EFE Gyratory Crusher

TRAYLOR CRUSHER INSTALLATION, OPERATION, AND MAINTENANCE MANUAL .

INST INSTA A L L A TION, TION, OPE OPERATION RATION,, an an d MAINTENANCE MAINTENANCE MANUAL MANUA L FOR FOR 1525mm x 287 2870m m (60 (60” x 113” ) TRAYLOR TYPE “ NT” GYRATORY GYRA TORY CRUSHER CRUSHER VOL VOL UME UME 3 o f 3 (ELECTRICAL) PLANT LOCATION :

SOCIEDAD MINERA CERRO VERDE S.A.A.  AREQUIPA,  A REQUIPA, PERU

PURCHASE PURCHASE ORDER No.:

 A1WF-59-0  A 1WF-59-001-PO 01-PO

CUSTOMER:

04-31645-720 C-3110-CR-001

FFEM CONTRACT No.: EQUIPMEN EQUIPMENT T No.: No .: COPYRIGHT © FFE Minerals USA Inc. 2005

COVE COVER R PAGE - VOLUME VOLUME 3 Manual Volume Prep. Prep. by  App by

3 Manual Section

Preface ai  

Contract No.

SRH

Date

11/21/2005

04-31645-720 FFEM DWG. No. 5.401478

MDS

Date

11/21/2005

Rev.

0

Page 1 of 1

TRAYLOR CRUSHER INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

FFE MINERAL MINERAL S USA., INC. DISTRIBUTION and REVISION RECORD SHEET FOR

1525 1525 X 2870 2870 (60 (60““ x113“ )

TRAYLOR® TRAYLOR® TYPE TYPE “ NT” NT” GYRATORY GYRA TORY CRUSHER CRUSHER INSTAL INSTALL L A TION, TION, OPER OPERATION, ATION, an an d MAINTENANCE MAINTENANCE MANUAL CUSTOMER: CUSTOMER: Manual Volume 3 3

SOCIEDAD SOCIEDAD MINERA MINERA CERRO VERDE S.A.A . REV. No.

REMARKS MANUAL - CERTIFIED

0

S.R. HARRIS

TRANSMITTAL DATE 12/22/2005

ELECTRONIC ELECTRONIC MANUAL - CERTIFIED CERTIFIED

0

S.R. HARRIS

12/22/2005

Manual Distribution:

Customer : FFEM CHQ Engineering : FFEM Chile Office :

BY

6 Hard & 3 Electronic copies 1 Hard & 3 Electronic copy 3 Hard & 3 Electronic copy

DISTRIBUTION AND REVISION RECORD Prep. by

SRH

Date

11/21/2005

04-31645-720 FFEM DWG. No. 5.401479

 Ap p. b y

MDS

Date

12/12/2005

Rev

Manual Volume

3 Manual Section

Preface

aii

Contract No.

1

Page 1 of 1

TRAYLOR® CRUSHER INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

DISCLAIMER

This manual is a service of FFE Minerals U.S.A. Inc. In spite of our best efforts certain of the information in this manual may become out of date over time. FFE Minerals U.S.A. Inc. accepts no liability for the accuracy or completeness or use of, nor any liability to update, the information contained on this manual. These materials are provided "AS IS" WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR NON-INFRINGEMENT. YOU  ASSUME  ASSUME COMPLETE COMPLETE RESPONSIBI RESPONSIBILITY LITY AND RISK FOR USE OF THESE MATERIALS. Some jurisdictions do do not allow the exclusion of implied warranties, so the above exclusion may not apply to you. FFE MINERALS U.S.A. INC. ITS AGENTS, REPRESENTATIVES  AND EMPLOYEES EMPLOYEES ARE NEITHER NEITHER RESPONSIBL RESPONSIBLE E NOR LIABLE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL, CONSEQUENTIAL, SPECIAL, EXEMPLARY, PUNITIVE, OR OTHER DAMAGES  ARISING  ARISING OUT OF OR RELATING IN ANY WAY TO THIS MANUAL  AND/OR CONTENT OR TRANSLATIO TRANSLATION N OR INFORMATIO INFORMATION N CONTAINED WITHIN THE MANUAL. YOUR SOLE REMEDY FOR DISSATISFACTION WITH THE MANUAL IS TO STOP USING THE MANUAL.  All content within this manual, including, but not limited to text, logos and images are the property of FFE Minerals U.S.A. Inc. No portion of the materials on these pages may be reprinted or republished in any form without the express written permission of FFE Minerals U.S.A. Inc. BY USING THIS MANUAL YOU AGREE THAT YOU HAVE READ, UNDERSTAND AND AGREE TO THE TERMS OF USE.

DISCLAIMER Manual Volume all Manual Section Orig. Orig. by Date J. Anth Anthon on Rev. b Date M. Solomon

Contract ALL FFEM DWG. No. 1/22/2003 7.500267 Rev. Rev. 1 Pa e 1 of 1 5/14/2004

preface

TRAYLOR® CRUSHER INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

SAFETY

BASIC RULES REGARDING SAFETY IN AND AROUND A MINERAL PROCESSING PLANT ARE OUTLINED IN THIS MANUAL IN SECTION 1.2, SAFE JOB PROCEDURES . OPERATOR SAFETY—AND THE SAFETY OF OTHERS—DEPENDS UPON REASONABLE CARE AND JUDGEMENT IN THE OPERATION OF MINERAL PROCESSING EQUIPMENT. A CAREFUL OPERATOR IS GOOD INSURANCE AGAINST AN ACCIDENT. MOST ACCIDENTS, NO MATTER WHERE THEY OCCUR, ARE CAUSED BY FAILURE TO OBSERVE AND FOLLOW SIMPLE FUNDAMENTAL RULES OR PRECAUTIONS. FOR THIS REASON, MOST ACCIDENTS CAN BE PREVENTED BY RECOGNIZING HAZARDS AND TAKING STEPS TO AVOID THEM BEFORE AN ACCIDENT OCCURS.

REGARDLESS OF THE CARE USED IN THE DESIGN AND CONSTRUCTION OF THIS TYPE OF EQUIPMENT, THERE  ARE CONDITIONS THAT CANNOT BE COMPLETELY SAFEGUARDED AGAINST WITHOUT INTERFERING WITH REASONABLE ACCESSIBILITY AND EFFICIENT OPERATION. WARNINGS ARE INCLUDED IN THIS INSTRUCTION MANUAL TO HIGHLIGHT THESE CONDITIONS.

SAFETY STATEMENT Manual Volume all Manual Section Orig. by Date J. Anthon Rev. b Date M. Solomon

Contract ALL FFEM DWG. No. 1/22/2003 7.500268 Rev. 1 Pa e 1 of 1 5/14/2004

prefac

TRAYLOR CRUSHER CHANCADOR TRAYLOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL MANUAL DE INSTAL ACION, 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 versión en Español para el Manual de  Instalatción, Mantención y Operación. Esta versión fue realizada  por servicios externos a nuestra compañia. Aunque fue FFE  Minerals USA, Inc. No se hace responsable ni garantiza su exacto traducción, este manual se considerará como el documanto oficial  para cualquier propósito.  En la eventualidad de existir alguna disconformidad o mala interpretación de la traducción Inglés al Español, o que su versión omita o no corresponda con lo indicado en Inglés, prevalecerá e término en Inglés

TRANSLATION WARNING Manual Volume Orig. by Rev. by

all Manual Section Date SRH Date MDS

prefac

Contract ALL FFEM DWG. No. 08/19/2004 7.500433 0 Page 1 of 1 08/19/2004 Rev.

TRAYLOR CRUSHER INSTALLATION, OPERATION, AND MAINTENANCE MANUAL  AB OUT THIS MANUAL

THIS MANUAL CONSISTS OF 3 VOLUMES. EACH VOLUME CONTAINS THIS DESCRIPTION AND A TABLE OF CONTENTS FOR THE VOLUME. THE CONTENTS OF THE VOLUMES ARE: VOLUME 1: MECHANICAL - INSTALL ATION, OPERATION,  AND MAINTENA NCE INSTRUCTIONS AND FFEM MECHANICAL DRA WINGS. VOLUME 2: VENDOR DRAWINGS AND INSTRUCTIONS. VOLUME 3: ELECTRICAL

 ABOUT THIS MANUAL preface

Manual Volume

all Manual Section

Prep. by

SRH

Date

Contract 04-31645-720 No. FFEM DWG. No. 11/21/2005 5.401468

MDS

Date

11/21/2005

 App by

Rev. No.

0

Page 1 of 1

TRAYLOR CRUSHER INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

TABLE OF CONTENTS

VOLUME 3 SECTION

TITLE

Drawing No.

Rev

(or p age No.) ai

Cover Page

5.401478

0

aii

Distribution and Revision Record

5.401479

0

aiii

Disclaimer

7.500267

1

aiv

Safety Statement

7.500268

1

av

Translation Warning

7.500433

0

5.401468

0

5.401480

0

 About This Manual

avi

INDEX 1

TABLE OF CONTENTS CONTROL & INSTRUMENTS DIAGRAMS

1

Legend Sheet 1

8.500980-1

0

2

Legend Sheet 2

8.500980-2

0

3

Legend Sheet 3

8.500980-3

0

4

Crusher Overview

8.500980-4

3

5

Crusher Hydraulic Oil System

8.500980-5

3

6

Crusher Spider Bushing Lubrication System

8.500980-6

3

7

Crusher Lube Oil System Lube Skid

8.500980-7

3

2

ELECTRICAL LOAD L IST

8.500983

2

3

FIELD INSTRUMENT LIST

8.500981

2

4

I/O LIST

8.500982

2

5

FUNCTIONAL SPECIFICATION

8.500985

1

6

CRUSHER DRIVE MOTOR 6.506964

2

1

Motor Outline Drawing

TABLE OF CONTENTS Manual Volume Pre . b  App. by

3 Manual Section Date SRH Date MDS

INDEX Contract No. FFEM DWG. No. 12/12/2005 0 12/12/2005 Rev.

04-31645-720 5.401480 Page 1 of 2

TRAYLOR CRUSHER INSTALLATION, OPERATION, AND MAINTENANCE MANUAL 6

CRUSHER DRIVE MOTOR – CON’T 2

Nameplate

6.506948

2

3

Main Terminal Box

6.506949

1

4

Space Heater Terminal Box

6.506950

2

5

Stator RTD Terminal Box

6.506951

1

6

Shaft Outline

6.506952

1

7

Starting Characteristic Curve

6.506991

0

8

Thermal Curve

6.506992

0

9

Motor Specifications

6.506997

0

10

Installation & Maintenance Manual – English

EME000077-D

11

Installation & Maintenance Manual – Spanish

EME300051-a

TABLE OF CONTENTS Manual Volume Pre . b  App. by

3 Manual Section Date SRH Date MDS

INDEX Contract No. FFEM DWG. No. 12/12/2005 0 12/12/2005 Rev.

04-31645-720 5.401480 Page 2 of 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

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

I/O SIGNAL LIST CRUSHER CERRO VERDE PROJECT PERU, S. AMERICA

The information transmitted by this document is proprietary and confidential property of FFE MINERALS and may not be duplicated disclosed or utilized without written consent from FFE MINERALS.

FFE MINERALS USA INC.

No.: 8.500982

2

DOCUMENT NO. 8.500982

INPUT/OUTPUT SIGNAL LIST

REV. 2

CRUSHER CERRO VERDE PROJECT PERU, S. AMERICA R

C&ID

E

SOURCE

V

TAG NUMBER

31 ZSO-6717

I/O DESCRIPTION

8.500980 HEET NO.

SIGNAL RANGE

I/O TYPE DEVICE

7

OPEN LIMIT SWITCH

NOTE 1

MOTOR CONTROL IO NOT INCLUDED

NOTE 2

30 JULY 05

AI

AO

DI

1

DO EQUIPMENT OR SYSTEM

CRUSHER LUBRICATION

SUBSYSTEM

MEASURED VARIABLE

LUBE OIL FILTER

DRAIN VALVE

STATE

@ SIGNAL

ENGR.

STATUS

UNITS

MIN.

MAX.

COMMENTS

OPEN

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

01

16SEP05

JYY

JYY

MDS

00

30JULY05

JYY

JYY

MDS

Description

REVISED PER CUSTOMER COMMENTS

FFE Minerals Document No. 8.500985 FILENAME: 8500985.doc

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

D. E. F. G. H.

REVISION 01

Normal Shutdown Sequence ................................................................... 35 Abnormal and Emergency Shutdowns..................................................... 35 HMI Control Summary ............................................................................. 36 Alarms...................................................................................................... 36 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

1

REVISION 01

About This Document

The purpose of this functional specification is to describe the system control philosophy in a user-friendly, yet practical approach. It is intended to provide guidance 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 Equipment/Device Descriptions section (Section D of Chapter 2), for use with other FFE Minerals documents.

Normal Startup Sequence This section describes the function group’s 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 group’s 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 monitored by the control system and are used to automatically control equipment. 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 function 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 group’s 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 process or equipment abnormalities or activation of individual equipment safety devices. 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 buttons 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 Emergency 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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. Interlock 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. Hardwired 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 equipment 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 interlocks 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 contactor 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 individual 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 “downstream conveyor is running.” The following table summarizes the modes of operation for the three types of interlocks defined above: INTERLOCK MODES OF OPERATION

Mode Selector Switch

Operator Control Station Component Mode Selection

MAINTENANCE

--MANUAL

OPERATION AUTO

PAGE 7

Interlock Type Safety

X X X

Start

Process

---

---

---

---

X

X

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

2

REVISION 01

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 group’s relevant chapter: 3. 4. 5. 6. 7.

Crusher Lubrication Group Crusher Hydraulic Adjustment Group Crusher Spider Bushing Lubrication Group Crusher Dust Seal Air Group Crusher Main Drive Motor

B. System Startup Sequence When starting the Crusher from a total shutdown, refer to the Contract Instruction 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 appropriate chapters of this document.

PAGE 8

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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

FISL-0143

CRUSHER INNER ECCENTRIC BUSHING LUBE OIL SUPPLY LINE FLOW SWITCH

FISL-0141

CRUSHER OUTER ECCENTRIC BUSHING LUBE OIL SUPPLY LINE FLOW SWITCH

FISL-0142

CRUSHER COUNTERSHAFT BEARING LUBE OIL SUPPLY LINE FLOW SWITCH

TE-0111A

CRUSHER MAIN DRIVE MOTOR INBOARD BEARING TEMPERATURE ELEMENT

TE-0111B

CRUSHER MAIN DRIVE MOTOR OUTBOARD BEARING TEMPERATURE ELEMENT

TE-0112A

CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE ELEMENT

TE-0112B

CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE ELEMENT

TE-0112C

CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE ELEMENT

TE-0112D

CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE ELEMENT

TE-0112E

CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE ELEMENT

TE-0112F

CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE ELEMENT

TE-0140A

CRUSHER COUNTERSHAFT INBOARD BEARING TEMPERATURE ELEMENT

TE-0140B

CRUSHER COUNTERSHAFT OUTBOARD BEARING TEMPERATURE 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

Equipment/Device Tag

REVISION 01

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

PSV-6701

CRUSHER LUBRICATION MAIN OIL PUMP DISCHARGE OIL PRESSURE RELIEF VALVE

PSV-6702

CRUSHER LUBRICATION STANDBY OIL PUMP DISCH. OIL PRESSURE RELIEF VALVE

ZSO-6717

CRUSHER LUBE OIL FILTER DRAIN VALVE OPEN POSITION LIMIT SWITCH

ZSC-6717

CRUSHER LUBE OIL FILTER DRAIN VALVE CLOSED POSITION LIMIT SWITCH

PDSH-6719 TI-6707

CRUSHER LUBE OIL SUPPLY FILTER DIFFERENTIAL PRESSURE SWITCH CRUSHER LUBRICATION RETURN LINE OIL TEMPERATURE 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

ZSC-6716

CRUSHER LUBE OIL COOLER DRAIN VALVE CLOSED POSITION LIMIT SWITCH

ZS0-6716

CRUSHER LUBE OIL COOLER DRAIN VALVE OPEN POSITION LIMIT 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

Equipment/Device Tag

REVISION 01

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

XV-6507

CRUSHER MANTLE RAISE/LOWER HYDRAULIC OIL CONTROL 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

PDSH-6506

CRUSHER HYDRAULIC OIL FILTER DIFFERENTIAL PRESSURE 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

PSV-6503

CRUSHER HYDRAULIC PUMP DISCHARGE OIL PRESSURE RELIEF VALVE

CP1

CRUSHER SPIDER BUSHING GREASE LUBRICATION CONTROLLER

M-8.0

CRUSHER SPIDER BUSHING GREASE PUMP

FQS-6603

CRUSHER SPIDER BUSHING GREASE SUPPLY LINE FLOW CYCLE 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

Equipment/Device Tag

REVISION 01

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

YL-6505

CRUSHER HYDRUALIC MAIN OIL PUMP RUNNING INDICATION LIGHT

YL-6505

CRUSHER HYDRUALIC MAIN OIL PUMP RUNNING INDICATION LIGHT

YL-6705

CRUSHER LUBRICATION MAIN OIL PUMP RUNNING INDICATION LIGHT

YL-6710

CRUSHER LUBRICATION MAIN OIL PUMP RUNNING INDICATION LIGHT

PAGE 12

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 Lube Oil Reservoir Low Level Lube Oil Reservoir Low-Low Level Lube Oil Reservoir Low Temperature Lube Oil Reservoir Heater On Lube Oil Reservoir Heater Off Lube Oil Reservoir High Temperature Lube Oil Cooler Main Fan Off Lube Oil Main Cooler Fan On Lube Oil Cooler Standby Fan Off Lube Oil Cooler Standby Fan On Lube Oil Cooler Outlet Temperature Moving Average Lube Oil Cooler Outlet Temperature Moving Average Interval Lube Oil High Return Line Temperature Lube Oil High-High Re-  turn Line Temperature Lube Oil Filter High Differential Pressure  Inner Eccentric Bushing Lube Oil Low Flow Outer Eccentric Bushing Lube Oil Low Flow

Description

Type

Value

Low alarm/interlock reservoir level.

Constant

2/3 FULL

Low-low alarm/interlock oil reservoir level (* must be above tank discharge line).

Constant

1/3 FULL

Low oil reservoir temperature alarm set point.

Constant

Low oil reservoir temperature heater control set point. High oil reservoir temperature heater control set point. High oil reservoir temperature alarm set point. Low Lube Oil Cooler Outlet Temperature Moving Average Main Cooler Fan “OFF” control set point. High Lube Oil Cooler Outlet Temperature Moving Average Main Cooler Fan “ON” control set point. Low Lube Oil Cooler Outlet Temperature Moving Average Standby Cooler Fan “OFF” control set point. High Lube Oil Cooler Outlet Temperature Moving Average Standby Cooler Fan “ON” control set point. The average Lube Oil Cooler Outlet Temperature continuously calculated over a selected time interval. The adjustable time interval over which the Lube Oil Cooler Outlet Temperature Moving Average is calculated.

Constant

100 DEGF

Constant

Constant

105 DEGF

Constant

115 DEGF

Variable

Calculated

Adjustable

2-5 minutes

High alarm oil reservoir return line temperature.

Constant

High-high alarm/interlock oil reservoir return line temperature.

Constant

Pressure at or above this value is alarmed indicating filter is dirty or clogged.

Constant

Low alarm/interlock for lube oil flow to Inner Eccentric Bushing.

Constant

34 GPM

Low alarm/interlock for lube oil flow to Outer Eccentric Bushing.

Constant

34 GPM

PAGE 13

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

Signal / Set point

REVISION 01

Type

Value

Low alarm/interlock for lube oil flow to Countershaft Bearings.

Constant

2 GPM

High alarm/interlock bearing temperature.

Constant

High-high alarm/interlock bearing temperature.

Constant

High alarm/interlock bearing temperature.

Constant

High-high alarm/interlock bearing temperature.

Constant

Low alarm/interlock reservoir level.

Constant

2/3 FULL

Low-low alarm/interlock reservoir level (* must be above tank discharge line).

Constant

1/3 FULL

Position (elevation) of the crusher mantle.

Analog

Varies

Pressure at or above this value is alarmed indicating filter is dirty or clogged.

Constant

Crusher Mantle Low Position

Low alarm/interlock mantle position.

Constant

Crusher Mantle High Position

High alarm/interlock mantle position.

Constant

Countershaft Bearings Lube Oil Low Flow Countershaft Inboard Bearing High Tempera-  ture Countershaft Inboard Bearing High-High Temperature Countershaft Outboard Bearing High Tempera-  ture Countershaft Outboard Bearing High-High Temperature Hydraulic Oil Reservoir Low Level Hydraulic Oil Reservoir Low-Low Level Crusher Mantle Position Hydraulic Oil Filter High Differential Pressure Set Point 

Crusher Main Drive Mo-  tor Minimum Run Time Crusher Main Drive Mo-  tor Minimum Stop Time Crusher Main Drive Mo-  tor Winding High Tem-  perature Crusher Main Drive Mo-  tor Winding High-High Temperature Crusher Main Drive Mo-  tor Inboard Bearing High Temperature Crusher Main Drive Mo-  tor Inboard Bearing High-High Temperature Crusher Main Drive Mo-  tor Outboard Bearing High Temperature Crusher Main Drive Mo-  tor Outboard Bearing High-High Temperature

Description

Minimum duration Crusher Main Drive Motor must run prior to adjusting mantle position. Minimum duration from when the Crusher Main Drive Motor is stopped to when it may be restarted.

Constant

Constant

50mm above minimum point of travel 25mm below maximum point of travel Provided by Motor Manufacturer Provided by Motor Manufacturer

High alarm/interlock winding temperature.

Constant

135 DEGC

High-high alarm/interlock winding temperature.

Constant

145 DEGC

High alarm/interlock bearing temperature.

Constant

90 DEGC

High-high alarm/interlock bearing temperature.

Constant

100 DEGC

High alarm/interlock bearing temperature.

Constant

90 DEGC

High-high alarm/interlock bearing temperature.

Constant

100 DEGC

PAGE 14

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

REVISION 01

F. Reference Documents FFE Doc./Dwg. Number

Document/Drawing Description

8.500980, SHT. 1

CONTROL AND INSTRUMENTATION DIAGRAM, LEGEND SHEET 1

8.500980, SHT. 2

CONTROL AND INSTRUMENTATION DIAGRAM, LEGEND SHEET 2

8.500980, SHT. 3

CONTROL AND INSTRUMENTATION DIAGRAM, LEGEND SHEET 3

8.500980, SHT. 4

CONTROL AND INSTRUMENTATION DIAGRAM, CRUSHER OVERVIEW

8.500980, SHT. 5

CONTROL AND INSTRUMENTATION DIAGRAM, CRUSHER HYDRAULIC OIL SYSTEM

8.500980, SHT. 6

CONTROL AND INSTRUMENTATION DIAGRAM, CRUSHER SPIDER BUSHING LUBE SYSTEM

8.500980, SHT. 7

CONTROL AND INSTRUMENTATION DIAGRAM, 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

3

REVISION 01

Crusher Lubrication Group

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

A. Equipment This group consists of the following equipment, which is monitored and controlled 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 Lubrication System Reservoir has the following devices associated with it: 1. Level Switches There are two (2) oil level switches 31-LSL-6721 and 31-LSLL6721located 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 Lubrication 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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-6718 and 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 response 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 outlet 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 bearings 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 supply 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 reservoir, 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 Diagrams and in the Field Instrument List.

A3. Countershaft Bearing Temperature Elements

PAGE 18

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

REVISION 01

1. Temperature Elements Two (2) temperature elements monitor the countershaft (inboard and outboard) 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  31TAHH-0111B set points for alarming and interlocking.

B. Normal Startup Sequence Prior to starting the Crusher Lubrication Group, the operator should first perform 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 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 Lubrication Group is as follows: 1. Place cooler drain valve in “AUTO” mode A/M STATION 31-XS-6717, 31XS-6716, so that they may open (pump off) and close (pump on) automatically 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

REVISION 01

C. Normal Operation Once the Crusher Lubrication Group is started, normal operation simply consists 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-TCH6723. 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 supply 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 interlocks (see Section H of this chapter). PAGE 20

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 continue to operate unless shutdown by the operator or other required interlocks (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 immediately 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 Owner’s 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-ZLO6716) (31-ZLC-6716)

14.

Status of the Lube Oil Filter Drain Valve (open or closed). 31-ZLO6717) (31-ZLC-6717) PAGE 21

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 TE MPERATURE

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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

REVISION 01

H. Interlocks Equipment or Control System

Interlock Type Signals

Start

Process

LUBE RESERVOIR OIL TEMPERATURE NOT LOW (below the Lube Oil Reservoir Low Temperature 

X

X

STANDBY LUBE OIL SUPPLY PUMP NOT RUNNING

X

X

LUBE OIL RESERVOIR TEMPERATURE NOT LOW (below the Lube Oil Reservoir Low Temperature 

X

X

MAIN LUBE OIL SUPPLY PUMP NOT RUNNING

X

X

Permissive LUBE OIL RESERVOIR HEATERS

MAIN LUBE OIL SUPPLY PUMP

STANDBY LUBE OIL SUPPLY PUMP

LUBE OIL COOLER FAN A

LUBE OIL RESERVOIR TEMPERATURE NOT HIGH (below the Lube Oil Reservoir High Temperature )

X

LUBE RESERVOIR OIL LEVEL NOT LOWLOW (below the Lube Oil Reservoir Low-  Low Level )

X

LUBE OIL RESERVOIR LEVEL NOT LOWLOW (below the Lube Oil Reservoir Low-  Low Level )

X

LUBE OIL RESERVOIR LEVEL NOT LOWLOW (below the Lube Oil Reservoir Low-  Low Level )

X X

LUBE OIL COOLER OUTLET TEMPERATURE MOVING AVERAGE NOT LOW (below the Lube Oil Cooler Standby Fan Off ) MAIN OR STANDBY LUBE OIL PUMP RUNNING

LUBE OIL COOLER DRAIN VALVE

X

LUBE OIL COOLER OUTLET TEMPERATURE MOVING AVERAGE NOT LOW (below the Lube Oil Cooler Main Fan Off ) MAIN OR STANDBY LUBE OIL PUMP RUNNING

LUBE OIL COOLER FAN B

Safety

X X

X

X

ANY ONE (1) OIL LUBE PUMPS RUNNING (CLOSE VALVE)

X

BOTH OIL LUBE PUMPS NOT RUNNING (OPEN VALVE)

X

PAGE 23

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

REVISION 01

H. Interlocks (cont’d) Equipment or Control System

Interlock Type Signals

Permissive

Safety

Start

LUBE OIL START PERMISSIVE FOR THE CRUSHER MAIN DRIVE MOTOR

LUBE RESERVOIR OIL LEVEL NOT LOW (below the Lube Oil Reservoir Low Level )

X

COUNTERSHAFT BEARINGS OIL FLOW NOT LOW (below the Countershaft Bearings Lube Oil Low Flow )

X

C1LBSTART (SEE CHAPTER 7, SECTION H)

INNER ECCENTRIC BUSHING OIL FLOW NOT LOW (below the Inner Eccentric Bush-  ing Lube Oil Low Flow )

X

OUTER ECCENTRIC BUSHING OIL FLOW NOT LOW (below the Outer Eccentric Bush-  ing Lube Oil Low Flow )

X

LUBE OIL RETURN LINE TEMPERATURE NOT HIGH (below the Lube Oil High Return Line Temperature )

X

COUNTERSHAFT INBOARD BEARING TEMPERATURE NOT HIGH (below the Counter-  shaft Inboard Bearing High Temperature ) COUNTERSHAFT OUTBOARD BEARING TEMPERATURE NOT HIGH (below the Countershaft Outboard Bearing High Tem-  perature )

PAGE 24

X X

Process

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

H.

REVISION 01

Interlocks (cont’d)

LUBE OIL 30-SECOND DELAYED STOP INTERLOCKS FOR THE CRUSHER MAIN DRIVE MOTOR C1LBSTOP (SEE CHAPTER 7, SECTION H)

COUNTERSHAFT INBOARD BEARING TEMPERATURES NOT HIGH-HIGH (below the Countershaft Inboard Bearing High-High Temperature )

X

COUNTERSHAFT OUTBOARD BEARING TEMPERATURES NOT HIGH-HIGH (below the Countershaft Outboard Bearing High-  High Temperature )

X

COUNTERSHAFT BEARING OIL FLOW NOT LOW (below the Countershaft Bearings Lube Oil Low Flow )

X

OUTER ECCENTRIC BUSHING OIL FLOW NOT LOW (below the Outer Eccentric Bush-  ing Lube Oil Low Flow )

X

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 High-High Temperature )

X

INNER ECCENTRIC BUSHING OIL FLOW NOT LOW (below the Inner Eccentric Bush-  ing Lube Oil Low Flow )

X

PAGE 25

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

4

REVISION 01

Crusher Hydraulic Adjustment 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 position 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 Instrument 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-PDSH6506. 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 provided and is used to control the direction of high pressure oil flow. The solenoids 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 chapter.

PAGE 27

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 system and provides local pressure accumulation. The accumulator is of the hydro-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 Crushers (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 accumulator and other hydraulic adjustment group components from excessive pressure. 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 below 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 transformer. Flux change is converted to a signal proportional to the position 31ZY-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 Position 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 crushing 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 hydraulic oil supply pump automatically starts (if it is not already running), the LOWER solenoid S2 remains de-energized and the RAISE solenoid S1 is energized. Oil is then ported towards the hydraulic cylinder. Simultaneously, a thirty (30) minute run timer begins timing out. When the run timer expires, the hydraulic 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 hydraulic 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 position. 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 during the mantle lowering operation.

PAGE 29

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 Control 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

REVISION 01

H. Interlocks Equipment or Control System

Interlock Type Signals

permissive HYDRAULIC OIL PUMP

Safety

HYDRAULIC RESERVOIR OIL LEVEL NOT LOW (below the Hydraulic Oil Reservoir Low Level ) HYDRAULIC RESERVOIR OIL LEVEL NOT LOW-LOW (below the Hydraulic Oil Reservoir Low-Low Level )

Start

X X

MANTLE LOWER SOLENOID VALVE

CRUSHER MANTLE POSITION NOT LOW

MANTLE RAISE SOLENOID VALVE

CRUSHER MANTLE POSITION NOT HIGH (below the Crusher Mantle High Position )

HYDRAULIC START PERMISSIVE FOR THE CRUSHER MAIN DRIVE MOTOR

HYDRAULIC RESERVOIR OIL LEVEL NOT LOW-LOW (below the Hydraulic Oil Reservoir Low-Low Level )

X

MANTLE POSITION NOT LOW (BELOW MINIMUM NORMAL RECOMMENDED OPERATING POINT)

X

MANTLE POSITION NOT HIGH (ABOVE MAXIMUM NORMAL RECOMMENDED OPERATING POINT)

X

C1HYSTART (SEE CHAPTER 7, SECTION H)

HYDRAULIC DELAYED STOP INTERLOCKS FOR THE CRUSHER MAIN DRIVE MOTOR

(below the Crusher Mantle Low Position )

X X

HYDRAULIC RESERVOIR OIL LEVEL NOT LOW-LOW (below the Hydraulic Oil Reservoir Low-Low Level )

X

C1HYSTOP (SEE CHAPTER 7, SECTION H)

PAGE 32

Process

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

5

REVISION 01

Crusher Spider Bushing Lubrication 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 components: 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 progressive 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 LED’s LED’s 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 Installation, 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 signal 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 controlled 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 control system permissive

Interlock Type Signals

SPIDER LUBRICATION POWER-ON SIGNAL SPIDER LUBRICATION DELAYED STOP INTERLOCKS FOR THE CRUSHER MAIN DRIVE MOTOR

CRUSHER MAIN DRIVE MOTOR RUNNING

C1SBLSTOP

Safety

Start

X

X

CRUSHER SPIDER GREASE CONTROLLER NO FAULTS.

X

SEE CHAPTER 7, SECTION H)

PAGE 36

Process

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

6

REVISION 01

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 Instrumentation Diagram 8.500980 sheet 4 for details.

A. Equipment The Crusher Dust Seal Air Blower Group consists of the following components: 1. Dust Seal Air Blower There is one (1) dust seal air blower supplying air to the outer eccentric 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 consists 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 associated with the Crusher Dust Seal Air Blower 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 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

REVISION 01

G. Alarms Non-debounced Alarms Alarm Tag 31-XA-0110

Alarm Text

DUST SEAL AIR BLOWER TRIPPED (If trips on run command)

H. Interlocks Interlock Type Equipment DUST SEAL AIR BLOWER DUST SEAL AIR BLOWER START PERMISSIVE FOR THE CRUSHER MAIN DRIVE MOTOR (SEE CHAPTER 7, SECTION H)

Signals

C1SBSTART

STOP PUSH BUTTON NOT DEPRESSED DUST SEAL BLOWER MOTOR RUNNING

Safety

X

X

PAGE 39

Start

X

Process

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

7

REVISION 01

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 Owner’s Motor Protection Relay. 2. Motor Protection Relay (by others) From the Owner’s Motor Protection Relay, the following status and Crusher Main Drive Motor parameters are wired to the Control system: Status/Alarm Tag

Alarm Text

UA-0105

MOTOR PROTECTION RELAY FAULT

XA-0105

MOTOR PROTECTION RELAY TRIP

TAH-0111A

CRUSHER MAIN DRIVE MOTOR INBOARD BEARING HIGH TEMPERA-  TURE

PAGE 40

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

REVISION 01

Status/Alarm Tag TAHH-0111A

Alarm Text CRUSHER MAIN DRIVE MOTOR INBOARD BEARING HIGH-HIGH TEM-  PERATURE

TAH-0111B

CRUSHER MAIN DRIVE MOTOR OUTBOARD BEARING HIGH TEMPERA-  TURE

TAHH-0111B

CRUSHER MAIN DRIVE MOTOR OUTBOARD BEARING HIGH-HIGH TEM-  PERATURE

TAH-0112

CRUSHER MAIN DRIVE MOTOR HOTTEST WINDING HIGH TEMPERA-  TURE

TAHH-0112

CRUSHER MAIN DRIVE MOTOR HOTTEST WINDING HIGH-HIGH TEM-  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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

REVISION 01

B. Normal Startup Sequence 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 elevation as described described in 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 interlocks for the Crusher are confirmed to be normal per the Interlock section (section H of the same chapter). 7. The Owner’s 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 satisfied. 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 follows: 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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   (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 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 described 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 shutdown by the operator as described in Chapter 7 of this document.

E. Abnormal and Emergency Shutdowns Shutdowns 1. Abnormal Shutdown, Crusher Crusher Delayed Trip

PAGE 43

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

REVISION 01

If the Crusher is operating and any of the delayed trip interlock conditions occur (see Section H of this chapter), the Control system will provide an alarm to the operator. The Control system shall immediately stop the Owner’s 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 Crusher Instantaneous Instantaneous Trip If the Crusher is operating and any of the instantaneous trip interlock conditions 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 Instruction 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 immediately 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 limits 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 Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group 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 JAH-0105 JAHH-0105 IAH-0105

Alarm Text CRUSHER MAIN DRIVE MOTOR KILOWATTS HIGH CRUSHER MAIN DRIVE MOTOR KILOWATTS HIGH-HIGH 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 TAH-0111B TAHH-0111B

CRUSHER MAIN DRIVE MOTOR INBOARD BEARING TEMPERATURE HIGH-HIGH CRUSHER MAIN DRIVE MOTOR OUTBOARD BEARING TEMPERATURE HIGH CRUSHER MAIN DRIVE MOTOR OUTBOARD BEARING TEMPERATURE HIGH-HIGH

TAH-0112 TAHH-0112

CRUSHER MAIN DRIVE MOTOR HOTTEST WINDING TEMPERATURE HIGH CRUSHER MAIN DRIVE MOTOR HOTTEST WINDING TEMPERATURE HIGH-HIGH

PAGE 45

FFE MINERALS USA INC.

Functional Specification Document No. 8.500985

A member of the F.L. Smidth-Fuller Engineering Group Gyratory Crusher, Cerro Verde Project, Peru.

REVISION 01

H. Interlocks Equipment or Control System

Interlock Type Signals

Permissive CRUSHER MAIN DRIVE MOTOR START PERMISSIVE

CRUSHER MAIN DRIVE MOTOR DELAYED STOP INTERLOCKS

C1LBSTART

Start

LUBE OIL START PERMISSIVE FOR THE CRUSHER MAIN DRIVE MOTOR SATISFIED (SEE CHAPTER 3, SECTION H)

X

C1SBSTART

DUST SEAL AIR BLOWER RUNNING (SEE CHAPTER 6, SECTION H)

X

C1HYSTART

HYDRAULIC START PERMISSIVE FOR THE CRUSHER MAIN DRIVE MOTOR SATISFIED (SEE CHAPTER 4, SECTION H)

X

C1LBSTOP

C1SBLSTOP

C1HYSTOP

CRUSHER MAIN DRIVE MOTOR INSTANTANEOUS STOP INTERLOCKS

Safety

(by others)

LUBE OIL DELAYED STOP INTERLOCKS FOR THE CRUSHER MAIN DRIVE MOTOR SATISFIED (SEE CHAPTER 3, SECTION H)

X

SPIDER LUBRICATION DELAYED STOP INTERLOCKS FOR THE CRUSHER MAIN DRIVE MOTOR (SEE CHAPTER 6, SECTION H)

X

HYDRAULIC DELAYED STOP INTERLOCKS FOR THE CRUSHER MAIN DRIVE MOTOR SATISFIED (SEE CHAPTER 4, SECTION H)

X

CRUSHER MAIN DRIVE MOTOR PROTECTION RELAY INTERLOCK AND WINDING  /BEARING TEMPERATURES SATISFIED

PAGE 46

X

Process

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..............................................................................................

5.5

Prevention of shaft current ............................................................................. 12

5.6

Piping .............................................................................................................. 13

11

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. -1 The power frequency in Hz is as f, the synchronous speed N (min ) of the motor  becomes:

 N 

120  f  P

min   1

Before using the motor, be sure to check the power frequency against the frequency indicated on the rating 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 (η) 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.

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. the motor against the invoice.

(2)

First unpack carefully.

(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 card and remove the protectors.  As there is case that this protective devices are not only attached on the load side bearing but also on the opposite load side bearing, confirm certainly that the protective devices on the both bearings are removed before trial run

(5)

Check

Check each component for shipping damage.

CAUTION !! 1. Remove the red painted bearing  protective device before  putting the motor into operation. 2. Put the bearing protective device in case of re-transport the motor after fitting the shaft end with coupling or   pulley.

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

Item Component

Stator 

Rotor 

Bearings

1

Styles of long-term storage and methods of quality preservation for AC motor assemblies

Measure for quality preservation Style of  Inspection Inspection Rust Protection from storage method cycle inhibition and deformation and moistureproofing damage (1) Wrap with (1) Pretreat and (1) Put a canvas (1) Unpack and a polyapply an airsheet 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 creeapply air-dry (2) Never  windings. page of  type coil stack the moisture varnish on the components (3) Every six 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 polyinside 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 3 g/m ) (4) Inspect the months shaft journals (1)Pretreat the every six shaft journal months. and oil slingers, and (5) For the apply rust anti-friction inhibitive oil. bearings, turn them every (1) For sleeve six months, bearings: and supply Pretreat the grease or  spherical replace the surface and grease babbit metal, completely. and apply rust inhibitive oil. Place of  storage

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

 Air  cooler 

Seal N2 gas into the tube. 49kPa 2 (0.5kg/cm )

Protect the  Attach a pressure Every cooling fins to gauge, and three prevent damage. monitor the N2 months gas sealed

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) Speed of rotation

Over  -1 1500 min

Over 1000 up to -1 1500 min

Up to -1 1000 min

0.02

0.03

0.04

0.03

0.04

0.05

0.06

0.08

Less than 0.1

Deviation of degree of  eccentricity Rigid coupling Deviation of  parallelism Gear coupling

Dial indicator 

Coupling matchmark

Load side

Motor 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.

B

90



180



0



Left-to-right corrected quantity =



2

A

C

Top-to-bottom corrected quantity = 270

A-C

D

B-D

EME000077-d 10 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

G1

F2

E1

G2

H1

Left-to-right corrected quantity =

F1+F2 - H1+H2

Top-to-bottom corrected quantity =

E1+E2 - G1+G2

E2

H2 (Measured value) Fig.4

(Corrected quantity) 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 can’t 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

EME000077-d 11

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 f ollowing 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.

EME000077-d 12 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

EME000077-d 13 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 won’t 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 14 (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 100mesh 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 15 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 c onnect 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 f actory. 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

EME000077-d 16 Instruction for connecting conductor (WAGO Rail Mount Terminal Blocks with CAGE CLAMP) Stripping of Wire

Please strip a conductor‘s stripped length related as drawings. Please fix splayed, bent or twisted wire.

Ｌ

Conductor’s stripped length (Std) Connecting

For space heaters (WAGO 282) For RTD’s etc. (WAGO 870)

: 12 to 13 mm : 6 to 7 mm

Please follow the instructions.

[1] Put a screwdriver to the operating slot.

[2] Insert a screwdriver to the inside of the terminal block.

[3]The screwdriver will be fixed when operated   correctly.

[4] Insert a wire to the wire hole.

[5] Pull out a screwdriver  from the operating slot. (Please hold a wire.)

[6] Pull a wire slightly to check if connecting has been 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 17 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 18 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 Nm

Tolerable range 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 19 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.

8.

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 f reely 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.

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.

EME000077-d 20 (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 s ame 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.

EME000077-d 21

(b)

term trouble-free operation. 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

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 23 Table 5-1 Maintenance and inspection standard - Daily inspection (during motor operation)

Category 1. Power  source

2. Running conditions

Inspection procedure Subject of  Inspection Method of  inspection cycle inspection

Requirements Limit: Within ±10% of rated values at rated frequency.

Voltage

Daily

Voltmeter  

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%.

Vibration

Weekly

Sense of touch and vibrometer 

Where the vibration is felt to increase over  ordinary level, measure the value. Judge the vibration level according to section 10.4.1.

3. Environment

4. Bearing

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 (frame,bearing, coil)

Sense of touch, thermometer 

Cover and the like

Weekly

Visual inspection No falling off and loosening of fixing bolts.

Ladder and platform

Weekly

Visual inspection No falling off and loosening of fixing bolts.

 Ambient temperature

W eekly

Thermometer

W ithin the standard values and normal

Ventilation

Weekly

Visual check

No blockage in the ventilation grills, etc: The motor blower, if working, is normal.

Temperature

Daily

Sense of touch, thermometer 

When the temperature is sensed as abnormal, measure it with a thermometer.

No corrosion

4.1 Sleeve bearing

4.2 Antifriction bearing

No change in temperature rise from the values at the initial time.

Temperature limits of self-cooled bearings: Up to 92℃, measured at the metal lower half  (reading value) Oil level and oil leakage

Daily

Visual inspection Be normal oil level.

Oil pressure

Daily

Visual inspection Be normal.

Oil ring

Daily

Visual inspection Be rotating smoothly.

Rotating noise

Daily

Sense hearing, stethoscope

Temperature (includes oil slinger)

Daily

Sense of touch, thermometer 

of  Be normal

When the temperature is sensed as abnormal, measure it with a thermometer. Temperature limits (reading value): Up to 100℃, measured by embeded   thermometer 

EME000077-d 24 Table 5-2

Category 5. Cooler

Maintenance inspection standard - Daily inspection (during motor operation)

Inspection procedure Subject of  Inspection Method of  inspection cycle inspection

Requirements

Water   leakage

Daily

Visual check

No leak

Water  pressure

Daily

Pressure gauge

Specified pressure

Water flow

Daily

Flow sight

Flowing

EME000077-d 25 Table 6

Category

Maintenance inspection standard - Daily inspection (when the motor is stopped) Inspection procedure Subject of  Inspection Method of  inspection cycle inspection

Requirements

1. Cooler

Check in detail the troubles recorded on the service log

Monthly

Service log

2. Appearance

Damage and dirt on the frame and terminals

Monthly

Visual check

Clean and make repairs

Cooling pipes, air duct and filter 

Monthly

Visual check

Cleaning of found clogging

3.1 Sleeve bearing

Oil contamination

Monthly

Visual check

No sludge babbit metal chaffings or any other  foreign objects

3.2 Antifriction bearing

Discharged grease

Monthly

Drain port

No metallic powder or any other foreign objects, or contamination in grease

Visual check

Check the amount of brush wear with reference to the following page, and exchange brushes according to the wear extent.

3. Bearing

4. Earth brush The amount of  Monthly (when brush wear  attached)

EME000077-d 26 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 m otor 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 27 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 Inspection Method of  cycle inspection

Category

Subject of  inspection

Requirements

1. Investigation

Check in operation log for abnormalities

2 years

Service log

Make repairs if necessary

2. Measurement

Coil insulation resistance

2 years

Megger

Desired values of stator coils R ≧  kV + 1 (MΩ) where R: minimum insulation resistance at 40 ℃ kV: rated voltage (kV)

 Air gap

2 years

Gap gauge

Max, value  min, value Mean value

3. Appearance

4. Stator

5. Rotor

×100



20%

Pollution or  worn painting on the frame

2 years

Visual check

Cleaning and repairs

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.

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 materials

2 years

Visual check

Freedom from varnish spouting, void and 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 Visual check

Freedom from loosening and cracks

Core

2 years

Visual check

Freedom from rust, loosening, dust, oil, moisture, other foreign objects, overheating, discoloring and damage

Connection of  rotor bars and end ring

2 years

Visual check

Freedom from cracks and bar shifting

EME000077-d 28 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)

Category

Subject of  inspection

Inspection procedure Inspection Method of  cycle inspection

Requirements

6. Bearing 6.1 Sleeve bearing

6.2 Antifriction bearing

Metal Contact

2 years

(Overhaul inspection of  bearing) Visual check (magnifying glass)

Lower metal to be in good working order  Upper metal to be free from contact marks

Metal adhesion

2 years

Color check

50% or more

Metal clearance

2 years

Micrometer

Refer to sleeve bearing instruction manual

Oil slinger

2 years

Thickness gauge

Within limit

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 gauge

Within limit

Scale

Refer to Sect. 5.2 Table 2.

Grease contermination

2 years

Visual check

Grease replacement

7. Instruments Dirt, damage

2 years

Visual check

Freedom from dust, oil, moisture, foreign objects and damage

8. Coupling

Deviation of  degree of eccentricity and parallelism

 As required

Dial gauge

Within tolerances, Refer to Sect. 5.2.

Centering

As required

Dial gauge

W ithin tolerances, Refer to Sect. 5.2.

Direct coupling As required

Visual check

Freedom from the loosening of the bolts and nuts.

Damage

Visual check

Freedom from damage and breakage of key way

(color check if  required)

No abnormal wear on tooth surface of the gear  coupling.

 Abnormal 2 years noise, vibration abnormal odor 

Sense of   hearing Sense of touch Sense of smell

No abnormality

Rotational direction

2 years

Visual check

Normal rotational direction

Protective

2 years

Visual check

9. Operation on load

10.Shaft

As required

 After cleaning, measure insulation resistance

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)

Category 1. Investigation

2. Measurement

3. Appearance

4. Stator

5. Rotor

Inspection procedure Subject of  Inspection Method of  inspection cycle inspection Check the * Service log operation log 4 years for abnormalities Shaft level Level meter

Requirements Make repairs if necessary

Measure the level at both journals, and make sure that the difference is within 0.05 mm/m. More than specified values Refer to Table 7.

Coil insulation resistance

4 years

Megger

Space heater  insulation resistance  Air gap Pollution or  worn painting on the frame Filter

4 years

Megger  

More than 1kΩwith a 500V megger 

4 years 4 years

Gap gauge Visual check

Refer to Table 7 Cleaning and repairs

4 years

Visual check

Bolt joints

4 years

Visual check

Core and coil

4 years

Visual check

Core

4 years

Visual check

Core ends

4 years

Visual check

 Air ducts Coil ends

4 years 4 years

Visual check Visual check

Insulating materials Coil supports

4 years

Visual check

4 years

Visual check

Wedge

4 years

Hammering

Coil binding strings Lead cable and terminals

4 years 4 years

Visual check Sense of touch Visual check

 Air deflector

4 years

Visual check

Space heater

4 years

Visual check

Core

4 years

Visual check

Clean and repair   (Replace when necessary) Freedom from looseness, dropping off and damage. Freedom from dust, oil, moisture and foreign objects. Freedom from unevenness, overheating, discoloring, damage, loosening, rust, etc. Freedom from tumble or protrusion of air duct spacers, loosened or damaged core sheets. Freedom from clogging Freedom from deformations, damage and pollution Freedom from varnish spouting, void and tracking, etc. Freedom from shifting, getting out and loosening. Freedom from withering, loosening and falling off. Freedom from shifting, loosening, discoloring and deterioration. Freedom from damage, deterioration and deformation of terminals. Freedom from dust, oil, moisture and adhering foreign objects. No abnormality in the welded part. No loosened bolts. Freedom from loosened fastener parts, dust, oil, moisture and adhering foreign objects. Freedom from rust, loosening, dust, oil, moisture, other foreign objects, overheating,

EME000077-d 30 Table 8-2 Maintenance inspection standard - Regular inspection (Full-scale regular inspection by drawing out the rotor) Category

6. Bearing 6.1 Sleeve bearing

Inspection procedure Subject of  Inspection Method of  inspection cycle inspection Joint of rotor  * Visual check bars and end 4 years Color check ring Rotor bar 4 years Hammering Fan 4 years Visual check Balance weight 4 years Hammering Shaft journal Visual check Sense of touch Metal contact

Yearly

Metal adhesion Metal clearance Oil slinger Oil ring

9. Operation on load

Freedom from cracks. Dislocation of silver  solder shall be less than 50% for each side of joint surface. No bar shifting. Freedom from loosening. Freedom from fan blade deformation. Freedom from loosening. Freedom from scars, knock marks, pressing marks.

Yearly

(Overhaul inspection of  bearing) Visual check (magnifying glass) Color check

More than 50%

Yearly

Micrometer

Refer to sleeve bearing instruction manual.

Yearly

Within limit

Yearly

Thickness gauge Visual check

Oil

Yearly

Visual check

End play

Yearly Yearly

Thickness gauge Scale Visual check

* 4 years  As required

Comparison with standard Dial gauge

6.2 AntiGrease confriction termination bearing 7. Instruments Correction 8. Coupling

Requirements

Deviation of  degree of eccentricity and parallelism Centering As required Direct coupling As required

Dial gauge Visual check

Damage

As required

Visual check

Yearly

(color check if  required) Sense of   hearing, touch, and smell

Lower metal to be in good working order  Upper metal to be free from contact marks

Freedom from deformation and serious wear: freedom from loosened setscrews Freedom from dirt, deterioration and foreign objects Refer to Sect. 5.2 , Table 2 Grease replacement Within standard values. Refer to Sect. 5.2.

Refer to Sect. 5.2. Freedom from the loosening of the bolts and nuts. Freedom from damage and breakage of key way No abnormal wear on tooth surface of the gear  coupling. No abnormalities

Yearly

Visual check

Normal rotational direction

* 4 years 4 years 4 years

Visual check

11.Piping

 Abnormal noise, vibration abnormal odor  Rotational direction Inside inspection Hydraulic test Damage

Hydraulic test Visual check

12.Shaft

Protective

Yearly

Visual check

Freedom from abnormal corrosion and pinholes. Freedom from leakage and deformation. Freedom from loosened fastenings, water   leakage, oil leakage and corrosion.  After cleaning, measure insulation resistance

10.Cooler

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 Thermal class A

    m     e      t      I

Thermal class E

Thermal class B

(JEC-2137)(Unit K)

Thermal class F

Thermal class H

Method of temperature measurement Th : Thermometer method R : Resistance method ETD : Embedded temperature detector method

Induction machine part

Th

R

ETD

Th

R

ETD

Th

R

ETD

Th

R

ETD

Th

R

ETD

-

60

65

-

75

80

-

80

85

-

100

105

-

125

130

-

60

65

-

75

80

-

80

90

(1)

105

110

-

125

130

(1)

60

-

(1)

75

(1)

80

(1)

105

(1)

125

(1)

65

-

(1)

75

(1)

80

-

110

(1)

130

-

65

-

-

75

-

80

-

110

-

130

-

60

-

-

75

-

80

-

105

-

125

Stator windings a. Output: 5000kW or  more b. Output: In excess of  200kW; less than 5000 c. Output: No more than 1 200kW and other  than d and e(2) d. Output: Less than 600kW e. Self-cooled mold type without cooling fans (2)

2 Insulated rotor winding 3 Squirrel-cage winding 4

Commutator, brush

-

-

-

-

slip-ring,

Cores and all structure components (excluding 5 bearings) regardless of  contacts with winding

The temperature of this part must not have harmful impacts on its insulating materials and neighbouring materials.

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

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

(MΩ)

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 300MΩ 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 doesn’t 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

Peak to peak values (Unit  m  Allowable value of Vibration (Overall)

1 

Number of    Poles Frequency Single motor 50 Hz 60 Hz Rated load operation 50 Hz after directly coupled 60 Hz

1000

mm)

2P

4P

6P

20 20 30 26

30 25 50 43

30 30 50 50

8P or  over  40 40 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.

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)

(2)

Vibration with changeable amplitudes The following cases, when the amplitude change with time under the constant speed and voltage, are tak en 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.

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 

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. 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.

If the

(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 f ollowing 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)

(b)

(c)

(2)

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. 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. 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.

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 isn’t 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 Noise caused by bearing itself 

Roller dropped out Squeak

Noise caused by anti-friction bearing

Cage noise  Abnormal noise

Boom noise Defect noise

Noise caused by case of setting up the bearing to the machine Fig. 10.

Dust noise Beat(relating to bearing housing or frame)

Noise caused by anti-friction bearing

EME000077-d 38

(b)

(3)

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. 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.

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)

(b)

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. 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. Starting and maximum torque

Influences of characteristics on motor with regard to the fluctuations Synchronous speed

% slip

Voltage change 110% (+)21% unchanged (-)17% voltage Relation 1 2 with (voltage) constant 2 (voltage) voltage 90% (-)19% unchanged (+)23% voltage

Full-load speed

Full-load current

Starting current

Temperature rise at full load

(+)0.4%

(-)7%

(+)10 to 20%

(-3) to 4%

－－－

Frequency change 105% (-)10% (+)5% frequency Relation 1 with (frequency) (frequency) frequency 95% (+)10% (-)5% frequency

－

practically no change

(-)0.5%

(+)11%

(+)5%

(-) slight

(voltage)

Magnetic noise Particularly no-load condition

(+) slight

－ －

(-)10 to 12%

(+)10 to 15%

(+) slight

(-)5 to 6% 1

(-) slight

(+) slight

－－－ － － － practically no change

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

(-)5%

(+) slight

(frequency) (+)6 to 7%

(+) slight

(+) slight

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 Positive phase sequence voltage

× 100 %

Current unbalance ratio = Negative phase sequence current Positive phase sequence current

(2)

× 100 %

Influences of unbalanced voltage of the power source (a)

(b)

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. 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 threephase-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.

EME000077-d 41 11. Troubleshooting Table 11 shows the various troubles, their causes and counter-measures. you consider the troubles serious, immediately contact us. Table 11-1 Trouble

Troubleshooting

Cause

1. The motor  will not start. Even when the main switch is turned on, the motor  remains non-rotated.

The starting conditions have not yet been prepared. The circuit from power source to motor main terminals is wrong.

2. The motor  generates abnormal noise without starting up.

If 

Countermeasure

Some interlocks have not yet been released. No voltage is supplied to the starter; starting contractor is wrong. The fuses of two-phases are blown.

Check for wrong wires and contacts on the circuit.

The motor condition remains one phase

One phase fuse is blown. One-phase of  starter circuit is wrong. Starting contractor is wrong.

Check for wrong wires and contacts on the circuit.

Mechanical lock.

The driven machine is locked. The coupling connection is wrong (belting too tight: misalignment; installation error, etc.) Bearing is melted. The metal contact in air  gap due to bearing melting

Check the driven machine and coupling and consider proper  countermeasures.

The stator winding of  the motor is broken.

One-phase is broken.

Repair the defective stator winding.

Deterioration of insulation caused by overheat, vibration, shocks, etc.

Repair the defective stator winding.

The stator winding of  the motor is broken.

3. The protec- Starter failure. tive relay Rotor winding is trips when shorted or earthed. main switch is turned on. Mechanical lock. Improper setting of  protective relay.

Exchange blown fuses. Check the main terminal. Repair the detective stator winding.

Same as item 2 above Correct the relay setting.

EME000077-d 42 Table 11-2 Trouble 4. Abnormal noise and vibration

Troubleshooting

Cause

Countermeasure

One-line fault; unbalanced voltage

Wire in circuit is broken. The fuse is blown. Contact is wrong.

Check each line to locate defective points.

Mechanical abnormalities of motor 

Unbalanced rotor  Cracked end ring; ruptured bar 

Overhaul inspection Overhaul inspection

Slackened core laminations

Overhaul inspection

Unbalance or contact of  air gap

Overhaul inspection

Intrusion of foreign objects

Overhaul inspection

Bending or cracking trouble of shaft

Overhaul inspection

Oscillating in the driven machine

Vibration of the driven machine

Disconnect the mating machine, and check for  the causes.

Misalignment

Bending trouble of shaft

5. Excessive  Abnormalities in the temperature power source rise and smoking Overload

Poor cooling

Slackened coupling

Tighten up the coupling bolts.

Improper connection with foundation

Make repairs.

Unbalanced voltage one-line fault; wrong voltage or frequency; voltage drop

Check the power source and starter for  abnormalities.

Overload caused by the fault of the driven machine

Disconnect the motor, and check for troubles.

Excessive start and stop; excessive reverse running.

Review the selection of  motor.

Clogged filter; intrusion of foreign objects into the ventilation grille.

Cleaning

EME000077-d 43 Table 11-3 Trouble

6. Seizure of  sleeve bearing (For details, refer to the bearing manual.)

7. Defect of  grease lubricated anti-friction bearing For details, refer to the bearing manual.)

8. Irregular 

Troubleshooting

Cause

Countermeasure

Defective winding

Stator winding is shorted or earthed.

Repair winding.

Mechanical fault

The metal contact in air   gap. Overheat of  bearing caused by bad directed coupling (Excessive belt tension, misalignment, etc.)

Same as item 2

Shortage of lubricant

Fault of rotation caused by deformation or  abrasion of oil ring; Shortage of oil quantity; Oil leakage.

Exchange or repair of oil ring

Defective contact of   bearing caused by abrasion or vibration etc.

Overhaul inspection

Defective lubricant

Change in quality; incorrect brand; mixture of dust and metal sludge

Oil exchange

The defect identified by noise, vibration and temperature. In many cases, the trouble is concerned with grease. If the noise is excessive, charge grease.

Fatigue galling of  raceways and rolling elements; Depressions and other defects imparted upon the raceways and rolling elements caused by poor handling.

Wash the bearing and check for defects. If the bearing is found defective, replace it with a new one.

Shortage or excessive charge of grease.

Supply a specified quantity with grease of  specified brand.

Change in quality of  grease or wrong brand

Wash the bearing.

Mixture of dust and metal sludge.

Bearing exchange

Deformation or damage of retainer in bearing; Improper mounting of  bearing; Excessive thrust load; Too small clearance.

Correct the bearing setting. Correct the alignment. Check the driven machine.

Early indication of the

Winding fault; bearing

EME000077-d 経 変更 REV.

変更発行日   REV.ISSUED

歴

書

変更箇所及び内容 PAGE

CHANGED PLACE AND CONTENTS

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Mar.24.’01

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Oct.17.’01

SOME DESCRIPTIONS AND DRAWINGS  ARE ADDED OR CHANGED.

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Nov.21.’01

DESCRIPTION OF TITLE PAGE IS CHANGED.

INITIAL ISSUED

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d

Jun.10.’04

3

Retraced Company name changed. Nameplate changed.

44 FINAL 承 認

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 APPROVED BY REVIEWEDBY PREPARED BY

Y.Amasaka

H.Masuda

Y.Nabara

Mar.24.’01

Mar.24.’01

Mar.24.’01

Y.Amasaka

H.Masuda

Y.Nabara

Oct.17.’01

Oct.17.’01

Oct.17.’01

Y.Amasaka

H.Masuda

Y.Nabara

Nov.21.’01

Nov.21.’01

Nov.21.’01

H.Kanzaki

Y.Fukushima

N.Fujita

Jun.10.’04

Jun.10.’04

Jun.10.’04

EME3OOO51 -a

21-L SERIES MANUAL DE INSTRUCCIÓNES

CHUMACERAS Y SOPORTES DE CHUMACERA

TMA ELECTRIC CORPORATION

EME3OOO51 - a 1/19 CONTENIDO 1. 2. 3.

Construcción del ensamble de chumacera.............. Conductos................................................................ Mantenimiento.......................................................... 3.1 Mantenimiento diario.......................................... 3.2 Mantenimiento anual....................................... 3.3 Mantenimiento de reparaciones completas....... 4. Lubricante................................................................... 5. Solución de problemas............................................... 6. Desmontaje y reensamblaje de las chumaceras........ 6.1 Preparación para el desmontaje......................... 6.2 Procedimiento de desensamble de chumaceras. 6.3 Procedimiento de reensamble..................................

.............................................................. 2 .............................................................. 3 .............................................................. 5 .............................................................. 5 .............................................................. 6 .............................................................. 7 .............................................................. 9 ............................................................ 10 ............................................................ 11 ............................................................ 11 ............................................................ 11 ............................................................ 16

EME300051-a

EME300051-a 3/19 2. Conductos (Para el tipo de lubricación forzada) Cuando el sistema conductos se diseña y ejecuta por su parte, preste atención 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 máquina 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 máquina 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 presión dentro del tanque de aceite y de los conductos a una presión atmosférica 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 sección transversal es demasiado pequeña, entonces el aceite no fluirá fácilmente y puede inundar o puede causar fugas. d) El diámetro de los conductos debe ser lo suficientemente grande.

(2)

(3)

(4)

Asegúrese de contar con un manómetro a la entrada de aceite y de suministro de agua así como un indicador de flujo en la salida de aceite y de agua de enfriamiento para facilitar la inspección PRECAUCION !!! flujo y presión de aceite y agua de enfriamiento a las chumaceras. 1. El motor tiene orificios para Instale el conducto a lo largo del cuerpo controlar la cantidad de aceite en su línea de del equipo y hágalo con los montajes entrada al soporte, como apropiados para prevenir movimientos. se muestra. necesaria en Asegúrese de adjuntar una placa de caso de instalar las orificio (refiérase a la tarjeta de precaución entradas de las líneas de adjunta) o una válvula para el ajuste de la lubricación. presión a la entrada de aceite. Si la placa o la válvula fuera suministrada por la planta ya estaría calibrada de fábrica. Evite la manipulación del mismo.

EME300051-a 4/19 (5) El conducto de aceite debe diseñarse y debe ajustarse tomando en cuenta la bomba de aceite, regulador de presión y otros conductos deben ser adecuados para el flujo y la presión especificada en el dibujo general de motor donde puede verse la información de las entradas a las chumaceras del motor. (6) Asegúrese que no hay ningún objeto extraño como trapos o herramientas dentro de los conductos. Entonces, límpielos completamente y conéctelos. La limpieza antes de la conexión de los conductos se cumple en uno de los siguientes dos métodos. Un método es inyectar vapor a una presión de 200 a 300 kPa. El otro es con un lavado de 10% de solución acuosa de ácido sulfúrico o el ácido clorhídrico, neutralice inmediatamente con un 20% de solución acuosa de sodio cáustico y entonces enjuague con agua. Cualquier método debe ser seguido de la lubricación con aceite tipo turbina para prevenir el óxido. (7) Las líneas de regreso utilizan la gravedad para el flujo. Esto exige al sistema de aceite de lubricación estar debajo de la elevación de la chumacera del motor y una pendiente continua dejando caer el aceite de retorno. (8) Después 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 alimentación de aceite junto con el motor o una bomba de aceite adicional que también se usará con un filtro. Cuando el vaciado se ha llevado a cabo usando la bomba de alimentación de aceite, asegúrese de limpiar el tanque de aceite completamente antes de un período de pruebas. Puesto que el aceite de lavado puede contener materiales extraños, este no debe ser introducido a las chumaceras. Específicamente, los conductos deben tener una desviación 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 estará completo cuando los objetos extraños ya no se entrampen en el filtro. El filtro debe reemplazarse a un intervalo de varias horas. El vaciado tomará de 24 a 48 horas o una semana si el conducto es largo. Con el propósito del vaciado, prepare el aceite regenerado así como el aceite nuevo. El aceite para el vaciado se usa para temperatura de 70°C a 80°C. Durante las operaciones de vaciado, martillen los conductos para desalojar las incrustaciones de los conductos, las paredes internas y así arrastrarlos con el aceite de lavado. Limpie completamente el alojamiento de chumacera, chumaceras, tanque de aceite y enfriador de aceite; además asegúrese que no hay objetos extraños dejados en el sistema de conductos. Después 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 período 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 operación de la máquina. 3.1 mantenimiento diario (1) La temperatura de chumacera La temperatura anormal de la chumacera puede descubrirse a través de la comparación de los archivos acumulado de datos diarios y por esta razón, los archivos de datos de operación diarios son importantes. La temperatura de la chumacera es medida por los métodos siguientes: (a) Use un termómetro de dial, o un termocople, o un R.T.D. u otros instrumentos adecuados. (b) El uso de un termómetro de barra. Un termómetro de barra se inserta en el agujero de la medición del alojamiento de chumacera como se muestra en Fig.2. (Este agujero normalmente está tapado, pero el tapón es movible para permitir la instalación de un termómetro de dial o el instrumento adecuado.) Al instalar instrumentos en este agujero, avísenos para tomar previsiones. (c) Con chumaceras con lubricación forzada la temperatura de la chumacera puede conocerse por la temperatura del aceite a la salida de flujo, además de los métodos (a) y (b). Sin importar el método, cuando la temperatura anormal de chumacera se descubre, la chumacera debe inspeccionarse inmediatamente. Dado que la viscosidad del aceite aumenta en invierno o e n las regiones frías, la

temperatura de la chumacera puede subir. En este caso, reemplace el lubricante con uno de buenas características a temperaturas bajas o en el caso de un lubricante de alimentación forzada, es recomendable se instale un calentador al tanque de aceite para mantenerlo a una temperatura óptima. (2) Cantidad de aceite (a) El tipo Enfriamiento natural Quite el tapón 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. Asegúrense 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 lubricación adecuada. Mientras la máquina este operando el nivel de aceite puede variar ligeramente. Por lo que no suministre aceite a la máquina mientras esté en operación.

EME300051-a 6/19 (b)

Lubricación forzada  Asegúrese de instalar las salidas de los conductos de aceite con pendiente ( de 1/30 a 1/50 ) en la dirección de regreso de aceite.  Asegúrese de lavar el interior de los conductos y los dispositivos de circulación antes de empezar el operación. No fluyan el aceite sucio en la chumacera, porque contiene objetos extraños que estaban presentes en el conducto. (Para detalles, refiérase a.. “Conductos” en el manual de operaciones de “motores de inducción de 3 fases”. Confirme que la presión de alimentación de aceite es correcta con el manómetro de alimentación 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 inducirá el goteo y el aceite en escasez causará 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 rotación a través 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 operación por largo plazo Cuando el motor es apagado durante mucho tiempo o se encuentra en pausa, asegúrese de girar el rotor mientras abastece aceite a la chumacera o una vez cada dos semanas para prevenir oxidación en la chumacera.

3.2 Mantenimiento anual (1)

Verificando la chumacera Quiten la mitad superior del alojamiento de chumacera e inspeccione el patrón de contacto en la superficie de metal de la chumacera para que exista un contacto uniforme y verifique la chumacera en busca de daños en la superficie. Así, 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 deformación y tornillos de acoplamiento sueltos.

(3)

Cambio de lubricante  Asegúrese de cambiar el aceite una vez cada 6 meses para la chumacera de enfriamiento natural, o máximo un año, dependiendo de condiciones como la temperatura ambiente, nivel de limpieza del ambiente, nivel de continuidad de operación y severidad de la operación. El nivel de deterioro del aceite puede  juzgarse convenientemente por el color oscuro, más objetivamente, por el nivel de oxidación que debe medirse. Cuando el número 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 características además de la acidez del aceite las cuales están listadas en la tabla 1; sin embargo, esto varía, 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 Número ácido total (mgKOH/g) Volumen de agua (ppm) Color (ASTM) Viscosidad cinemática (cst a 40º C) Residuo de inhibidor de corrosión oxidante (%) Vida RBOT (minuto a 150º C)

Valor de aceite nuevo No más de 0.12 0.5 Basado en el grado de viscosidad 100

Referencia de cambio 0.2 a 0.3 No menos de 100 No menos de 4.0 Variable en ±10%

310

No más de 50

No más de 20

3.3

Mantenimiento y reparación 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 micrómetro para encontrar el claro chumacera-flecha. Cuando el motor no es totalmente desmontado el claro también puede medirse más 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 presión de la flecha con un micrómetro, ese es el claro físico. En este procedimiento use un alambre cuyo diámetro sea más grande que el del claro a medir en 5/100 a 10/100 mm. Evalúe el claro por la ecuación siguiente y si el claro es más grande que el valor calculado, cambie la chumacera. C = 1.185 100

d + 0.1

(2)

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

(3)

Reparación Cuando la chumacera se encuentra en las condiciones descritas en la tabla 2, ejecute la reparación respectiva.

EME300051-a 8/19 Tabla 2 Mantenimiento del sopor te Problema, etc

Medidas Posibles Limpieza Limpie completamente las ranuras de aceite, orificios de salida, orificios de inserción de aceite y las salidas-entradas de aceite con detergente limpiador. Finalmente, seque el soporte con algodón suave y libre de pelusa o sople con aire. Contacto desnivelado con la flecha La observación cuidadosa sobre la superficie de metal blanca revela el patrón de contacto. Después de observar el patrón del metal examine que esté correcto el acoplamiento del motor y si la chumacera misma es la causante, raspe el metal del área de la superficie donde el patrón del metal está concentrado y así obtenga contacto uniforme. En este proceso, verifique el contacto aplicando óxido de plomo rojo finamente en la chumacera y cuide de no remover mucho babbitt a la vez, sólo remueva el mínimo requerido. La superficie de empuje está 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 estén 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 inspección. Si el tornillo está suelto, use un tornillo más 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 pequeños rasguños 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 mínimo requerido. Se encontró erosión electrolítica Verifique el aislamiento entre la chumacera y el alojamiento y el termómetro, para bloquear completamente la corriente de flecha. Repare las la superficie de metal babbitt cuidadosamente. El soporte ha sido deformado o dañado Reemplace el metal de la chumacera. La superficie de la chumacera está oxidada Pula la superficie con trapo usando polvo de óxido 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. Asegúrese 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. Refiérase a "mantenimiento” para el procedimiento de cambio de aceite. Tabla 3

Productor

Lubricantes Comerciales

Nombre comercial  Aceite turbo grado 2 ISOVG32 Energol THB32 Perfecto T32 DTE aceite ligero

 Aceite turbo grado 2 ISOVG46 Energol THB46 Perfecto T46 DTE aceite medio

 Aceite Nipón Mitsubishi FBK turbo 32 Shell Turbo T32 TEXACO Aceite Regal R&O 32

FBK turbo 46 Turbo T46 Aceite Regal R&O 46

BP Castrol Exxon Mobil

 Aceite turbo grado 2 ISOVG68 Energol THB68 Perfecto T68 DTE aceite pesadomedio FBK turbo 68 Turbo T68 Aceite Regal R&O 68

Nota: debido a las fusiones, etc de las compañías de aceite, algunos nombres pueden ser cambiados o reintegrados; por tanto, para mayores detalles, contacte a las compañías de aceite más importantes

EME300051-a 10/19 5. Solución 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, avísenos inmediatamente. Defecto

Causa 1.

Detalle

Insuficiente (1) aceite en la superficie de la chumacera

Daño de Chumacera

2. Lubricación pobre

3. falla en el enfriamiento de la chumacera (sistema de enfriamiento directo) 4. corriente de flecha

5.causas externas

defectuoso anillo de aceite (no gira, gira lentamente, gira demasiado) insuficiente alimentación de aceite

Presíntomas de daño de chumacera de

Posibl e solu ción Cambie si están deformadas por el desgaste o reducción de peso Cambie el aceite  Alimentación de aceite

normal

Corrija Corrija

Corrija

Rectifique marca de aceite Revise color y valor de acidez Verifique sistema de enfriamiento

Estudie ruta de contaminación (1) falla en el sistema Sistema de Revise sistema de de enfriamiento conductos o válvula enfriamiento bloqueada o falla de la bomba de lubricación (1) falla en Contaminación, agua Limpie y verifique aislamiento de en el aceite, falla en Resistencia de chumacera aislamiento de aislamiento conductos 1.vibración excesiva desalineación del Corrija alineamiento acoplamiento, eje doblado, instalación desalineada 2. empuje anormal

Calentamiento excesivo chumacera

Causa actual

Deformación del anillo de aceite, desgaste, juntas flojas, desalineación, Incorrecta viscosidad (2) de aceite Insuficiente cantidad de aceite, fuga de aceite, falla de la bomba de la circulación, conductos bloqueados, goteo, claros de chumaceras (3) defectuoso excesivos contacto de chumacera Desgaste del metal, flotación, objetos extraños en el claro de chumacera (1) incorrecta Demasiada alta o calidad de aceite baja viscosidad de aceite, degradación de aceite (2) temperatura de  Alta temperatura aceite ambiente, pobre demasiado alta enfriamiento de aceite (3) objetos extraños en aceite  Agua, sólidos (polvo, metal pulverizado)

impactos de la Verifique carga de la máquina de trabajo máquina Guarde registros de la temperatura normal de chumacera, ponga atención a aumentos ligeros de temperatura y pare la operación 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 según los tipos de motor, pero típicamente se ejecutan como se describen abajo: 6.1

Preparación para el desensamble (1) o o (2) o o

(3)

Estudie completamente la estructura de la máquina a ser desmontada Haga los preparativos para el procedimiento de desensamble Prepare las herramientas de desensamble Seleccione cuidadosamente el área para el desensamble. Evite áreas polvorientas Tenga cuidado del clima cuando desmonte las máquinas a la intemperie, si es necesario Cuidadosamente limpie el área alrededor de la chumacera, Incluso el eje y el alojamiento de chumacera.

6.2

Procedimiento de desensamble de chumacera

6.2.1

Quitando accesorios

6.2.2

(1)

Quite el termómetro de dial u otro dispositivo que mida la temperatura de chumacera.

(2)

Drene el lubricante del alojamiento de chumacera a través del puerto de dren, quitando el tapón.

(3)

Desconecte el conducto de alimentación de aceite si esta conectado.

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 quítelos. Sobre todo, para prevenir el daño 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 atención a él durante el desmontaje y reensamblaje.  Además, tenga cuidado de mantener libre esta área de contaminación por objetos extraños 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 través de los tornillos y levante verticalmente el armazón de chuamacera- mitad superior. Tenga cuidado para no dañar el metal mientras quite la chumacera y asegúrese 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)

(2)

Gire la junta del anillo de aceite y entonces quite la unión atornillada(7).

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 posición superior y quítelo. Al sacar los sellos flotantes ponga atención para evitar daño.

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 límite 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 límite de levantamiento aceptable es 0.5 mm. o Ejemplo de método 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 protección a la cadena de levantamiento para no dañar la flecha.

Como otro método, está el caso del lado de carga opuesto también se levanta como se muestra en i), o cuando el eje no está 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 atención y debe confiarse al personal experimentado.

(2)

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

(3)

Atornille los tornillos de ojo a la mitad baja de la chumacera (8), y levántela (vea Fig. 10). Tenga mucho cuidado en este procedimiento de la misma manera que en el caso de la mitad superior de la chumacera.

EME300051-a 15/19

6.2.7

Desmontaje de la mitad inferior del alojamiento de chumacera (vean Fig. 11) La mitad inferior del alojamiento de chumacera sólo se desmonta cuando el rotor está 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 atención a la ubicación del centro de gravedad.

(3)

Quite los tornillos que están 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 diámetro de la pestaña exterior del acoplamiento debe ser más pequeña que la perforación del núcleo del estator), y quite la mitad inferior del alojamiento del soporte del lado opuesto para prevenir daño al colector, etc.

(5)

Cuidadosamente baje el rotor aflojando el gato y el cable y ubique el rotor en el núcleo 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 núcleo.

EME300051-a 16/19

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 máximo 0.5 mm., poniendo atención 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 posición exacta, y sujételo al armazón del estator. Quite el cable de sostén 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 Querosén. y sópleteelo 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 deslícela a su posición debajo del eje.

(4)

Alinee la superficie de la unión de la mitad inferior de chumacera con la unión de la superficie de la mitad inferior del soporte usando una extensión.

(5)

Verificando el calibrado del centro magnético Confirme que el indicador de centro magnético (13) esté montado en la mitad inferior del alojamiento de chumacera del lado de la carga y que coincida con la línea de referencia roja sobre la flecha de motor.

EME300051-a 17/19 (6) (7)

Cuidadosamente baje el rotor y apóyelo con la mitad inferior del alojamiento de chumacera. Instale el portador de sello que fue movido en 6.2.7 y asegúrese 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 alineación. Si se ensamblan erróneamente las mitades, no encajan bien o es elíptico, provocará una impropia rotación. La conjunción 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, reensámblelos 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 así como el broche de anti-rotación está ensamblado en el alojamiento de chumacera. (3) Revise que no haya objetos extraños como herramientas o tornillos olvidados en el alojamiento del soporte. (4) Asegúrese 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 diámetro 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 girándolas. Asegúrese que el orificio de dren está hacia adentro del recipiente de aceite.

EME300051-a 18/19 (3)

Instale la mitad superior del sello flotante. Coloque el resorte alrededor del sello flotante y ciérrelo. Cuidadosamente alinee las mitades superior e inferior del sello flotante para hacer que sus superficies sean continuas. Después de ensambladas, asegúrese 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-rotación del sello está 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 termómetro de carátula, el termocople u otro dispositivo al soporte.

(3)

Con una chumacera de lubricación 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 asegúrese de aplicar una capa de sellador en las áreas periféricas según figura 13. (El área de aplicación de sellador esta achurado en la fig. 13 ) Dado que el motor ha sido sellado en todas las partes que así 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.

CHA CHA NCA NCA DOR DOR TRA TRA YLOR MANUAL DE INSTAL INSTAL ACION, OPERACION Y MANTENIMIENT MANTENIMIENTO O

MANUAL DE INSTALACION, OPERACION Y MANTENIM MA NTENIMIENTO IENTO DE 1525mm x 2870m m (60” x113 x113” ) TIPO “ NT” CHANCADOR GIRATORIO TRAYLOR VOL VOL UMEN UMEN 3 of o f 3 (ELECTRICIDAD) SOCIEDAD SOCIEDAD MINERA MINERA CERRO VERDE S.A.A.

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prefac

Contract ALL FFEM DWG. No. 08/19/2004 7.500433 0 Page 1 of 1 08/19/2004 Rev.

CHANCADOR TRAYLOR MANUAL DE INSTALACION, OPERACION Y MANTENIMIENTO INFORMACION ACERCA ESTE MANUAL

ESTE MANUAL CONSTA DE 3 VOLUMENES. CADA VOLUMEN CONTIENE ESTA DESCRIPCIÓN & UNA TABLA DE CONTENIDOS DEL VOLUMEN. EL CONTENIDO DE LOS VOLUMENES ES: VOLUMEN 1: INSTRUCCIONES DE INSTALACIÓN, OPERACIÓN & MANTENCIÓN MECANICAS & PLANOS FFEM MECANICOS VOLUMEN 2: PLANOS E INSTRUCCIONES DE SUMINISTRADORES VOLUMEN 3: EL ECTRICIDAD

 ABOUT THIS MANUAL Manual Volume

all Manual Section

Prep. by App by

SRH MDS

Date Date

preface

Contract 04-31645-720 No. FFEM DWG. No. 11/21/2005 5.401468 Rev. No. 0 Page 1 of 1 11/21/2005

 

CHANCADOR

TRAYLOR

MANUAL DE INSTAL ACION, OPERACION Y MANTENCION

TABLA DE CONTENIDOS

VOLUMEN 3 SECCION

Plano No.

TITULO

Rev

(o págin a No.) ai

Cubierta

5.401478

0

aii

Registro de Distribución y Revisión

5.401479

0

aiii

Exención de Responsabilidad

7.500267

1

aiv

Declaración de Seguridad

7.500268

1

av

 Algunos datos sobre este manual

7.500433

0

avi

 Acerca de este Manual

7.500468

0

5.401480

0

INDICE 1

TABLA DE CONTENIDOS 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

5

Sistema Hidráulico de Lubricación con Aceite del Chancador

8.500980-5

3

6

Sistema de Lubricación del Buje de la Araña del Chancador

8.500980-6

3

7

Patín de Lubricación del Sistema de Lubricación con Aceite del Chancador

8.500980-7

3

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

Pre . or 

SRH MDS

 Aprobado por

Sección

INDICE Fecha Fecha

Contrato No.

12/12/2005 12/12/2005

04-31645-720

PLANO FFEM No.

Rev.

0

5.401480 Pag. 1 de 2