING HIGH TEMPERA-
TAH-0112 TURE
CRUSHER MAIN DRIVE MOTOR HOTTEST WINDING HIGH-HIGH TEM-
TAHH-0112 PERATURE

IAH-0105 MOTOR CURRENT HIGH

IAHH-0105 MOTOR CURRENT HIGH-HIGH

JAH-0105 MOTOR KILOWATTS HIGH

JAHH-0105 MOTOR KILOWATTS HIGH-HIGH

PAGE 41
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

B. Normal Startup Sequence


The following preconditions must be verified before the motor may start:

1. The Crusher Lubrication Group is started as described in Chapter 3 of this


document.

2. The Crusher Hydraulic Adjustment Group is started and mantle position is ad-
justed to minimum elevation as described in Chapter 4 of this document.

3. The Crusher Compressed Air Seal Group is started as described in Chapter 6


of this document.

4. The Motor Protection Relay (by others) status is confirmed to be normal.

5. The Crusher Main Drive Motor Minimum Stop Time has elapsed since the
last Crusher operation.

6. All FFE Minerals interlocks for the Crusher are confirmed to be normal per the
Interlock section (section H of the same chapter).

7. The Owners downstream process equipment is running.

8. The Crushing chamber is empty, so that the motor may be started in the
unloaded condition.

If the above conditions are satisfied, a permissive signal is sent to the Crusher to
permit local operation. This signal shall be hardwired to the Crusher Main Drive
Motor control circuit to prevent local operation when the permissive is not satis-
fied.

Normal startup is defined as startup under no load. When starting the Crusher
under load, refer to the FFEM Installation, Operation and Maintenance Manual
for the Gyrator Crushers (see the Contract Instruction Manual).

Normal startup of the Crusher main drive motor and accessories proceeds as fol-
lows:

1. The operator issues a START command from Control system to start the
Main Drive Motor.

2. If the Crusher Main Drive interlocks are satisfied, the motor start command is
accepted. A pre-start warning horn (by others) sounds for 10 seconds, to
alert any personnel in the Crusher area that the Crusher is about to start.

PAGE 42
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

3. After the warning horn (by others) sounds, the Crusher Main Drive Motor is
started.

C. Normal Operation

After the motor is running for the Crusher Main Drive Motor Minimum Run
Time, the Crusher Mantle Position (as sensed by the position transmitter) can
be adjusted to the required crushing setting. Material may then be fed to the
crushing chamber.

Refer to the Operating and Maintenance Instructions in the Contract Instruction


Manual for further details of monitoring operation.

D. Normal Shutdown Sequence


The operator may decide to manually stop the Crusher Main Drive Motor at any
time, as operating conditions require at the time. Usually, the motor is only
stopped at the end of a shift or other production period. The normal shutdown
sequence for the Crusher Main Drive Motor is as follows:

1. Stop the feed of any new material to the Crusher inlet.

2. Allow the Crusher material to flow out of the Crusher, until it is completely
empty. This step is to ensure that the Crusher may later be re-started without
a high starting load on the Crusher Main Drive Motor.

3. The Crusher Main Drive Motor stop is then initiated by the operator and the
Crusher Main Drive Motor automatically stops.

4. The Crusher Hydraulic Adjustment Group is automatically shutdown as de-


scribed in Chapter 4 of this document.

5. The Crusher Lubrication Group may continue to operate, until shutdown by


the operator as described in Chapter 3 of this document.

6. Also, the Crusher Dust Seal Air Group may continue to operate, until shut-
down by the operator as described in Chapter 7 of this document.

E. Abnormal and Emergency Shutdowns


1. Abnormal Shutdown, Crusher Delayed Trip

PAGE 43
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

If the Crusher is operating and any of the delayed trip interlock conditions oc-
cur (see Section H of this chapter), the Control system will provide an alarm
to the operator.

The Control system shall immediately stop the Owners upstream feed
conveying equipment, ensuring that no material continues to be
dumped into the Crusher.

After a time delay (shall be decided during commissioning) to allow some of


the material already in the Crushing chamber to unload, the Crusher Main
Drive Motor is automatically stopped. The duration of the time delay depends
on the Crusher size and feed rate to the Crusher, but must not exceed two (2)
minutes.

2. Abnormal Shutdown, Crusher Instantaneous Trip

If the Crusher is operating and any of the instantaneous trip interlock condi-
tions occur (see Section H of this chapter), the Control system will provide an
alarm to the operator. The Crusher Main Drive Motor is immediately stopped.
Refer to the Operating and Maintenance Instructions in the Contract Instruc-
tion Manual for further details of restarting.

3. Emergency Shutdowns

If the emergency stop push button(s) (by others) is depressed while the
Crusher Main Drive Motor is running the Crusher Main Drive Motor will imme-
diately stopped. Furthermore, the Crusher Main Drive Motor is prohibited
from restarting until the emergency stop push button(s) is reset.

F. HMI Control Summary


The following signals are displayed on the operator control station:

1. Status of the Crusher Main Drive Motor (ready, running, stopped or tripped).
2. Crusher Main Drive Motor Current (within normal limits or alarm state).
3. Crusher Main Drive Motor Inboard Bearing Temperature (within normal limits
or alarm state).
4. Crusher Main Drive Motor Outboard Bearing Temperature (within normal lim-
its or alarm state).
5. Crusher Main Drive Motor Hottest Winding Temperature (within normal limits
or alarm state).
6. Status of the Owner-supplied Crusher Main Drive Motor Protection Relay
(satisfied or alarm state).

PAGE 44
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

7. Crusher Main Drive Motor kilowatts (kW).

G. Alarms
Non-debounced Alarms
Alarm Tag Alarm Text

UA-0105 CRUSHER MAIN DRIVE MOTOR PROTECTION RELAY TROUBLE

XA-0105 CRUSHER MAIN DRIVE MOTOR PROTECTION RELAY TRIP

Debounced Alarms
Alarm Tag Alarm Text

JAH-0105 CRUSHER MAIN DRIVE MOTOR KILOWATTS HIGH


JAHH-0105 CRUSHER MAIN DRIVE MOTOR KILOWATTS HIGH-HIGH
IAH-0105 CRUSHER MAIN DRIVE MOTOR AMPS HIGH
IAHH-0105 CRUSHER MAIN DRIVE MOTOR AMPSHIGH-HIGH
TAH-0111A CRUSHER MAIN DRIVE MOTOR INBOARD BEARING TEMPERATURE HIGH
TAHH-0111A CRUSHER MAIN DRIVE MOTOR INBOARD BEARING TEMPERATURE
HIGH-HIGH
TAH-0111B CRUSHER MAIN DRIVE MOTOR OUTBOARD BEARING TEMPERATURE HIGH
TAHH-0111B CRUSHER MAIN DRIVE MOTOR OUTBOARD BEARING TEMPERATURE
HIGH-HIGH
TAH-0112 CRUSHER MAIN DRIVE MOTOR HOTTEST WINDING TEMPERATURE HIGH
TAHH-0112 CRUSHER MAIN DRIVE MOTOR HOTTEST WINDING TEMPERATURE
HIGH-HIGH

PAGE 45
FFE MINERALS USA INC. Functional Specification
A member of the F.L. Smidth-Fuller Engineering Group Document No. 8.500985
Gyratory Crusher, Cerro Verde Project, Peru. REVISION 01

H. Interlocks
Equipment or Interlock Type
Control System Signals
Permissive Safety Start Process

CRUSHER C1LBSTART LUBE OIL START PERMISSIVE


MAIN DRIVE
MOTOR
FOR THE CRUSHER MAIN
DRIVE MOTOR SATISFIED X
START PER- (SEE CHAPTER 3, SECTION H)
MISSIVE C1SBSTART DUST SEAL AIR BLOWER
RUNNING X
(SEE CHAPTER 6, SECTION H)
C1HYSTART HYDRAULIC START PERMIS-
SIVE FOR THE CRUSHER
MAIN DRIVE MOTOR SATIS- X
FIED
(SEE CHAPTER 4, SECTION H)
CRUSHER C1LBSTOP LUBE OIL DELAYED STOP
MAIN DRIVE INTERLOCKS FOR THE
MOTOR CRUSHER MAIN DRIVE MO- X
DELAYED TOR SATISFIED
STOP INTER- (SEE CHAPTER 3, SECTION H)
LOCKS SPIDER LUBRICATION DE-
C1SBLSTOP
LAYED STOP INTERLOCKS
FOR THE CRUSHER MAIN X
DRIVE MOTOR
(SEE CHAPTER 6, SECTION H)
C1HYSTOP HYDRAULIC DELAYED STOP
INTERLOCKS FOR THE
CRUSHER MAIN DRIVE MO- X
TOR SATISFIED
(SEE CHAPTER 4, SECTION H)
CRUSHER (by others) CRUSHER MAIN DRIVE MO-
MAIN DRIVE TOR PROTECTION RELAY
MOTOR INTERLOCK AND WINDING
INSTAN- /BEARING TEMPERATURES
SATISFIED
X
TANEOUS
STOP INTER-
LOCKS

PAGE 46
EME000077-d

SERIES
INSTRUCTION MANUAL

GENERAL INSTRUCTIONS FOR LARGE-CAPACITY

THREE-PHASE INDUCTION MOTOR

TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION


EME000077-d
1 of 44

CONTENTS

1. Introduction.............................................................................................................. 3

2. How to interpret the nameplates ............................................................................. 3


2.1 TYPE,FRAME NO. .............................................................................................. 3
2.2 POLES,RATED SPEED,RATED FREQUENCY ....................................................... 3
2.3 RATED OUTPUT,RATED VOLTAGE,RATED CURRENT.......................................... 4
2.4 SEC. VOLTAGE,SEC. CURRENT ......................................................................... 4
2.5 RATING............................................................................................................. 4
2.6 MAX. AMB.,ALTITUDE ........................................................................................ 4
2.7 THERMAL CLASS .............................................................................................. 4
2.8 STANDARD,PROTECTION,COOLING METHOD .................................................... 4
2.9 SERIAL NO,MANUFACTURED IN ......................................................................... 5

3. Acceptance inspection ............................................................................................ 5

4. Storage .................................................................................................................... 6

5. Installation ............................................................................................................... 8
5.1 Foundation design and engineering............................................................... 8
5.2 Centering and alignment ................................................................................ 8
5.3 End play and damage prevention of sleeve bearing...................................... 10
5.4 Mortar grouting.............................................................................................. 11
5.5 Prevention of shaft current ............................................................................. 12
5.6 Piping .............................................................................................................. 13

6. Preparations and inspections before trial run ......................................................... 15


6.1 Measurement of insulation resistances.......................................................... 15
6.2 Inspection of electrical circuits........................................................................ 15
6.3 Inspection of grounding wires......................................................................... 15
6.4 Bearings.......................................................................................................... 15
6.5 Dielectric strength test .................................................................................... 17
6.6 Others ............................................................................................................. 18

7. Trial run ................................................................................................................... 19


EME000077-d
2

8. Normal run............................................................................................................... 19
8.1 Starting............................................................................................................ 19
8.2 Running........................................................................................................... 20

9. Maintenance ............................................................................................................ 20
9.1 Contents of inspection .................................................................................... 20
9.2 Interval of regular inspection .......................................................................... 20
9.3 Major inspection items .................................................................................... 21
9.4 Test run after inspection ................................................................................. 22

10. Basic knowledge for maintenance and inspection ................................................. 31


10.1 Starting duty.................................................................................................... 31
10.2 Limit of temperature rise................................................................................. 31
10.3 Insulation resistance ....................................................................................... 32
10.4 Vibration .......................................................................................................... 32
10.5 Noise ............................................................................................................... 36
10.6 Influences of power supply fluctuation ........................................................... 38
10.7 Influences of unbalanced voltage of the power source.................................. 40

11. Troubleshooting....................................................................................................... 41
EME000077-d
3

1. Introduction

Thank you very much for purchasing our company motor. This manual has
been published to ensure safe and efficient use of your motor. Please be sure to
read through this manual carefully as it has been prepared to provide you with a full
knowledge of installation, operation, maintenance and inspection.
Besides this manual, be sure to read other manuals and all Danger / warning /
caution name plates which are attached to the motor.

2. How to interpret the nameplates

Every motor is fitted with a name plate containing the basic rating data according
to relevant standards. A typical rating nameplates is shown in Fig. 1.

Fig. 1 Rating nameplate

In addition, auxiliary plates are attached depending on necessity.


The interpretation of the rating nameplates is given below.

2.1 TYPE,FRAME NO.


The symbols specified by our company are described to indicate the electrical
and mechanical characteristics of the motor.

2.2 POLES,RATED SPEED,RATED FREQUENCY


The number of North & South poles is determined by the stator coil connection
and is indicated by P.
The power frequency in Hz is as f, the synchronous speed N (min-1) of the motor
becomes:
120 f
N=
P
(
min -1 )
Before using the motor, be sure to check the power frequency against the
frequency indicated on the rating nameplate.
At the rated load, rotational speed (full load speed) is slightly below the value
indicated above and is indicated on the nameplate.
EME000077-d
4

2.3 RATED OUTPUT,RATED VOLTAGE,RATED CURRENT


The output is shown by the maximum shaft output power (P) in kW or HP at
which the motor can be operated continuously.
The voltage is the value of the power source voltage (V). Rated current (A) is
the value when the motor generates rated load under the rated voltage and
frequency.
The relationship among these values is given by the following equation when the
motor power factor (Pf) and efficiency () are shown by %.

Before using the motor, be sure to check the power source voltage against the
value indicated on the rating nameplate.
Operate the motor with current at or below the value indicated on the rating
nameplate.

2.4 SEC. VOLTAGE,SEC. CURRENT


These values are only applicable in the case of wound rotor motors.
The secondary current is the current value of the rotor when the motor generates
rated load at voltage and frequency.
Operate the motor within the range of the secondary current indicated on the
rating nameplate.
The secondary voltage is the open circuit voltage of the rotor circuit.
Care should be taken during start up because this voltage is generated in the
brush/collector ring area.

2.5 RATING
This shows the kind of duty cycle the motor is designed for.
In the case of continuous duty or unspecified, the motor is capable of continuous
running.
When the value is expressed by the hour or minute, the motor is capable of
operation only for the time indicated on the rating nameplate. Run the motor again
only the motor has cooled down.

2.6 MAX. AMB.,ALTITUDE


When unspecified, operate the motor with an air inlet temperature of 40 or
less, and with altitude below 1000 m. Operate the motor with the ambient
temperature and altitude within the range specified on the rating nameplate. For
water cooled motors, water inlet temperature will be indicated.

2.7 THERMAL CLASS


This shows the insulation class.
As the value of temperature rise varies with the measuring method, refer to the
conforming standard.

2.8 STANDARD,PROTECTION,COOLING METHOD


The specified standard will be applied. Otherwise, our standard is JEC-2137.
The protection type is specified as IPXX. The first characteristic indicates the
degree of protection provided by the enclosure with respect to persons and also to
the parts of the machine inside the enclosure. The second characteristic indicates
the degree of protection provided by the enclosure with respect to harmful effects
due to ingress of water.
The cooling method is specified as ICXX. For details, refer to the standard.
EME000077-d
5

When unspecified, operate the motor with an air inlet temperature of 40 or


less, and with altitude below 1000 m. Operate the motor with the ambient
temperature and altitude within the range specified on the rating nameplate. For
water cooled motors, water inlet temperature will be indicated.

2.9 SERIAL NO,MANUFACTURED IN


The serial No. is specified for each machine to permit finding the records of the
machine. The manufacture indicates the year of completion of machine.

3. Acceptance inspection

Upon receipt of your motor, please take care of the following points.

(1) We have already provided a packing list or an invoice with your motor. Check
the motor against the invoice.

(2) First unpack carefully. Check each component for shipping damage.

(3) Make sure that the output, voltage, frequency and model designation indicated
on the rating nameplate comply with your ordering specifications.

(4) Special shipping protectors are fitted on


the bearing housing.
To prevent damage to the bearings
during transportation, the red painted
bearing protective devices are attached
on this motor. Refer to the attached CAUTION !!
caution card and remove the protectors. 1. Remove the red painted bearing
As there is case that this protective protective device before
devices are not only attached on the putting the motor into
load side bearing but also on the operation.
opposite load side bearing, confirm 2. Put the bearing protective
certainly that the protective devices on device in case of re-transport
the both bearings are removed before the motor after fitting the
trial run shaft end with coupling or
pulley.

(5) Check the entire motor carefully for damage, rust parts, fouled parts and
intrusion of harmful objects. If you have any question about your motor, please
do not hesitate to contact our representative.

The following should always be referred to any correspondence with us.

Data indicated on the rating nameplate (type, frame No., number of poles
output, voltage and frequency)
Serial No. (indicated on the rating plate)
Your specific requested information or questions.
EME000077-d
6

4. Storage

(1) Temporary storage


If the motor remains in the packed condition for some time before installation, it should
be kept in a dry place free from direct sunlight and drastic temperature change.
If the motor is stored at a place where the ambient temperature changes sharply, its
metallic surfaces are sure to sweat and corrode by the decreasing of temperature.
After it is unpacked, the motor should be provided with careful protection until the
installation is ready of from installation until it is put into actual service, to prevent
damage due to moisture, contaminants, entry of foreign objects, insects, etc., physical
abuses, tampering or violence.
The motor windings are sometimes subjected to the reduction of insulation resistance
due to moisture absorption, and metallic surfaces such as cores, teminal box, etc.
may rust due to condensation during storage, if proper precaution are not taken.
Anti-friction bearings are filled with grease; however, since sleeve bearing are without
a lubricant, they should be supplied with oil quantity specified in the motor outline
drawing or up to the mark indicated on the oil level gauge. Turn the rotor at regular
intervals to lubricate and protect the journal from rust.
Machined metal surfaces have been protected with rust inhibitive paint, rust inhibitive
oil or grease in our factory.
If damage on these surfaces is found, then repaint rust inhibitive agent for protection
after removing rust and moisture thoroughly.
If the motor has a space heater, be sure to turn the heater on.
When turning on the space heater source, check to see that the heater surroundings
are free from foreign objects and be sure that the voltage is normal. Check for
abnormal temperature rises during the first several hours after the power is turned on.

(2) Long term storage


The following explains what to do if the motor is to be stored or left unused for more
than six months.
In this case, the countermeasures shown in Table 1 should be provided in addition to
the ones specified for the temporary storage above.
The countermeasures for long term storage vary depending on the type of
construction or installed conditions, etc. Please be sure to consult our representative
for further information if you have questions.
Final inspection, treatment and adjustments before operation require expert
knowledge and skill. Our supervisors are available if needed.

Lifting of the motor


I) Lift and move the motor using
wire rope at lifting lugs with
crane.
II) Lift the motor properly balanced,
using chain hoist for adjusting
motor horizontally.
III) When lifting the motor, ensure
safety and take care, use wire
rope support or lifting beam etc.
so as not to cause damage to
any parts by wire rope.
(see an example shown in right)
IV) If the wire rope comes in contact
with any sharp corners, use
padding materials.
EME000077-d
7

Table 1 Styles of long-term storage and methods of quality preservation


for AC motor assemblies

Item Measure for quality preservation


Place
Style of Rust Protection from Inspection Inspection
of
Com- storage inhibition and deformation and method cycle
storage
ponent moistureproofing damage
(1) Wrap with (1) Pretreat and (1) Put a canvas (1) Unpack and
a poly- apply an air- sheet over for check the
ethylene dry type coil protection appearance
sheet, and varnish on the from damage for damage.
put on base mounting and rain and
sleepers surface. air borne (2) Measure the
in order to contaminants. insulation
prevent (2) Pretreat and resistance of
the cree- apply air-dry (2) Never windings.
page of type coil stack the
moisture varnish on the components (3) Every six
Stator from the exposed parts and parts on months,
floor. of machined top of each remove the
surfaces. other. rust inhibitor
(2) Pack by from the shaft
sealing a (3) Attach a (3) Protect any ends and
desiccant space heater instruments couplings,
in the poly- inside the with plywood and check
ethylene motor, and boards. visually for
sheet. keep it rust
(silica-gel energized at development.
300 to 500 all times. Every six
Indoors
g/m3) (4) Inspect the months
(1)Pretreat the shaft journals
shaft journal every six
and oil months.
Rotor slingers, and
apply rust (5) For the
inhibitive oil. anti-friction
bearings, turn
(1) For sleeve them every
bearings: six months,
Pretreat the and supply
spherical grease or
surface and replace the
babbit metal, grease
and apply rust completely.
Bearings
inhibitive oil.

(2) In case of
anti-friction
bearings:
Supply grease.

Seal N2 gas into Protect the Attach a pressure Every


the tube. cooling fins to gauge, and three
Air
49kPa prevent damage. monitor the N2 months
cooler
(0.5kg/cm2) gas sealed
condition.
EME000077-d
8

5. Installation

5.1 Foundation design and engineering


For the design and construction of the foundation, expert knowledge of civil
engineering is necessary that cannot be explained in detail here, but in the
foundation preparation the following points should be considered.

(1) The foundation should not only have enough strength to support static and
dynamic loads of the motor itself, but also it must endure the mechanical
vibrations.

(2) The load supporting areas, shape and weight of the foundation should be
determined so as not to develop ground subsidence, sliding, floatation and
wandering.
If the subsoil conditions are poor, the usual practice is to drive in piles and it
should be considered that all loads are borne only by the piles. In this case,
the supporting capacity of the soil is usually neglected.

(3) When a ventilation duct is to be set in the foundation, care should be taken not
to allow ground water into the duct. If water seeps into the duct, the coil
insulation will deteriorate due to moisture.

(4) During the first four weeks after concrete is poured, and particularly in the first
one to two weeks, the concrete will increase its strength sharply. Thus, the
concrete surfaces and boards should be covered with mats, cloths or sand and
sprayed with water. They should be kept wet for at least one week in summer
and at least two weeks in winter in order to ensure thorough curing.

(5) Be sure to cover the anchor bolt holes to prevent foreign objects entering.

(6) The upper surface of the foundation should be finished as flat as possible in
order to facilitate the motor installation.

(7) Chip the concrete foundation surface to a depth of about 50mm and roughen in
enough to allow easy centering or increase adhesion between mortar and
foundation.

5.2 Centering and alignment


After the foundation has been cured completely, the centering and alignment
work which is the most important in the motor installation is performed. The
centering and alignment practices vary depending on the type of motor to be
installed. Here we shall show a typical example, that is, a bracket type motor.
When the driven machine has already been installed, the installation of the motor
should be carried out with the coupling of the driven machine as a reference.

(1) While checking the magnetic center gauge at the bearing end, adjust the rotor
end play to the value specified in the drawing. The end play means the
maximum axial play of the rotor. Standard end-play tolerances are as shown in
Table 2, except when equipped with special thrust bearings, when requested
from directly-coupled machines or when the end-play is slightly restrained as in
the case of wound-rotor motors with brush-lifting devices. Adjust the axial
center of the stator by measuring the relative positions of the stator and rotor
cores.
EME000077-d
9

Table 2 End play tolerances


End play (mm) Tolerances (mm)
8 +2.5
(End float=16) -2.5

(2) As shown in Fig.2, install the dial indicator onto the coupling of the motor side,
measure the parallelism and the degree of eccentricity while quietly turning the
rotor of the motor by using the coupling section, and adjust the shaft center.
However, since this may vary depending on the type of the machine, also contact
the machine manufacturer for further details.

Generally, for measurement of the parallelism, the thickness gage or taper gage
is used, whereas, for measurement of the degree of eccentricity, a dial gage is
installed on the coupling of one side and the shaft is turned by 0 degree, 90
degrees, 180 degrees and 270 degrees to read the values of the four locations.
(see Figures 3 and 4)

Table 3 Alignment Reference Values (Unit: mm)


Over 1000
Over Up to
Speed of rotation -1 up to
1500 min 1000 min-1
1500 min-1
Deviation of degree of
Rigid eccentricity
0.02 0.03 0.04
coupling Deviation of
parallelism
0.03 0.04 0.05
Gear coupling 0.06 0.08 Less than 0.1

Coupling matchmark Dial indicator

Motor side Load side

Fig. 2 Centering and alignment method with the coupling as a reference

Measurement of degree of eccentricity


Measure and record the values of the four locations with the dial gage by turning
both shafts. Find the corrected value as shown below.

90 B
Left-to-right A-C
corrected quantity = 2
180 0 C A
Top-to-bottom B-D
corrected quantity =
2
270 D

(Measurement point) (Measured value) (Corrected quantity)


Fig.3 Measurement of degree of eccentricity
EME000077-d
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Measurement of parallelism
Measure and record the values of the four locations, E1, F1, G1, and H1, with a
thickness gauge at the combination position of both shafts for the measurement of
parallelism. Next, rotate the both shafts by 180 degrees, and then measure and
record the values of the other locations, E2, F2, G2, and H2. Find the measured
values as shown below.

F1 F2
Left-to-right (F1+F2)-(H1+H2)
corrected quantity =
2
G1 E1 G2 E2
Top-to-bottom (E1+E2)-(G1+G2)
corrected quantity =
H1 H2 2

(Measured value) (Corrected quantity)

Fig.4 Measurement of parallelism

If your machine system is large or runs at a high speed, high-level technique is


necessary for adjustment at journals, or axial and radial runout adjustment at
the coupling etc., because of taking into consideration rotor deflection or critical
speed vs. running speed relationship, etc. We recommend that you ask us for
expert technical assistance. Note) The end float means the total value of the
both-side end plays.

(3) Next, measure the gap between the stator and rotor at three or four positions for
both the coupling side and the opposite side, and be sure that the differences
between the maximum and minimum gaps is within 20% of the average values
gap measurements.

5.3 End play and damage prevention of sleeve bearings


When a sleeve bearing motor is run independently, the rotor turns at the
magnetic center. If the rotor was shifted in the axial direction for some reason, a
return force acts. Since this force is very small, the rotor cant return easily to the
magnetic center if the rotor is held by an external force. When a flexible coupling is
used on a high-speed machine, it becomes more difficult for the flexible coupling to
slip in proportion to the increase in contact pressure to transmit the torque.
The flexible coupling has a movable distance in the axial direction, and should be
less than the end play of the motor.

[1] There are cases that the motor end play becomes zero, because the coupling
can move freely due to the absence of torque to transmit when the motor
stops.
If the motor is restarted at this time, the bearing side surface of the motor will
be in a state of metallic contact.
[2] If the motor shaft receives an axial thrust during rotation, the result will be the
same as above.

In general, the end-play of the bearing of motor should have a greater value than
that of flexible coupling or gear coupling, in order to prevent the burning of the
bearing.
When installing the motor, check the dimensions in Fig.5.
EME000077-d
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Fig.5 Relation between the end-play of the bearing and the flexible coupling

The space of 1mm or more is necessary.

When assembling the two flanges, align the magnetic center gauge with the red
datum-line of the shaft, in order to decide the position of the motor.
Note: Examine the connecting surface of the coupling or faucet whether there are
scars on it. If any, polish the surface gently with an abrasive stone.

5.4 Mortar grouting


After the motor has been installed correctly and the anchor bolts have been
tightened, grout mortar under the base and into the anchor bolt holes.
In this case, pay attention to the following items.

(1) Roughen the foundation surface in order to ensure adhesion of mortar after
clearing thoroughly.

(2) Spud the mortar to drive out cavities.

(3) During mortar grouting work, take care not to move the packers and subpackers
by mistake.

(4) After the mortar has been grouted, thoroughly cure it by the same way as the
foundation concrete work.
The curing period should be at least one week in summer and at least two
weeks in winter.
After the concrete has cured enough, tighten up the anchor bolts, and check the
record of the alignment workmanship. If there is nothing wrong with the
installation, assemble the floor deck plates and piping, and drive dowel pins into
the foot of the stator frame. For some motors, the dowel pins are driven in after
trial run and readjustment.
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5.5 Prevention of shaft current


Shaft insulation is applied to the motor for prevention of harmful shaft currents.
Usually, the shaft is insulated on the opposite side bearing to the load as shown in
Fig.6.
But when selecting a double shaft-end motor, the couplings should be insulated
because it is also necessary to insulate on the opposite side coupling to the main
load in addition to the above measure.
Refer to the bearing instruction manual for details of shaft insulation.

Fig. 6 Shaft insulation arrangement


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5.6 Piping (For motors requiring external lubrication oil supply or water cooling)
When the piping system is designed and executed on your part, pay attention to
the following points.

(1) Prepare the oil discharge system of the motor as described below, in order that
the vapor in the bearing on the machine side and the oil tank may not cause the
counterflow into the bearing of the motor.
a) Separate the oil discharge pipes of the motor from those of the machine. Do
not connect them in the middle.
b) Establish the oil tank with a vapor drain, which is big enough to have either
[1] or [2], in order to decrease the inside pressure of the oil tank and of the
pipes to a natural atmospheric pressure.
[1] a discharge drain without a fan
[2] a drain with an exhaust fan
c) As for the oil draining pipes from the common pipes to the oil tank, the
gradient must be between 1/30 and 1/50. If the gradient of the oil draining
pipes is not sufficient, and/or its cross section is too small, then, the oil wont
flow smoothly, and it may overflow or cause a leak.
d) The pipe diameter must be large enough.

(2) Be sure to attach a pressure gauge and


a flow meter to the oil inlet line and the
water supply line. Also provide an oil
sight for the oil outlet line and a water
sight for the water drain line to facilitate
inspection of the pressure and flow of the
fluids.

(3) Install the piping along the machine body,


and saddle them with proper fittings to
prevent them from shaking.

(4) Be sure to attach the orifice plate (refer


to attached caution card) or flange type
adjusting valve to the oil inlet. Since the
size of the orifice plate or the valve
opening has been adjusted in our factory,
it should not be tampered with.
EME000077-d
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(5) The oil piping should be designed and adjusted with account taken of the oil
pump, pressure regulator and other pipes so that the pressure and flow rate
specified in the outline drawing can be attained at the motor bearing inlets.

(6) Make sure that there are no foreign objects like rags left inside the pipes. Then,
clean them thoroughly and connect them. The cleaning before the pipe
connection is accomplished in one of the following two methods.
One method is to blow in steam at a pressure of 200 to 300 kPa. The other is
to pickle with 10% aqueous solution of sulfuric acid or hydrochloric acid,
neutralize immediately with a 20% aqueous solution of caustic soda, and then
rinse with water.
Either method should be followed by lubrication with turbine oil for preventing
rust.

(7) Return oil lines utilize gravity for flow. This requires the lubrication oil system
to be below the motor bearing elevation and a continually dropping elevation of
the return oil piping.

(8) After the piping has been completed, it should be flushed thoroughly before
being fitted to the motor bearings.
The flushing can be carried out by using the oil feed pump furnished together
with the motor or a separate oil pump which doubles as a filter.
When the flushing has been carried out by using the oil feed pump, be sure to
clean the oil tank thoroughly before a trial run. Since flushing oil circulating in
the piping system is including foreign matter, it should not be run into the
bearing metals. Specifically, the piping should be modified to bypass the
bearing metals and to connect the inlet and outlet lines at the outside of the
bearing housing.
The flushing oil returning to the oil tank should be passed through an 80-to 100-
mesh wire filter. The flushing will be complete when foreign matter is no longer
trapped by the filter.
The filter should be replaced at an interval of several hours.
The flushing will take 24 to 48 hours, or as long as a week if the piping is long.
For the purpose of flushing, prepare reclaimed oil as well as fresh oil.
The flushing oil is used by heated to 70 to 80. During flushing operations,
hammer the pipes to dislodge incrustations from the pipe inner walls and scour
them away with the running oil. Clean the bearing housings, bearings, oil tank
and oil cooler thoroughly, and make sure that there is no foreign matter left in
the piping system.
After the flushing has been completed, set up the original piping, charge fresh
oil, and check for oil leaks and adjust the oil quantity to prepare for the trial run.
EME000077-d
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6. Preparations and inspections before trial run

The motor has passed strict factory tests.


But we cannot prevent accidents during transportation or harmful effects during
long-term storage.
Thus, pay attention to the following items.

6.1 Measurement of insulation resistances


If the rated voltage is less than 600V, use a 500V megger. If it is 600V or more,
use a 1000V megger.
For insulation resistances, refer to the section titled as insulation resistance.

6.2 Inspection of electrical circuits


Check the wiring for power supply circuits and protective devices based on the
wiring diagram.
Also inspect tightening condition in each connection, insulation, and clearance
where no electrical contact is allowed.
Especially when a current transformer (CT) is installed, confirm that its
secondary terminals are connected to a measuring instrument or are short-circuited.
If used with the secondary terminals left open, a high voltage will arise between the
terminals, which can sometimes damage the CT.

Terminal connection in auxiliary terminal box


If not specified, terminal blocks for wiring of protective devices may be WAGO
type without screws. When connecting terminals, please see outline drawing of
terminal box or instructions of next page, and connect terminals properly.

6.3 Inspection of grounding wires


Grounding terminals are provides on the stator frame and terminal box. Check
them with the outline drawing and make sure that the grounding wires are
connected properly.

6.4 Bearings
For the inspection of the bearings, refer to the bearing cooling system described
in the motor specifications and outline drawing. If the bearing cooling system is not
stated, the bearings are the natural cooling type; the anti-friction bearings are
lubricated by grease, and the sleeve bearings are lubricated by oil rings. Be sure
to greases and oils specified in the nameplate or outline drawing.

(1) Natural cooling type (anti-friction bearings)


Grease has been filled in the bearings at the factory.
Confirm whether there is grease leakage on the shaft, oil slinger, or bearing
housing, etc.

(2) Natural cooling type (sleeve bearings)


Fill lubricant up to the level marked on the oil gauge.
Oil supply over the oil gauge level may result in oil leakage, and oil shortage
may lead to excessive temperature rise.

(3) Forced feed lubrication type


Confirm that the orifice plate of bearing or flange type adjusting valve is fitted.
After checking the lubricating system according to the piping diagram, circulate
the specified lubricant. During check the oil flow, oil pressure and oil
circulation through the oil site make sure that the piping has not trace of oil
leakage.
EME000077-d
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Instruction for connecting conductor (WAGO Rail Mount Terminal Blocks with CAGE CLAMP)
Stripping of WirePlease strip a conductors stripped length related as drawings.
Please fix splayed, bent or twisted wire.

Conductors stripped length (Std) For space heaters (WAGO 282) : 12 to 13 mm


For RTDs etc. (WAGO 870) : 6 to 7 mm
Connecting Please follow the instructions.

[1] Put a screwdriver to the [2] Insert a screwdriver to the [3]The screwdriver will be
operating slot. inside of the terminal block. fixed when operated
correctly.

[4] Insert a wire to the wire [5] Pull out a screwdriver [6] Pull a wire slightly to check
hole. from the operating slot. if connecting has been
(Please hold a wire.) done completely.
(Do not pull strongly.)

Removal Operate a screwdriver in the same way with connecting.


Open a spring and pull out wire.
EME000077-d
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6.5 Dielectric strength test

Measure the insulation resistance, and make sure that it is higher than the
specified limit. Then conduct a dielectric strength test according to the following
procedures.
The test voltage to be impressed should have an effective value specified below
and should be free of harmonics. The test voltage should also be adjustable up to
a specified value. To test the motor, increase the test voltage to a specified value
at the rate of 1000V/sec. Keep the test voltage at that value for a specified period,
and then reduce it to zero immediately.

(Caution: When impressing the test voltage, be sure to use a device capable of
adjusting the test voltage. Never impress or cut off the full voltage directly by
making use of a switch.) After the dielectric strength test has finished, be sure to
discharge the tested winding. Never touch the windings until they have been
discharged.
To carry out the dielectric strength test, connect together those terminals which
are rated at the same voltage, and impress a specified test voltage between this
connection and the ground. All other windings except those to be impressed with
the voltage must be grounded.
When a specific phase or a part of a specific winding is subjected to a dielectric
strength test, disconnect the ends of that phase or that part completely and connect
the ends together. Impress a test voltage between the ends and the ground.
All other phases and windings should be grounded in advance. Since a high
voltage is used in the dielectric strength test, take care to shield people from electric
shock by keeping them away from the motor during the test.
For the rules concerning the dielectric strength test voltages, refer to the specific
technical standards applicable.
Excerpts from the Technical Standards for Electrical Instruments.
Chapter 1; Section 3, Insulation and Earthing of Distribution Line
Article 15
The generators, motors, synchronous condensers and other rotating machinery (exclusive of
rotary converters) shall withstand for consecutive 10 minutes the test voltages specified below in
relation to their maximum service voltage when applied between their windings and the ground.

The test voltage shall be 1.5 times as high as the maximum service voltage if the maximum
service voltage is up to 7,000V.
(If the test voltage calculated as above is less than 500V, it shall be set at 500V.)
The test voltage shall be 1.25 times the maximum service voltage if the maximum service voltage
is higher than 7,000V.
(If the test voltage calculated as above is less than 10,500V, it shall be set at 10,500V.)

Further, the foregoing dielectric strength test voltage apply to new motors, and
when the dielectric strength test is being conducted after a regular inspection, etc., it
is necessary to review the voltage value.
EME000077-d
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6.6 Others
Check for loosened bolts, nuts, dowel pins and connections. Unless
otherwise designated, use the tightening torques listed in Table 4 when
tightening bolts.
Table 4 Specified torques for bolt tightening

Screw nominal Reference value Tolerable range


Nm Nm
M5 0.8 3.24 2.75 3.63
M6 5.49 4.71 6.37
M8 13.2 11.3 15.3
M10 26.5 22.6 30.4
M12 46.1 39.2 53.0
M16 110 93.2 127
M20 216 181 245
(M22) 284 245 333
M24 363 314 422
M30 735 628 843
M36 1280 1090 1470
M42 2050 1750 2350
M48 3090 2650 3520
M56 4950 4220 5680
M64 7350 6280 8420
EME000077-d
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7. Trial run

At first, after running the motor independently by disconnecting the intermediate


shaft, etc. from the motor and confirming that there is no problem, connect it to its
driven machines, and run together.
Whenever energizing the motor including a trial run, be sure to attach the cover
to the terminal box.

1) Measure the supply voltage to check if the line voltages are balanced and are
roughly in agreement with the rated motor voltages.

2) When starting the motor, keep the driven machine free from or at minimum
possible load. Cut off the power source immediately after starting and perform
the following inspection while it is rotating freely by inertia.
(1) Confirm that the motor is running in the rotating direction specified in the
outline drawing or in the rotational arrow plate.
(2) Confirm that the bearing oil ring is turning normally.
(3) Confirm that there are no abnormal noises or vibration, or there is no
smell insulating materials burning.

3) If there is no abnormalities under the above inspection, restart the motor and
inspect the bearing temperature, vibration, end play and oil ring rotation.

4) Continue the no-load running until the bearing temperature reaches saturation.
After confirming that there are no abnormalities, proceed to full-load operations.

8. Normal run

8.1 Starting

(1) Confirm that the starting conditions have been established.


(a) Oil are lubricated to the bearings in the case of forced lubrication system.
(b) When a starting device is used, the circuit is set up to suit the starting
conditions.

(2) During the starting, check that the starting is normal.


(a) Starting current
(b) Starting time

(3) In case of starting failure, follow the conditions of starting duty.


For details, refer to the section starting duty of motor.
When the motor is restarted immediately after the power source was cut off,
even if restarting is possible, the motor is likely to be damaged because of an
abnormal starting current caused by the residual induced voltage. Therefore,
wait for 10 sec to restart after the power source was cut off.

(4) To restart after a long-term stop of two weeks or more, check the following.
(a) Insulation resistance measurement of the motor circuit.
When it does not satisfy the values noted in section 10.3, dry with a
space heater, etc., and restart after the insulation resistance has
recovered.
(b) The oil level should be in the indicated line.
(c) Upon starting, the noise, vibration and oil ring turning condition should be
as usual.
(d) Conduct the routine inspection of Table 5-1.
EME000077-d
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(5) Starting abnormalities


Check by Table 11. When the cause and conditions cannot be determined,
contact us.

8.2 Running
During a run, check by Tables 5-1 and 5-2 to confirm that there are no
abnormalities.

9. Maintenance

The service life of motor is dependent largely upon maintenance. Record the
data at regular intervals according to the following maintenance and inspection
standard.
The data logging makes clear the trend of motor conditions to prevent troubles.

9.1 Contents of inspection


The inspection of the motor may be divided into the following two groups
according to their contents.

9.1.1 Daily inspection


Inspect the motor by a visual check, sense of touch, sense of hearing, etc. on its
external appearance.

9.1.2 Regular inspection

(1) Simplified inspection


After dismounting the motor and its cover, inspect the coil end and the bearing
metal especially. (About every 2 years)

(2) Full-scale regular inspection


By pulling out the rotor from the motor, check the internal parts minutely.
In addition, regarding the auxiliary equipment such as lubricating devices.
Check it according to the respective manuals, as same in the case of the motor.

9.2 Interval of regular inspection


The basic idea for maintenance inspection is systematic monitoring. For this
purpose, it is important to carry out the inspection continuously at proper intervals on
necessary items.
The extent and interval of the regular inspection should be determined by taking
the operation environment, starting duty, the starting time, and characteristics
important to the driven machine, into account.

(1) Simplified inspection


Simplified inspection should be performed between full-scale inspections, at
your convenience.

(2) Full-scale regular inspection


(a) Initial inspection
1-2 years after starting operation is recommended
There are cases where so-called initial failures are induced by causes
such as the structural adaptation to the environment, entry of foreign
objects during transportation or assembly at site, fit of structures, etc.
The maintenance inspection that removes these initial failure factors at
the proper time after starting operation is extremely effective for long-
EME000077-d
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term trouble-free operation.


(b) Interval of regular inspections after the initial inspection
About every 4 years after the initial inspection is recommended

9.3 Major inspection items


At the time of the daily inspection and regular inspection, the inspection should
be carried out according to maintenance and inspection standards as shown in
Table 5 to 8, including the following major inspection items.

(1) Check for the looseness of stator coil wedges and stator coil end bound by
strings
The core slot part of the stator coil and the coil end part are prevented from
looseness caused by the electromagnetic vibration acting on the coils by means
of wedges and binding strings. The coil, wedges, spacers and binding strings,
etc. are composed of insulators, and sometimes the wedges and binding strings
become loose due to electromagnetic vibration during operation and the
changing fit from the heat cycle. If these are left for a long period, insulator
wear off and insulation may break down because the coils are caused to
oscillate by the electromagnetic force and mechanical vibration. Therefore, it
is necessary to inspect them at regular interval.

(2) Check for the looseness, dislodgment of soldered parts and axial movement for
rotor bars
In the case of the squirrel cage type induction motor, fatigue progress on the
rotor bars, the short-circuit rings and its soldered part because of thermal stress
and electromagnetic force caused by inrush current at the starting time and
centrifugal force caused by rotation act on them. When checking the rotor at
the regular inspection, etc., there may be cases where the rotor bars are
slackened, all of the rotor bars shifted in the axial direction, and the soldered
parts between the rotor bars and the short-circuit ring are partially dislodged. If
operation continues under this condition, cracks and breakage may develop in
the rotor bar end part, the end part is expanded in the radial direction by the
centrifugal force, thus causing damage to the stator coil and developing
insulator breakdown. Therefore periodic inspection of these items is important.

(3) Bearing
The bearing periphery needs inspection for temperatures, abnormal noises, the
scars on the journal surface due to vibrations, and foreign objects. In particular,
the bearing periphery pay attention to (a) metal contacts and scars, (b)
movement, deformation and abrasion of oil rings, (c) oil blackening or grease
discoloring (d) oil level (e) oil leakage.

(4) Dust adhering to the stator coil and ventilation duct space of the core
Dust adhering to the stator coil will worsen the thermal conduction, and dust
adhering to ventilation duct space of the core will reduce the amount of cooling
air. Both causes lead to increase of temperature rise.
In case dust adhesion is found, either determine the cleaning interval
appropriate to the dust quantity or take countermeasures to prevent dust
intrusion.

(5) Checking the looseness of the stator core saddle plate stud and bolt fastening
parts
The saddle plate which supports the stator core is fixed to the frame with studs
and nuts (these are bolts if the machine is bipolar). Due to torque reactions and
machine vibrations resulting from operation, the stud and bolt fastening parts
may become loose. Leaving this unattended for a long time may cause the
adjustment plate to fall off or the stator to move thus resulting coming in contact
EME000077-d
22

with the rotor. Therefore, it is necessary to periodically check the looseness of the
stud and bolt fastening part and tighten the bolts more, as shown in Fig. 7 .

2 poles

4 poles and above

4 poles and above

Large machines

Fig. 7 Stator inner part fastening method

9.4 Test run after inspection


Execute the test run after the maintenance inspection according to the contents
of item 6 and item 7.
EME000077-d
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Table 5-1 Maintenance and inspection standard - Daily inspection (during motor operation)

Inspection procedure
Category Subject of Inspection Method of Requirements
inspection cycle inspection
1. Power Voltage Daily Voltmeter Limit: Within 10% of rated values at rated
source frequency.
Frequency Daily Frequency meter Limit: Within 5% of rated values
Where the voltage and frequency change
concurrently, the sum of the absolute values of
their changing ratio shall be within 10%.
2. Running Vibration Weekly Sense of touch Where the vibration is felt to increase over
conditions and vibrometer ordinary level, measure the value.
Judge the vibration level according to section
10.4.1.
Current Daily Ammeter The current shall be less than the rated value,
and shall be in order.
Odor Daily Sense of smell No burning smell.
Noise Daily Sense of hearing Check the noisy parts and use a stethoscope if
and stethoscope necessary.
Temperature Daily Sense of touch, No change in temperature rise from the values
(frame,bearing, thermometer at the initial time.
coil)
Cover and Weekly Visual inspection No falling off and loosening of fixing bolts.
the like
Ladder and Weekly Visual inspection No falling off and loosening of fixing bolts.
platform
No corrosion
3. Environ- Ambient Weekly Thermometer Within the standard values and normal
ment temperature
Ventilation Weekly Visual check No blockage in the ventilation grills, etc:
The motor blower, if working, is normal.
4. Bearing Temperature Daily Sense of touch, When the temperature is sensed as abnormal,
thermometer measure it with a thermometer.
4.1 Sleeve Temperature limits of self-cooled bearings:
bearing Up to 92, measured at the metal lower half
(reading value)
Oil level and Daily Visual inspection Be normal oil level.
oil leakage
Oil pressure Daily Visual inspection Be normal.
Oil ring Daily Visual inspection Be rotating smoothly.
4.2 Anti- Rotating Daily Sense of Be normal
friction noise hearing,
bearing stethoscope
Temperature Daily Sense of touch, When the temperature is sensed as abnormal,
(includes oil thermometer measure it with a thermometer.
slinger) Temperature limits (reading value):
Up to 100, measured by embeded
thermometer
Up to 95, measured on surface of housing
Grease fill-up As specified Grease gun Refill as required.
EME000077-d
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Table 5-2 Maintenance inspection standard - Daily inspection (during motor operation)

Inspection procedure
Category Subject of Inspection Method of Requirements
inspection cycle inspection
5. Cooler Water Daily Visual check No leak
leakage
Water Daily Pressure gauge Specified pressure
pressure
Water flow Daily Flow sight Flowing
EME000077-d
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Table 6 Maintenance inspection standard - Daily inspection (when the motor is stopped)

Inspection procedure
Category Subject of Inspection Method of Requirements
inspection cycle inspection
1. Cooler Check in Monthly Service log
detail the
troubles
recorded on
the service
log
2. Appear- Damage and Monthly Visual check Clean and make repairs
ance dirt on the
frame and
terminals
Cooling Monthly Visual check Cleaning of found clogging
pipes, air duct
and filter
3. Bearing
3.1 Sleeve Oil contami- Monthly Visual check No sludge babbit metal chaffings or any other
bearing nation foreign objects
3.2 Anti- Discharged Monthly Drain port No metallic powder or any other foreign
friction grease objects, or contamination in grease
bearing
4. Earth brush The amount of Monthly Visual check Check the amount of brush wear with reference
(when brush wear to the following page, and exchange brushes
attached) according to the wear extent.
EME000077-d
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Inspection and exchange of earth brush

The earthing brush may be attached near the bearing of a motor in order to prevent a
harmful shaft current. Some structures of earthing brush attachment are shown below, and
please check the amount of wear of a brush at the time of a motor stop. Brush exchange
should make the position of illustration a standard and should carry it out a little early.

[Example #1]
1. When the top of a brush comes to the position of A, exchange the brush for a new one.
2. If the wear extent of a brush is greater than 1mm per a month, adjust brush pressure within
18 to 22 kPa with adjusting screw.

Measuring method:
Put a thin paper between shaft and brush, and measure brush pressure
to pull up the support of a brush holder with a spring scale.
The brush pressure measured by a spring scale should be about 1kg
when the paper can be pulled out.

[Example #2]
This structure is a constant-pressure spring system.
Remove a brush at the time of a motor stop, and carry out a check of the amount of brush
wear and cleaning.
When it wears out from the metal plate of a brush to about 10mm as shown in a figure,
exchange the brush for a new one.
EME000077-d
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Table 7-1 Maintenance inspection standard - Regular inspection (Simplified inspection, field
disassembly of the protective cover upper half and bearing housing upper half for inspection)

Inspection procedure
Category Subject of Inspection Method of Requirements
inspection cycle inspection
1. Investiga- Check in 2 years Service log Make repairs if necessary
tion operation log
for abnormal-
ities
2. Measure- Coil insulation 2 years Megger Desired values of stator coils
ment resistance R kV + 1 (M)
where
R: minimum insulation resistance at 40
kV: rated voltage (kV)

Air gap 2 years Gap gauge Max, value - min, value


100 20%
Mean value

3. Appear- Pollution or 2 years Visual check Cleaning and repairs


ance worn painting
on the frame
Terminals 2 years Visual check Repair if abnormal
Filter 2 years Visual check Clean and repair
(Replace when necessary)
Bolt joints 2 years Visual check Freedom from looseness, dropping off and
damage.
4. Stator Core and coil 2 years Visual check Freedom from dust, oil, moisture and foreign
objects.
Core 2 years Visual check Freedom from unevenness, overheating,
discoloring, damage, rust, etc.
Core ends 2 years Visual check Freedom from tumble or protrusion of air duct
spacers, loosened or damaged core sheets.
Coil ends 2 years Visual check Freedom from deformations, damage and
pollution
Insulating 2 years Visual check Freedom from varnish spouting, void and
materials tracking, etc.
Wedge 2 years Visual check Freedom from loosening
Coil supports 2 years Visual check Freedom from shifting, getting out and
loosening
Air deflector 2 years Knocking sound Freedom from loosening and cracks
Visual check
5. Rotor Core 2 years Visual check Freedom from rust, loosening, dust, oil,
moisture, other foreign objects,
overheating, discoloring and damage
Connection of 2 years Visual check Freedom from cracks and bar shifting
rotor bars and
end ring
EME000077-d
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Table 7-2 Maintenance inspection standard - Regular inspection (Simplified inspection, field
disassembly of the protective cover upper half and bearing housing upper half for inspection)

Inspection procedure
Category Subject of Inspection Method of Requirements
inspection cycle inspection
6. Bearing
6.1 Sleeve Metal 2 years (Overhaul ins- Lower metal to be in good working order
bearing Contact pection of Upper metal to be free from contact marks
bearing)
Visual check
(magnifying
glass)
Metal 2 years Color check 50% or more
adhesion
Metal 2 years Micrometer Refer to sleeve bearing instruction manual
clearance
Oil slinger 2 years Thickness Within limit
gauge
Oil ring 2 years Visual check Freedom from deformation and serious
wear: freedom from loosened setscrew
Oil 2 years Visual check Freedom from dirt, deterioration and foreign
objects
End play 2 years Thickness Within limit
gauge
Scale Refer to Sect. 5.2 Table 2.
6.2 Anti- Grease con- 2 years Visual check Grease replacement
friction termination
bearing
7. Instruments Dirt, damage 2 years Visual check Freedom from dust, oil, moisture, foreign
objects and damage
8. Coupling Deviation of As required Dial gauge Within tolerances, Refer to Sect. 5.2.
degree of ec-
centricity and
parallelism
Centering As required Dial gauge Within tolerances, Refer to Sect. 5.2.
Direct coupling As required Visual check Freedom from the loosening of the bolts and
nuts.
Damage As required Visual check Freedom from damage and breakage of key
way
(color check if No abnormal wear on tooth surface of the gear
required) coupling.
9. Operation Abnormal 2 years Sense of No abnormality
on load noise, hearing
vibration Sense of touch
abnormal odor Sense of smell
Rotational 2 years Visual check Normal rotational direction
direction
10.Shaft Protective 2 years Visual check After cleaning, measure insulation resistance
current device Tester : 0.5M or more at single motor
when disassembled
EME000077-d
29

Table 8-1 Maintenance inspection standard - Regular inspection


(Full-scale regular inspection by drawing out the rotor)
* Cycle 4 years shows the intervals from the initial inspection. The initial
inspection shall be 1-2 years from the start of operation (Refer to Sect. 9.2)

Inspection procedure
Category Subject of Inspection Method of Requirements
inspection cycle inspection
1. Investiga- Check the * Service log Make repairs if necessary
tion operation log 4 years
for abnormal-
ities
2. Measure- Shaft level Level meter Measure the level at both journals, and make
ment sure that the difference is within 0.05 mm/m.
Coil insulation 4 years Megger More than specified values
resistance Refer to Table 7.

Space heater 4 years Megger More than 1kwith a 500V megger


insulation
resistance
Air gap 4 years Gap gauge Refer to Table 7
3. Appear- Pollution or 4 years Visual check Cleaning and repairs
ance worn painting
on the frame
Filter 4 years Visual check Clean and repair
(Replace when necessary)
Bolt joints 4 years Visual check Freedom from looseness, dropping off and
damage.
4. Stator Core and coil 4 years Visual check Freedom from dust, oil, moisture and foreign
objects.
Core 4 years Visual check Freedom from unevenness, overheating,
discoloring, damage, loosening, rust, etc.
Core ends 4 years Visual check Freedom from tumble or protrusion of air duct
spacers, loosened or damaged core sheets.
Air ducts 4 years Visual check Freedom from clogging
Coil ends 4 years Visual check Freedom from deformations, damage and
pollution
Insulating 4 years Visual check Freedom from varnish spouting, void and
materials tracking, etc.
Coil supports 4 years Visual check Freedom from shifting, getting out and
loosening.
Wedge 4 years Hammering Freedom from withering, loosening and falling
off.
Coil binding 4 years Visual check Freedom from shifting, loosening, discoloring
strings Sense of touch and deterioration.
Lead cable 4 years Visual check Freedom from damage, deterioration and
and terminals deformation of terminals.
Freedom from dust, oil, moisture and adhering
foreign objects.
Air deflector 4 years Visual check No abnormality in the welded part.
No loosened bolts.
Space heater 4 years Visual check Freedom from loosened fastener parts, dust,
oil, moisture and adhering foreign objects.
5. Rotor Core 4 years Visual check Freedom from rust, loosening, dust, oil,
moisture, other foreign objects, overheating,
discoloring and damage
EME000077-d
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Table 8-2 Maintenance inspection standard - Regular inspection


(Full-scale regular inspection by drawing out the rotor)
Inspection procedure
Category Subject of Inspection Method of Requirements
inspection cycle inspection
Joint of rotor * Visual check Freedom from cracks. Dislocation of silver
bars and end 4 years Color check solder shall be less than 50% for each side
ring of joint surface. No bar shifting.
Rotor bar 4 years Hammering Freedom from loosening.
Fan 4 years Visual check Freedom from fan blade deformation.
Balance weight 4 years Hammering Freedom from loosening.
Shaft journal Visual check Freedom from scars, knock marks, pressing
Sense of touch marks.
6. Bearing
6.1 Sleeve Metal contact Yearly (Overhaul ins- Lower metal to be in good working order
bearing pection of Upper metal to be free from contact marks
bearing)
Visual check
(magnifying
glass)
Metal Yearly Color check More than 50%
adhesion
Metal Yearly Micrometer Refer to sleeve bearing instruction manual.
clearance
Oil slinger Yearly Thickness Within limit
gauge
Oil ring Yearly Visual check Freedom from deformation and serious
wear: freedom from loosened setscrews
Oil Yearly Visual check Freedom from dirt, deterioration and foreign
objects
End play Yearly Thickness Refer to Sect. 5.2 , Table 2
gauge
Scale
6.2 Anti- Grease con- Yearly Visual check Grease replacement
friction termination
bearing
7. Instruments Correction * Comparison Within standard values.
4 years with standard
8. Coupling Deviation of As required Dial gauge Refer to Sect. 5.2.
degree of ec-
centricity and
parallelism
Centering As required Dial gauge Refer to Sect. 5.2.
Direct coupling As required Visual check Freedom from the loosening of the bolts and
nuts.
Damage As required Visual check Freedom from damage and breakage of key
way
(color check if No abnormal wear on tooth surface of the gear
required) coupling.
9. Operation Abnormal Yearly Sense of No abnormalities
on load noise, hearing, touch,
vibration and smell
abnormal odor
Rotational Yearly Visual check Normal rotational direction
direction
10.Cooler Inside inspec- * Visual check Freedom from abnormal corrosion and
tion 4 years pinholes.
Hydraulic test 4 years Hydraulic test Freedom from leakage and deformation.
11.Piping Damage 4 years Visual check Freedom from loosened fastenings, water
leakage, oil leakage and corrosion.
12.Shaft Protective Yearly Visual check After cleaning, measure insulation resistance
current device Tester : 0.5M or more at single motor
when disassembled
EME000077-d
31

10. Basic knowledge for maintenance and inspection

10.1 Starting duty


The standard allowable starting duty for each squirrel-cage induction motor is
specified to enable the concerned motor to start rotation twice consecutively under
the state in which the motor is cooled to the ambient temperature or enable it to start
rotation once after operation at the rated load.
When the motor starts, it receives a high level of thermal and mechanical stress
as a result of starting currents and electromagnetic vibrations. Therefore, frequently
repeated starts/stops are undesirable for its service life. Therefore, if a frequency of
at least four starts per day is planned, it is necessary to use a motor for frequent
starts.

10.2 Limit of temperature rise


In case the reference ambient temperature is 40, the limits of temperature rise
standardized in JEC-2137 become as shown in the following Table 9. (Since the
value may vary for other standards, refer to the specific standard applicable for
details.)

Table 9. Limits of temperature rise of air-cooled induction machines (JEC-2137) (Unit K)

Thermal class A Thermal class E Thermal class B Thermal class F Thermal class H

Method of temperature measurement


Induction machine Th : Thermometer method
Item

part R : Resistance method


ETD : Embedded temperature detector method

Th R ETD Th R ETD Th R ETD Th R ETD Th R ETD

Stator windings
a. Output: 5000kW or
more
- 60 65 - 75 80 - 80 85 - 100 105 - 125 130
b. Output: In excess of
200kW; less than - 60 65 - 75 80 - 80 90 (1) 105 110 - 125 130
5000
1 c. Output: No more than
200kW and other (1) 60 - (1) 75 (1) 80 (1) 105 (1) 125
than d and e(2)
d. Output: Less than
600kW
(1) 65 - (1) 75 (1) 80 - 110 (1) 130
e. Self-cooled mold type
without cooling fans - 65 - - 75 - 80 - 110 - 130
(2)
2 Insulated rotor winding - 60 - - 75 - - 80 - - 105 - - 125 -
3 Squirrel-cage winding
Commutator, slip-ring,
4 brush
Cores and all structure The temperature of this part must not have harmful impacts on its insulating materials and
components (excluding neighbouring materials.
5 bearings) regardless of
contacts with winding

Notes 1: If agreed upon between the manufacturer and the purchaser, the decision can be
made in accordance with the thermometer method.
2: When applying the overlay equivalent load method is applied to the winding of the
induction machine whose heat-resistance classes are A, E, B and F and ratings are
no more than 200kW, it is all right to exceed the temperature increase limit of the
resistance method by 5K only.
EME000077-d
32

The insulation degradation for the winding of the induction machine is mainly
caused by heat and local discharge.
As other deteriorating factors, mechanical fatigue, pollution, and absorption of
moisture should be considered.
The windings cause early insulation degradation and the motor life is
proportionately shortened when the motor temperature rise remains higher than the
limit of temperature rise allowable by fouling of the air duct.

10.3 Insulation resistance


The insulation resistance is an important value for checking the reliability of the
insulation.
The insulation resistance changes depending on the motor output, voltage,
speed, insulation class, temperature, moisture, degree of pollution on insulator
surface, test voltage, and duration of test voltage applied, etc. Thus, it is very
difficult to judge from the insulation resistance only whether the reliability of the
motor is high or not. There are no clear standards concerning what the insulation
resistance should be.
However, we have set the following values as reference.

R kV + 1 (M)
where,
R: minimum insulation resistance at 40
kV: rated voltage (kV)

The measurement of the insulation resistance should be carried out at the motor
terminals for the stator winding and rotor winding.
For the stator windings, use a 500V megger when the rated voltage is less than
600V, and use a 1,000V megger when it is 600V or over.
Further, the value after the voltage is applied for one minute should be used as
the measured insulation resistance. At this time, it is also important to record the
measured winding temperature.
As reference, the insulation resistance secured in our factory is generally as
follows.
Stator winding More than 300M
10.4 Vibration
Each motor is sufficiently balanced in our factory. But vibration may increase,
when directly coupled with the driven machine, under the influences of insufficient
coupling accuracy, vibration caused by the driven machine or the installed condition
on the foundation or base.
Excessive vibration possibly incurs fatigue failure of the shaft, bearings, core,
windings, etc., and may cause insulation trouble, destruction of the foundation, etc.
It is very important, therefore, to maintain and monitor each motor so that its
vibration is kept within allowable range.
EME000077-d
33

10.4.1 Allowable values of vibration

JEC-2137 defines that "the rated voltage and the rated frequency are used to
perform no-load operations and the vibration speed at this time is measured." Our
company defines the goal value of the vibration speed on the on-site bearing bracket
as follows:

Vibration speed goal value: No more than 4.5 mm/s r.m.s.


(On a single motor unit at site)

Conventionally, this is evaluated with the vibration amplitude value. One of the
most famous comprehensive surveys of the allowable values of general machine
vibration is VDI2056 complied by the VDI Vibration Expert Committee of Germany.
ISO also shows how to measure and evaluate the allowable value of vibration in
terms of the vibration severity.
These allowable values are, as it were experientially recommended value of
vibration, variable with the installed condition.
Shown in Fig. 8 are allowable values of vibration that we recommend. Fig. 8
shows allowable values of vibration measured per frequency spectrum, and when
the vibration exceeded the corresponding value indicated by the S line which
represents the standard level to require some measures against vibration for long
use, a suitable countermeasure must be taken in accordance with the result of
investigation into the cause of the vibration increase.

10.4.2 Causes of vibration


The following cases must be taken into consideration as the cause of vibration.

(1) Mechanical vibration


(a) Vibration with constant amplitude
The following cases, when the amplitude doesnt change at any time
under the constant speed and voltage, are taken into consideration.
(a-I) The frequency is number of revolution
(i) Vibration caused by unbalance
Bad installation .... Imperfect or improper connection with
foundation.
Bad direct coupling with machine .... Insufficient straightness of
coupling.
Misalignment .... Eccentricity of mutually coupled shafts.
Vibration increased gradually by unbalance in weight .... Sticking
of dust upon core and fan etc; withering of insulator.
Shortage or reduction of the inadequate or impaired fit between
rotor core and shaft.
(ii) Bending trouble of shaft
(iii) Insufficient rigidity or resonance of structural members
Resonance with structural members or excessive vibration due to
poorly installed foundation.
(iv) Metallic contact with stationary parts (bearing, etc.)
The direction of whip is opposite to the rotating direction.
(v) Unbalance of air gap caused by eccentricity of rotor
The vibration is increased by electromagnetic force whenever
voltage is induced.
EME000077-d
34

1
Peak to peak values (Unit mm = mm)
1000

Allowable value of Number of 8P


Poles 2P 4P 6P or
Vibration (Overall) Frequency over
Single motor 50 Hz 20 30 30 40
60 Hz 20 25 30 40
Rated load operation 50 Hz 30 50 50 50
after directly coupled 60 Hz 26 43 50 50

Allowable value
of Vibration
(by frequency
spectrum)

Notes 1. The measuring location shall be on the top of the bearing housing.
2. Each value indicates one after directly coupled.
3. The vibration frequencies show the maximum amplitudes of the
actually measured vibration; be aware that they do not necessarily
agree with the synchronous frequency on the motor.

Fig. 8 Allowable vibration frequency spectrum value


EME000077-d
35

(a-II) The frequency is twice of the synchronous one


(i) Bearing is deformed elliptically.
(ii) The fit between rotor core and shaft is insufficient in a specific
direction.

(b) Vibration with changeable amplitudes


The following cases, when the amplitude change with time under the
constant speed and voltage, are taken into consideration.
(b-I) The frequency is the same as the synchronous one
Bending trouble of shaft caused by heat distortion
The countermeasure, as it is complex phenomena with vibration
caused under the influence of thermal factor, is very difficult.
It is very important to classify the causes and characteristics
systematically.
Bending troubles of shaft caused by heat are as the following.
(i) Bending trouble of shaft caused by thermal expansion of rotor
conductors.
(ii) Labyrinth seal is contact lightly with the shaft, or bearing is contact
in a specific direction.
In the case of vibration caused by thermal factor, the vibration
phase often changes. Especially, the change of the phase, in
case of the above (ii), become periodically.
(b-II) The frequency is not related to the synchronous one.
(i) Oil whip
Oil whip caused under the influence of oil film in the bearing
becomes a large vibration. The whirling speed is nearly equal to
the critical speed of shaft, and the whirling direction agrees with
the rotation one.
The vibration is generated when the rotational speed reaches
twice or more as high as the critical speed.
Oil whip is generated easily in proportion to the smaller
eccentricity of the bearing.
(ii) Oil whirl
Although the above oil whip causes a large vibration, there is, on
the other hand, a phenomenon that vibrates at 1/2 frequency of
the shaft speed even if the shaft rotates at low speed.
This is called oil whirl. Like oil whip, the whirling direction agrees
with the rotational one, and it is generated easily in proportion to
the smaller eccentricity of the bearing.

(2) Electrical vibration


This vibration occurs as a result of mechanical resonance caused by
electromagnetic force.
(a) The frequency is twice of source one
The vibration is caused by unbalance of air gap, unbalance of source
voltage, unbalance of stator winding, or looseness of stator core, etc.
(b) The frequency is multiples of source one
It is vibration by deforming force on radical direction of the stator core
generated as the result of a bat slot combination.
(c) The frequency is twice of slip one
It is vibration by magnetic unbalance generated as the result of
unbalance of air gap on 2 pole motor, looseness of rotor core, or break of
rotor bar.
(d) Beat
It is vibration with beat caused by twice source frequency as the result of
unbalanced air gap coinciding with twice slip frequency.
EME000077-d
36

10.4.3 Investigating the causes of increased vibration


The causes of increased vibration must be investigated systematically.
Generally, the investigation should be carried out in the following procedure.

(a) Classify the causes into electrical and mechanical ones.


Turn off the power source, and investigate how the vibration changes. If the
vibration is ascribable to electrical causes, it will disappear.

(b) Check whether the vibration is due to the driven machine.


Disconnect the driven machine, and check the motor alone.

(c) Measure the change of vibration frequency, amplitude and phase.

(d) Check whether the amplitude changes with time.

(e) Check the alteration of the amplitude when the rotational speed changes, to
judge whether the vibration is caused as the result of resonance or not.

(f) Check the vibration with reference to the alteration of lubricant temperature,
temperature of motor inside, bearing temperature, etc. and also check the shaft
behavior.

(g) Arrange the data to analyze the cause of vibration.

10.5 Noise
Typical causes of motor noise generation are described in the following Fig. 9.

Noise due to fundamental magnetic flux waves


Electromagnetic noise
Noise due to higher harmonic magnetic
flux waves

Beat

Noise Mechanical noise Bearing noise

Vibration noise caused by mechanical unbalance

Others

Fan noise
Ventilation noise
Air duct noise

Other noises

Fig. 9. Typical causes of noise generation


EME000077-d
37

(1) Electromagnetic noise


Electromagnetic noise is caused when magnetic flux in the air gap between the
stator and rotor is transmitted to the stator core, frame, or rotor.
Electromagnetic noise is easily discriminable from noise caused by mechanical
force since it immediately stops when the power supply to the motor was
disconnected.

(a) Noise caused by fundamental waves of magnetic flux


Electromagnetic noise comprises noise whose frequency is twice as high
as the supply frequency. This noise is amplified when the air gap length,
magnetic circuit or primary voltage becomes unbalanced. Thus, when
this noise becomes excessive, it is necessary to check the air gap, etc.
(b) Noise caused by higher harmonics of magnetic flux
Main causes of this noise are the force based on higher harmonics of
magnetic flux ascribed to slot combination. Usually, this noise
frequency is 1,000Hz or more.
(c) Beat
This noise is caused by the unbalance on the secondary resistor, or the
eccentricity or deformation of the rotor. The frequency is twice as high
as the slip frequency. When this noise is caused, it is necessary to
check the rotor.

(2) Mechanical noise


Mechanical noise are classified into bearing noise and stator resonance noise.

(a) Bearing noise


Bearings are generally classified into sleeve bearing and anti-friction
bearing.
Noise isnt caused by the sleeve bearing unless it has a large gap in the
radical direction.
Noise caused by the anti-friction bearing is complex. Main causes of
anti-friction bearing noise are shown in Fig. 10.

Race noise

Normal noise Roller dropped out

Noise caused by Squeak


bearing itself
Noise caused by Cage noise
anti-friction bearing
Abnormal noise Boom noise

Defect noise

Noise caused by Dust noise


case of setting up Beat(relating to
the bearing to the bearing housing
machine or frame)

Fig. 10. Noise caused by anti-friction bearing


EME000077-d
38

Of these, race noise (basic noise having the frequency of 1,000Hz or


more), roller dropped out noise and squeak are classified as normal.
The remainder are referred to as abnormal. Typical of abnormal noises
is defect noise.
Defect noise is caused by defects on the raceways or rolling elements.
The noise frequency becomes higher in proportion to the motor speed or
the number of rolling elements.
It is necessary to replace the bearing if defect noise is found.
(b) Vibration noise caused by mechanical unbalance
If the balance of the rotor was disturbed, the motor generates vibration
noise at the equivalent frequency to the number of revolutions because
of excessive force acting on the bearing.
The frequency caused by this phenomenon in generally low; thus, it is no
problem as the motor noise.

(3) Ventilation noise


Ventilation noise usually has a uniform spectrum over a wide frequency range,
and it also contains unique frequencies concerned with the number of fan
blades, the number of ducts, etc.

(a) Fan noise


Fan noise is governed by the shape and speed of the fan. Generally,
fan noise becomes larger as the speed and size of the fan becomes
higher and larger.
(i) Noise caused by rotation of fan
This noise is caused as the fan blades give the impact by pressure
on air periodically. The fundamental frequency is equal to the
product given by multiply the number of blades by the speed.
(ii) Vortex noise caused by fan blades
There is a pressure gradient across the fan blades, and the air
flow makes a vortex. The noise caused by vortices usually has a
uniform spectrum over a wide frequency range.
(b) Duct noise
When the stator and rotor have air ducts in the radial directions, the
relative movement of the stator and rotor slots in the circumferential
direction generates compressional waves at the inlet and outlet of the air
duct, causing the so-called siren effect.
This frequency is usually high, and its fundamental frequency is equal to
product given by multiply the number of ducts by the speed.

10.6 Influences of power source fluctuation


JIS, JEC, and IEC show the following (1) and (2) for the influences of fluctuating
power source. Therefore, it is no problem, in practice, to use the motor within this
range. Influences of fluctuations on motor characteristics are shown in Table 10.

(1) Voltage variation


Induction motors, except those with special requirements for starting
characteristic or breakdown torque, shall operate without any practical difficulty
at the rated output, even if the terminal voltage varies within 10% of the rated
vale at the rated frequency.
EME000077-d
39

(2) Frequency variation


Induction motors shall be operated without any practical difficulty at the rated
output, even if the frequency of the power source varies within 5% of the
rated value.
And, even if the voltage and frequency of the power source vary simultaneously,
the motor shall operate without any practical difficulty at the rated output, as
long as the variations of voltage and frequency remain within 10% and 5%
of the rated values respectively and the sum of the absolute percentage values
in each variation does not exceed 10%.

Table 10. Influences of characteristics on motor with regard to the fluctuations


Magnetic
Starting Tempera- noise
Synchro-
and % Full-load Full-load Starting ture rise Particu-
nous
maximum slip speed current current at full larly
speed
torque load no-load
condition

Voltage change
110% (+)10 (-3) (+)
(+)21% unchanged (-)17% (+)0.4% (-)7%
voltage to 20% to 4% slight
Relation 1
with (voltage)2 constant (voltage)
voltage (voltage)2
90% (-)10 (+)10 (+)
(-)19% unchanged (+)23% (-)0.5% (+)11%
voltage to 12% to 15% slight

Frequency change
105% practically (-) (-)5 (-) (+)
(-)10% (+)5% (+)5%
frequency no change slight to 6% slight slight
Relation 1 1
with (frequency)
frequency (frequency) (frequency)
95% practically (+) (+)6 (+) (+)
(+)10% (-)5% (-)5%
frequency no change slight to 7% slight slight

Note: (+) denotes increase, and (-) decrease


EME000077-d
40

10.7 Influences of unbalanced voltage of the power source

(1) Definition of the voltage unbalance ratio


Generally, the voltage and current unbalance ratio are expressed as follows.

Voltage unbalance ratio =


Negative phase sequence voltage
100 (%)
Positive phase sequence voltage
Current unbalance ratio =
Negative phase sequence current
100 (%)
Positive phase sequence current

(2) Influences of unbalanced voltage of the power source

(a) When the motor is operated with unbalanced voltage, the current for
each phase will be shown in Fig. 11.
With unbalanced voltage, the input will increase while the output, torque
and efficiency will decrease. As is obvious from Fig. 11, the phase
carrying the larger current may be overheated extremely, namely, the life
of its winding will be short, and at the same time the power cost will be
high as the result of increased loss. In addition, if the unbalanced
voltage is large, there is danger of increasing the vibration or noise.
(b) An extreme case of unbalanced voltage is one line fault. In this case,
the full-load slip rises to about twice against the value under three-
phase-running, and the line current rises to more than 3 times against
the value under three phases running. Avoid running the motor for long
periods under such a condition, because the winding may burn out.

Fig. 11 Each phase current affected by unbalanced voltage (example)


EME000077-d
41

11. Troubleshooting

Table 11 shows the various troubles, their causes and counter-measures. If


you consider the troubles serious, immediately contact us.

Table 11-1 Troubleshooting

Trouble Cause Countermeasure


1. The motor The starting conditions Some interlocks have Check for wrong wires
will not start. have not yet been not yet been released. and contacts on the
Even when prepared. The circuit No voltage is supplied to circuit.
the main from power source to the starter; starting
switch is motor main terminals is contractor is wrong.
turned on, wrong. The fuses of two-phases Exchange blown fuses.
the motor are blown. Check the main terminal.
remains The stator winding of Repair the detective
non-rotated. the motor is broken. stator winding.

2. The motor The motor condition One phase fuse is Check for wrong wires
generates remains one phase blown. One-phase of and contacts on the
abnormal starter circuit is wrong. circuit.
noise Starting contractor is
without wrong.
starting up.
Mechanical lock. The driven machine is Check the driven
locked. The coupling machine and coupling
connection is wrong and consider proper
(belting too tight: countermeasures.
misalignment; installa-
tion error, etc.)
Bearing is melted.
The metal contact in air
gap due to bearing
melting

The stator winding of One-phase is broken. Repair the defective


the motor is broken. stator winding.

3. The protec- Starter failure.


tive relay Rotor winding is Deterioration of insu- Repair the defective
trips when shorted or earthed. lation caused by stator winding.
main switch overheat, vibration,
is turned on. shocks, etc.

Mechanical lock. Same as item 2 above


Improper setting of Correct the relay setting.
protective relay.
EME000077-d
42

Table 11-2 Troubleshooting

Trouble Cause Countermeasure


4. Abnormal One-line fault; Wire in circuit is broken. Check each line to
noise and unbalanced voltage The fuse is blown. locate defective points.
vibration Contact is wrong.

Mechanical abnormal- Unbalanced rotor Overhaul inspection


ities of motor Cracked end ring; Overhaul inspection
ruptured bar

Slackened core Overhaul inspection


laminations

Unbalance or contact of Overhaul inspection


air gap

Intrusion of foreign Overhaul inspection


objects

Bending or cracking Overhaul inspection


trouble of shaft

Oscillating in the driven Vibration of the driven Disconnect the mating


machine machine machine, and check for
the causes.

Misalignment Bending trouble of shaft

Slackened coupling Tighten up the coupling


bolts.

Improper connection Make repairs.


with foundation

5. Excessive Abnormalities in the Unbalanced voltage Check the power source


temperature power source one-line fault; wrong and starter for
rise and voltage or frequency; abnormalities.
smoking voltage drop

Overload Overload caused by the Disconnect the motor,


fault of the driven and check for troubles.
machine

Excessive start and Review the selection of


stop; excessive reverse motor.
running.

Poor cooling Clogged filter; Cleaning


intrusion of foreign
objects into the
ventilation grille.
EME000077-d
43

Table 11-3 Troubleshooting

Trouble Cause Countermeasure


Defective winding Stator winding is shorted Repair winding.
or earthed.

Mechanical fault The metal contact in air Same as item 2


gap. Overheat of
bearing caused by bad
directed coupling
(Excessive belt tension,
misalignment, etc.)

6. Seizure of Shortage of lubricant Fault of rotation caused Exchange or repair of oil


sleeve by deformation or ring
bearing abrasion of oil ring;
(For details, Shortage of oil quantity;
refer to the Oil leakage.
bearing
manual.) Defective contact of Overhaul inspection
bearing caused by
abrasion or vibration etc.

Defective lubricant Change in quality; Oil exchange


incorrect brand; mixture
of dust and metal sludge

7. Defect of The defect identified by Fatigue galling of Wash the bearing and
grease noise, vibration and raceways and rolling check for defects.
lubricated temperature. elements; Depressions If the bearing is found
anti-friction In many cases, the and other defects defective, replace it with
bearing trouble is concerned imparted upon the a new one.
For details, with grease. raceways and rolling
refer to the If the noise is elements caused by
bearing excessive, charge poor handling.
manual.) grease.
Shortage or excessive Supply a specified
charge of grease. quantity with grease of
specified brand.

Change in quality of Wash the bearing.


grease or wrong brand

Mixture of dust and Bearing exchange


metal sludge.

Deformation or damage Correct the bearing


of retainer in bearing; setting.
Improper mounting of Correct the alignment.
bearing; Excessive Check the driven
thrust load; machine.
Too small clearance.

8. Irregular Early indication of the Winding fault; bearing


deflection of above trouble seizure; faulty
ammeter connections or breaking
of wire; contact fault; etc.
EME000077-d
44 FINAL


REV. REV.ISSUED APPROVED BY REVIEWEDBY PREPARED BY
PAGE CHANGED PLACE AND CONTENTS

Y.Amasaka H.Masuda Y.Nabara


a Mar.24.01 INITIAL ISSUED Mar.24.01 Mar.24.01 Mar.24.01

SOME DESCRIPTIONS AND DRAWINGS Y.Amasaka H.Masuda Y.Nabara


b Oct.17.01
ARE ADDED OR CHANGED. Oct.17.01 Oct.17.01 Oct.17.01

Y.Amasaka H.Masuda Y.Nabara


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EME3OOO51 -a

21-L SERIES
MANUAL DE INSTRUCCINES

CHUMACERAS Y SOPORTES DE CHUMACERA

TMA ELECTRIC CORPORATION


EME3OOO51 - a
1/19

CONTENIDO

1. Construccin del ensamble de chumacera.............. .............................................................. 2


2. Conductos................................................................ .............................................................. 3
3. Mantenimiento.......................................................... .............................................................. 5
3.1 Mantenimiento diario.......................................... .............................................................. 5
3.2 Mantenimiento anual....................................... .............................................................. 6
3.3 Mantenimiento de reparaciones completas....... .............................................................. 7
4. Lubricante................................................................... .............................................................. 9
5. Solucin de problemas............................................... ............................................................ 10
6. Desmontaje y reensamblaje de las chumaceras........ ............................................................ 11
6.1 Preparacin para el desmontaje......................... ............................................................ 11
6.2 Procedimiento de desensamble de chumaceras. ............................................................ 11
6.3 Procedimiento de reensamble.................................. ............................................................ 16
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3/19
2. Conductos (Para el tipo de lubricacin forzada)
Cuando el sistema conductos se disea y ejecuta por su parte, preste atencin a los puntos
siguientes.
(1) Prepare el sistema de descarga de aceite del motor como se describe abajo para
que el vapor en la chumacera en el lado de la mquina y el tanque de aceite no
cause contra flujo dentro de la chumacera de motor.
a) Separe los conductos de descarga de aceite del motor de aquellos de la
mquina de trabajo. No los conecten en la mitad del equipo.
b) Establezca el tanque de aceite con un dren de vapor, el cual sea lo bastante
grande para tener a cualquier [1] o [2] en orden de disminuir la presin dentro
del tanque de aceite y de los conductos a una presin atmosfrica natural.
[1] Un dren de la descarga sin ventilador
[2] Un dren con un ventilador de descarga
c) En cuanto al aceite de los conductos de dren comunes al tanque de aceite, la
pendiente debe estar entre 1/30 y 1/50. Si la pendiente del aceite de los
conductos de dren no es suficiente y/o si seccin transversal es demasiado
pequea, entonces el aceite no fluir fcilmente y puede inundar o puede
causar fugas.
d) El dimetro de los conductos debe ser lo suficientemente grande.

(2) Asegrese de contar con un manmetro a la entrada de aceite y de suministro de


agua as como un indicador de flujo en la salida de aceite y de agua de
enfriamiento para facilitar la inspeccin PRECAUCION !!!
flujo y presin de aceite y agua de
enfriamiento a las chumaceras. 1. El motor tiene orificios para
(3) Instale el conducto a lo largo del cuerpo controlar la cantidad de
del equipo y hgalo con los montajes aceite en su lnea de
apropiados para prevenir movimientos. entrada al soporte, como
(4) Asegrese de adjuntar una placa de se muestra. necesaria en
orificio (refirase a la tarjeta de precaucin caso de instalar las
entradas de las lneas de
adjunta) o una vlvula para el ajuste de la
lubricacin.
presin a la entrada de aceite. Si la placa
o la vlvula fuera suministrada por la
planta ya estara calibrada de fbrica.
Evite la manipulacin del mismo.
EME300051-a
4/19

(5) El conducto de aceite debe disearse y debe ajustarse tomando en cuenta la bomba
de aceite, regulador de presin y otros conductos deben ser adecuados para el flujo y
la presin especificada en el dibujo general de motor donde puede verse la informacin
de las entradas a las chumaceras del motor.
(6) Asegrese que no hay ningn objeto extrao como trapos o herramientas dentro de los
conductos. Entonces, lmpielos completamente y conctelos. La limpieza antes de la
conexin de los conductos se cumple en uno de los siguientes dos mtodos. Un
mtodo es inyectar vapor a una presin de 200 a 300 kPa. El otro es con un lavado de
10% de solucin acuosa de cido sulfrico o el cido clorhdrico, neutralice
inmediatamente con un 20% de solucin acuosa de sodio custico y entonces
enjuague con agua. Cualquier mtodo debe ser seguido de la lubricacin con aceite
tipo turbina para prevenir el xido.
(7) Las lneas de regreso utilizan la gravedad para el flujo. Esto exige al sistema de aceite
de lubricacin estar debajo de la elevacin de la chumacera del motor y una pendiente
continua dejando caer el aceite de retorno.
(8) Despus de que el conducto se ha completado, debe vaciarse completamente antes
de ajustarse a los soportes de motor.
El vaciado puede llevarse a cabo usando la bomba de alimentacin de aceite junto con
el motor o una bomba de aceite adicional que tambin se usar con un filtro. Cuando el
vaciado se ha llevado a cabo usando la bomba de alimentacin de aceite, asegrese
de limpiar el tanque de aceite completamente antes de un perodo de pruebas. Puesto
que el aceite de lavado puede contener materiales extraos, este no debe ser
introducido a las chumaceras.
Especficamente, los conductos deben tener una desviacin para que el aceite sucio
entre a las chumaceras de motor. El aceite vaciado que regresa al tanque de aceite
debe atravesar por un filtro de alambre de malla de 80 a 100. El vaciado estar
completo cuando los objetos extraos ya no se entrampen en el filtro. El filtro debe
reemplazarse a un intervalo de varias horas.
El vaciado tomar de 24 a 48 horas o una semana si el conducto es largo. Con el
propsito del vaciado, prepare el aceite regenerado as como el aceite nuevo. El aceite
para el vaciado se usa para temperatura de 70C a 80C. Durante las operaciones de
vaciado, martillen los conductos para desalojar las incrustaciones de los conductos, las
paredes internas y as arrastrarlos con el aceite de lavado.
Limpie completamente el alojamiento de chumacera, chumaceras, tanque de aceite y
enfriador de aceite; adems asegrese que no hay objetos extraos dejados en el
sistema de conductos. Despus de que el aceite se ha vaciado completamente,
prepare los conductos, cargue el aceite nuevo y verifique fugas y ajuste la cantidad de
aceite para el perodo de pruebas.
EME300051-a
5/19
3. El mantenimiento
El mantenimiento de las chumaceras se describe abajo.
Las chumaceras deben mantenerse y deben inspeccionarse en programas apropiados
adaptados a las condiciones del operacin de la mquina.
3.1 mantenimiento diario
(1) La temperatura de chumacera
La temperatura anormal de la chumacera puede descubrirse a travs de la
comparacin de los archivos acumulado de datos diarios y por esta razn, los archivos
de datos de operacin diarios son importantes.
La temperatura de la chumacera es medida por los mtodos siguientes:
(a) Use un termmetro de dial, o un termocople, o un R.T.D. u otros instrumentos
adecuados.
(b) El uso de un termmetro de barra. Un termmetro de barra se inserta en el
agujero de la medicin del alojamiento de chumacera como se muestra en Fig.2. (Este
agujero normalmente est tapado, pero el tapn es movible para permitir la instalacin
de un termmetro de dial o el instrumento adecuado.) Al instalar instrumentos en este
agujero, avsenos para tomar previsiones.
(c) Con chumaceras con lubricacin forzada la temperatura de la chumacera
puede conocerse por la temperatura del aceite a la salida de flujo, adems de los
mtodos (a) y (b). Sin importar el mtodo, cuando la temperatura anormal de
chumacera se descubre, la chumacera debe inspeccionarse inmediatamente.
Dado que la viscosidad del aceite aumenta en invierno o en las regiones fras, la

temperatura de la chumacera puede subir. En este caso, reemplace el lubricante con


uno de buenas caractersticas a temperaturas bajas o en el caso de un lubricante de
alimentacin forzada, es recomendable se instale un calentador al tanque de aceite
para mantenerlo a una temperatura ptima.
(2) Cantidad de aceite
(a) El tipo Enfriamiento natural
Quite el tapn superior (vea Fig.1), y llene con el lubricante especificado en
el dibujo general. El suministro de aceite excesivo causa goteo y la escasez lleva al
incremento de temperatura y puede quemar el metal de la chumacera. Asegrense
que el nivel de aceite permanezca en la medida de la marca de nivel. La marca de
nivel de aceite sobre la mirilla asegura la lubricacin adecuada. Mientras la
mquina este operando el nivel de aceite puede variar ligeramente. Por lo que no
suministre aceite a la mquina mientras est en operacin.
EME300051-a
6/19
(b) Lubricacin forzada
Asegrese de instalar las salidas de los conductos de aceite con pendiente ( de
1/30 a 1/50 ) en la direccin de regreso de aceite.
Asegrese de lavar el interior de los conductos y los dispositivos de circulacin
antes de empezar el operacin. No fluyan el aceite sucio en la chumacera, porque
contiene objetos extraos que estaban presentes en el conducto. (Para detalles,
refirase a.. Conductos en el manual de operaciones de motores de induccin
de 3 fases. Confirme que la presin de alimentacin de aceite es correcta con el
manmetro de alimentacin a la entrada de la chumacera y que el flujo a la entrada
de aceite sea correcto en la mirilla de flujo de aceite.
Mantenga el nivel de aceite al nivel especificado porque el suministro de aceite
excesivo inducir el goteo y el aceite en escasez causar sobrecalentamiento de la
chumacera, como en el caso del enfriamiento natural descrito anteriormente.

(3) El anillo de aceite


Supervise el anillo de aceite pora una apropiada rotacin a travs de la ventana de
control.

(4) Fugas de aceite


Verifique la chumacera, los conductos y el alimentador de aceite, etc. para evitar
cualquier fuga.

(5) Fuera de operacin por largo plazo


Cuando el motor es apagado durante mucho tiempo o se encuentra en pausa,
asegrese de girar el rotor mientras abastece aceite a la chumacera o una vez
cada dos semanas para prevenir oxidacin en la chumacera.

3.2 Mantenimiento anual

(1) Verificando la chumacera


Quiten la mitad superior del alojamiento de chumacera e inspeccione el patrn de
contacto en la superficie de metal de la chumacera para que exista un contacto
uniforme y verifique la chumacera en busca de daos en la superficie. As, verifique
la superficie de contacto axial para los modelos con empuje axial.

(2) Verificando el anillo de aceite


Verifique el anillo de aceite de anormales usos, como deformacin y tornillos de
acoplamiento sueltos.

(3) Cambio de lubricante


Asegrese de cambiar el aceite una vez cada 6 meses para la chumacera de
enfriamiento natural, o mximo un ao, dependiendo de condiciones como la
temperatura ambiente, nivel de limpieza del ambiente, nivel de continuidad de
operacin y severidad de la operacin. El nivel de deterioro del aceite puede
juzgarse convenientemente por el color oscuro, ms objetivamente, por el nivel de
oxidacin que debe medirse. Cuando el nmero de acidez total se localiza 0.2 a
0.3 KOHmg/g, se recomienda cambiarlo, y menor 0.5, el aceite debe ser cambiado
necesariamente. Los valores de referencia incluyen otras caractersticas adems
de la acidez del aceite las cuales estn listadas en la tabla 1; sin embargo, esto
vara, dependiendo del fabricante del lubricante, contacte al fabricante del aceite
que ustedes usaran para checar detalles. Al cambiar el aceite, limpie el interior del
alojamiento de chumacera completamente y llene hasta la marca en la mirilla; Pare
el motor mientras esta cambiando el aceite, nunca lo cambie con el motor
operando.
EME300051-a
7/19

Tabla 1 Criterio para el cambio de aceite

Item Valor de aceite nuevo Referencia de cambio


Nmero cido total (mgKOH/g) No ms de 0.12 0.2 a 0.3
Volumen de agua (ppm) - No menos de 100
Color (ASTM) 0.5 No menos de 4.0
Viscosidad cinemtica (cst a Basado en el grado de Variable en 10%
40 C) viscosidad
Residuo de inhibidor de 100 No ms de 20
corrosin oxidante (%)
Vida RBOT (minuto a 150 C) 310 No ms de 50

3.3 Mantenimiento y reparacin completo


Al reparar el motor al intervalo fijado, verifique la chumacera de la misma manera que en el
"mantenimiento anual y adicionalmente, realice lo siguiente:

(1) Midiendo el claro de chumacera


Mida el E.D. de la flecha y el I.D. del metal babbitt de la chumacera en varias
posiciones con un micrmetro para encontrar el claro chumacera-flecha. Cuando el motor
no es totalmente desmontado el claro tambin puede medirse ms convenientemente
como sigue: Insertar un alambre comprimible entre la chumacera y la flecha antes de quitar
la mitad inferior del soporte; Mida el espesor del alambre deformado por la presin de la
flecha con un micrmetro, ese es el claro fsico.
En este procedimiento use un alambre cuyo dimetro sea ms grande que el del
claro a medir en 5/100 a 10/100 mm.
Evale el claro por la ecuacin siguiente y si el claro es ms grande que el valor calculado,
cambie la chumacera.

C = 1.185 d + 0.1
100

(2) Medicin de la resistencia de aislamiento de la chumacera


En aquellas chumaceras que estn provistas con un inhibidor de corriente de
flecha, mida su resistencia de aislamiento con un megger de 500V. Al menos a
0.5M en el momento del desensamble del motor debe ser aceptable.

(3) Reparacin
Cuando la chumacera se encuentra en las condiciones descritas en la tabla 2,
ejecute la reparacin respectiva.
EME300051-a
8/19

Tabla 2 Mantenimiento del soporte

Problema, etc Medidas Posibles


Limpieza Limpie completamente las ranuras de aceite,
orificios de salida, orificios de insercin de aceite
y las salidas-entradas de aceite con detergente
limpiador. Finalmente, seque el soporte con
algodn suave y libre de pelusa o sople con aire.
Contacto desnivelado con la flecha La observacin cuidadosa sobre la superficie de
metal blanca revela el patrn de contacto.
Despus de observar el patrn del metal
examine que est correcto el acoplamiento del
motor y si la chumacera misma es la causante,
raspe el metal del rea de la superficie donde el
patrn del metal est concentrado y as obtenga
contacto uniforme. En este proceso, verifique el
contacto aplicando xido de plomo rojo
finamente en la chumacera y cuide de no
remover mucho babbitt a la vez, slo remueva el
mnimo requerido.
La superficie de empuje est parcialmente en Verifique si la chumacera no ha sido
contacto o anormalmente desgastada ensamblada en forma equivocada, el motor
mismo que este nivelado, el juego axial es el
apropiado u otras condiciones externas que
estn en orden. Cuando la causa este en la
chumacera misma, corrija la superficie de metal
rascando la superficie como se explica arriba.
Excentricidad del anillo de aceite Corrija utilizando un torno para maquinarlos
Aflojamiento de los tornillos del anillo de aceite Cuidadosamente verifique el apriete de los
tornillos en la inspeccin. Si el tornillo est
suelto, use un tornillo ms largo, y rehaga la
rosca interna con una herramienta para cuerdas.
La superficie de metal muestra rayado menor o Cepille la superficie cuidadosamente los
golpes pequeos rasguos o abolladuras que sean demasiado
profundas, quite cuidadosamente las rebabas y
suavice la superficie del metal. Tenga cuidado
de no remover demasiado material a un tiempo,
solo el mnimo requerido.
Se encontr erosin electroltica Verifique el aislamiento entre la chumacera y el
alojamiento y el termmetro, para bloquear
completamente la corriente de flecha. Repare
las la superficie de metal babbitt
cuidadosamente.
El soporte ha sido deformado o daado Reemplace el metal de la chumacera.
La superficie de la chumacera est oxidada Pula la superficie con trapo usando polvo de
xido de cromo. Cuando el oxido sea demasiado
use lija para remover el oxido.
EME300051-a
9/19

4. Lubricante

En chumaceras use aceite tipo turbina como lubricante. Asegrese que el lubricante usado
es del tipo especificado en el dibujo general.

Evite mezclar diferentes tipos de aceite. La tabla 3 muestra un lista de lubricantes


comerciales.
Refirase a "mantenimiento para el procedimiento de cambio de aceite.

Tabla 3 Lubricantes Comerciales

Productor Nombre comercial


Aceite turbo grado 2 Aceite turbo grado 2 Aceite turbo grado 2
ISOVG32 ISOVG46 ISOVG68
BP Energol THB32 Energol THB46 Energol THB68
Castrol Perfecto T32 Perfecto T46 Perfecto T68
Exxon Mobil DTE aceite ligero DTE aceite medio DTE aceite pesado-
medio
Aceite Nipn Mitsubishi FBK turbo 32 FBK turbo 46 FBK turbo 68
Shell Turbo T32 Turbo T46 Turbo T68
TEXACO Aceite Regal R&O 32 Aceite Regal R&O 46 Aceite Regal R&O 68

Nota: debido a las fusiones, etc de las compaas de aceite, algunos nombres pueden ser cambiados o
reintegrados; por tanto, para mayores detalles, contacte a las compaas de aceite ms importantes
EME300051-a
10/19

5. Solucin de Problemas

Se muestran las causas y posibles soluciones a varios tipos de problemas en la tabla de abajo.
Si el problema es considerado serio, avsenos inmediatamente.

Defecto Causa Detalle Causa actual Posible solucin


1. Insuficiente (1) defectuoso Deformacin del Cambie si estn
aceite en la anillo de aceite anillo de aceite, deformadas por el
superficie de la (no gira, gira desgaste, juntas desgaste o reduccin
chumacera lentamente, gira flojas, desalineacin, de peso
demasiado) Incorrecta viscosidad
(2) insuficiente de aceite Cambie el aceite
alimentacin de Insuficiente cantidad
aceite de aceite, fuga de Alimentacin normal
aceite, falla de la de aceite
bomba de la
circulacin, Corrija
conductos
bloqueados, goteo, Corrija
claros de
chumaceras
(3) defectuoso excesivos
Dao de Chumacera contacto de
chumacera Desgaste del metal, Corrija
flotacin, objetos
extraos en el claro
de chumacera
2. Lubricacin pobre (1) incorrecta Demasiada alta o Rectifique marca de
calidad de aceite baja viscosidad de aceite
aceite, degradacin Revise color y valor
de aceite de acidez
(2) temperatura de Alta temperatura
aceite ambiente, pobre Verifique sistema de
demasiado alta enfriamiento de enfriamiento
aceite
(3) objetos extraos
en aceite Agua, slidos (polvo,
metal pulverizado) Estudie ruta de
contaminacin
3. falla en el (1) falla en el sistema Sistema de Revise sistema de
enfriamiento de la de enfriamiento conductos o vlvula enfriamiento
chumacera (sistema bloqueada o falla de
de enfriamiento la bomba de
directo) lubricacin
4. corriente de flecha (1) falla en Contaminacin, agua Limpie y verifique
aislamiento de en el aceite, falla en Resistencia de
chumacera aislamiento de aislamiento
conductos
5.causas externas 1.vibracin excesiva desalineacin del Corrija alineamiento
acoplamiento, eje
doblado, instalacin
desalineada

2. empuje anormal impactos de la Verifique carga de la


mquina de trabajo mquina
Calentamiento Presntomas de dao de chumacera Guarde registros de la temperatura normal de
excesivo de chumacera, ponga atencin a aumentos
chumacera ligeros de temperatura y pare la operacin
cuando suba la temperatura grandemente y
verifique
EME300051-a
11/19

6. Desensamble y reensamble de las chumaceras

Los procedimientos horizontales de desensamble y reensamble de chumaceras pueden


variar ligeramente segn los tipos de motor, pero tpicamente se ejecutan como se
describen abajo:

6.1 Preparacin para el desensamble

(1) Estudie completamente la estructura de la mquina a ser desmontada


o Haga los preparativos para el procedimiento de desensamble
o Prepare las herramientas de desensamble

(2) Seleccione cuidadosamente el rea para el desensamble.


o Evite reas polvorientas
o Tenga cuidado del clima cuando desmonte las mquinas a la intemperie, si
es necesario

(3) Cuidadosamente limpie el rea alrededor de la chumacera, Incluso el eje y


el alojamiento de chumacera.

6.2 Procedimiento de desensamble de chumacera

6.2.1 Quitando accesorios

(1) Quite el termmetro de dial u otro dispositivo que mida la temperatura de


chumacera.

(2) Drene el lubricante del alojamiento de chumacera a travs del puerto de


dren, quitando el tapn.

(3) Desconecte el conducto de alimentacin de aceite si esta conectado.

6.2.2 Remueva la mitad superior del Alojamiento de chumacera (vea Fig. 3, Fig. 4)

(1) Quite los tornillos (3) para la mitad superior de chumacera (1) y quite la
tapa mitad superior (2).

(2) Quite los tornillos sujetadores (5) de la mitad superior de chumacera y quite
la mitad inferior del alojamiento de chumacera (4)

(3) levante la mitad superior del alojamiento de chumacera (1) despacio y


cuidadosamente, teniendo el cuidado de no lastimar otros componentes y qutelos. Sobre
todo, para prevenir el dao a los sellos durante el desmontaje, al alzar la mitad superior del
alojamiento del soporte (1), deje la superficie del fondo en todo momento horizontal. Note
que el extremo opuesto a la chumacera de carga tiene normalmente un aislador para
prevenir la corriente de flecha: Preste atencin a l durante el desmontaje y reensamblaje.
Adems, tenga cuidado de mantener libre esta rea de contaminacin por objetos extraos
que puede permitir corriente en todo momento.
EME300051-a
12/19
EME300051-a
13/19

6.2.3 Desensamble de mitad superior de cubierta de chumacera (vea Fig. 5)

(1) Atornille el tornillo de ojo a la mitad superior de la cubierta de chumacera (6).

(2) Pase la soga a travs de los tornillos y levante verticalmente el armazn de


chuamacera- mitad superior. Tenga cuidado para no daar el metal mientras quite
la chumacera y asegrese de poner la chumacera en bloques de madera y no
directamente en el suelo.

(3) Muevan la cubierta de chumacera despacio y evite a toda costa que se caiga.

6.2.4 Desmontaje de anillo de aceite (vean Fig. 6)

(1) Gire la junta del anillo de aceite y entonces quite la unin


atornillada(7).

(2) Saque el anillo de aceite (7) de la chumacera.

6.2.5 Desensamble del sello flotante (vea Fig. 7)

(1) Desabroche el resorte (9), y quite la mitad superior (10) del sello flotante

(2) Gire el sello flotante-mitad inferior (11) a la posicin superior y qutelo. Al sacar los
sellos flotantes ponga atencin para evitar dao.

6.2.6 Desmontaje de la mitad inferior de la chumacera (vea Fig. 8. 9. 10)

Sincronice los procedimientos del desensamble en el lado de carga y el lado opuesto a la carga.
EME300051-a
14/19

(1) Levante el rotor dentro del lmite que pueda quitar la mitad inferior de la chumacera
(8). En este procedimiento, tenga cuidado para evitar el contacto entre el rotor y el
estator.
El lmite de levantamiento aceptable es 0.5 mm.
o Ejemplo de mtodo de levantamiento de rotor
i) Alzando el cople.
ii) Levante el extremo de flecha opuesto a la carga con un block cadena de
ajuste fino, aplique una proteccin a la cadena de levantamiento para no
daar la flecha.

Como otro mtodo, est el caso del lado de carga opuesto tambin se
levanta como se muestra en i), o cuando el eje no est extendido, esta el caso
donde un tubo se inserta en el extremo del eje y el tubo se levanta con una soga
(vea Fig. 9).

iii) Este trabajo debe ejecutarse con cuidado y suma atencin y debe
confiarse al personal experimentado.

(2) Durante el levantamiento del rotor, gire la mitad baja de la chumacera (8) a la
posicin superior para su extraccin.

(3) Atornille los tornillos de ojo a la mitad baja de la chumacera (8), y levntela (vea
Fig. 10).
Tenga mucho cuidado en este procedimiento de la misma manera que en el caso
de la mitad superior de la chumacera.
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6.2.7 Desmontaje de la mitad inferior del alojamiento de chumacera (vean Fig. 11)
La mitad inferior del alojamiento de chumacera slo se desmonta cuando el rotor est
desensamblado

(1) Quite el seguro de los tornillos para el portador del sello (12) en el lado de la carga
y en el lado opuesto de la carga.

(2) Ponga los tornillos de ojo en los agujeros de la mitad inferior del alojamiento de
chumaceras, pasando el cable sobre las ranuras, ponga atencin a la ubicacin
del centro de gravedad.

(3) Quite los tornillos que estn sujetando la mitad inferior del alojamiento de
chumacera del rotor.

(4) Remueva la mitad inferior del alojamiento de chumacera para prevenir la salida del
rotor, en general el rotor es jalado por el lado opuesto a la carga, baje la mitad
inferior del alojamiento de chumacera del lado de la carga solamente lo suficiente
para liberar el acoplamiento (el dimetro de la pestaa exterior del acoplamiento
debe ser ms pequea que la perforacin del ncleo del estator), y quite la mitad
inferior del alojamiento del soporte del lado opuesto para prevenir dao al colector,
etc.

(5) Cuidadosamente baje el rotor aflojando el gato y el cable y ubique el rotor en el


ncleo del estator. En este momento, baje el gato y el cable en ambos lados del
peso , al mismo tiempo para evitar contacto parcial e impacto a la superficie del
ncleo.
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6.3 Procedimiento de reensamble


Al volver a montar los soportes. limpie todas las partes desensambladas y cuidadosamente
evite dejar alguna sin ensamblar.

6.3.1 Reensamblaje la mitad inferior del alojamiento de chumacera.


(1) Levante el rotor mximo 0.5 mm., poniendo atencin al claro rotor-estator, como
en el caso del desmontaje de la mitad inferior del alojamiento de chumacera (6.2.6)
(2) Ubique la mitad inferior del alojamiento de chumacera en su posicin exacta, y
sujtelo al armazn del estator.
Quite el cable de sostn del alojamiento de chumacera.

6.3.2 Reensamble de la parte inferior de la chumacera. (vea Fig. 12)


(1) Lave la flecha con bencina o Querosn. y spleteelo completamente con aire
comprimido.

(2) Aplique lubricante a la flecha.

(3) Aplique lubricante a la superficie de la parte de metal babbitt de la mitad inferior de


la chumacera y deslcela a su posicin debajo del eje.

(4) Alinee la superficie de la unin de la mitad inferior de chumacera con la unin de la


superficie de la mitad inferior del soporte usando una extensin.

(5) Verificando el calibrado del centro magntico


Confirme que el indicador de centro magntico (13) est montado en la mitad
inferior del alojamiento de chumacera del lado de la carga y que coincida con la
lnea de referencia roja sobre la flecha de motor.
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(6) Cuidadosamente baje el rotor y apyelo con la mitad inferior del alojamiento de
chumacera.
(7) Instale el portador de sello que fue movido en 6.2.7 y asegrese que el espacio
libre con el eje es el correcto midiendo con un calibrador de espesores.

6.3.3 Reensamblado del anillo de aceite


Vuelva a montar las dos mitades del anillo de aceite cuidadosamente, evite una mala
alineacin. Si se ensamblan errneamente las mitades, no encajan bien o es elptico,
provocar una impropia rotacin. La conjuncin de los anillos debe ser dentro de la
superficie de los lados del anillo.
6.3.4 Reensamblado de la mitad superior de la chumacera
(1) Apriete los tornillos de ojo a la mitad superior de la chumacera y levante
verticalmente con la cuerda, reensmblelos con la mitad inferior de chumacera.
Alinee las marcas de registro en la mitad superior e inferior de las chumaceras.
(2) Verifique completamente que todas las partes as como el broche de anti-rotacin
est ensamblado en el alojamiento de chumacera.
(3) Revise que no haya objetos extraos como herramientas o tornillos olvidados en el
alojamiento del soporte.
(4) Asegrese de aplicar liquido sellador en las uniones del alojamiento para prevenir
fugas de aceite.

6.3.5 Reensamblando el sello flotante

(1) Aplique compuesto que no endurezca o grasa ligera en las caras laterales (A en
fig. 7) del sello flotante y aplique aceite lubricante ligero en el dimetro interior del
sello flotante.

(2) Inserte la mitad inferior del sello flotante (con el agujero de dren de aceite) en el
soporte de sello y la mitad inferior girndolas. Asegrese que el orificio de dren
est hacia adentro del recipiente de aceite.
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(3) Instale la mitad superior del sello flotante. Coloque el resorte alrededor del sello
flotante y cirrelo. Cuidadosamente alinee las mitades superior e inferior del sello
flotante para hacer que sus superficies sean continuas. Despus de ensambladas,
asegrese que esta libremente colocado y no esta atascado de tal forma que al
girar se pueda deformar.

(4) Durante el reensamble de la mitad superior del soporte de sello, confirme que el
perno anti-rotacin del sello est correctamente en su ranura.

6.3.6 Reensamble de la mitad superior del alojamiento de chumacera.

(1) Reensamble la mitad superior del alojamiento de chumacera de manera inversa al


procedimiento mostrado en 6.2.2.

(2) Instale el termmetro de cartula, el termocople u otro dispositivo al soporte.

(3) Con una chumacera de lubricacin forzada reensamble los conductos de entrada y
salida de aceite. Ponga lubricante al nivel indicado en la mirilla de nivel de aceite
del soporte de chumacera.

(4) Con un motor del tipo intemperie aplique una capa de sellador (ver fig. 13 )
Siempre que desensamble asegrese de aplicar una capa de sellador en las reas
perifricas segn figura 13.
(El rea de aplicacin de sellador esta achurado en la fig. 13 )
Dado que el motor ha sido sellado en todas las partes que as lo requieren , no es
necesario desensamblar y sellar nuevamente al recibirlo en su planta.
Use sellador marca Three Bond 1207D o equivalente.

(5) Confirme que el claro rotor-estator es uniforme alrededor de la circunferencia


interna completa.

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