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EXECUTIVE SUMMARY
Over the years, KRPC plants electric motors have
always been contracted to the third party for
rewinding of burnt stator coils. For the purpose of
effective and timely delivery of repaired motors,
reliability and conformity to standards as well as
saving cost for the corporation, KRPC management
engaged a committee to follow up the fact finding
report from WRPC rewinding workshop and come up
with modalities for establishing such in KRPC.
KRPC Rewinding Workshop Establishment Committee
Members participated in series of meetings with the
objective of doing justice to the committees terms of
reference. The meetings focused on a review of the
overall electric motor rewinding process, ways of
setting up a cost effective and efficient rewinding
workshop, location of coil winding workshop, required
resources and other recommendations based on
safety.
Purpose of the Report:
To keep KRPC management informed of the located
1
1.0
BACKGROUND
COMMITTEE MEMBERS
1. Daniel Senchi
(Chairman)
(13906)
MTCE.
2. Akinbode, O. F.
(90372)
MTCE.
3. Adebayo Amos
(13234)
MTCE.
4. Nasir Mahammed
(74073)
MTCE.
5. Frank O. Itua
(17332)
ETSD
(18995)
MTCE.
3.0
TERMS OF REFERENCE
REQUIRED RESOURCES
AVAILABLE RESOURCES
LOCATION OF WORKSPACE
Safety considerations.
Available space for standard rewinding workshop within KRPC
Cost of setting up the new structure/location of possible power
supply point.
Presence of an existing Over-head crane.
Presence of an existing Air, Steam and Water lines
Access for transportation.
Presence of existing office apartment.
Etc.
With these considerations one side of LAB Fabrication shop spaced
14.5m x 9.7m was considered suitable by the committee.
A section (14.5 m x 9.7 m) of the existing L.A.B. Fabrication
Workshop is thus recommended as highlighted on page 5.
7.1
Easy accessibility
7
8.0 RECOMMENDED
SPECIFICATIONS
EQUIPMENT/MACHINES
AND
THEIR
Manual
Motor Coil
Winding
Machine.
2.
Multipurpose
Heavy Duty
Motor Coil
Winding
Machine.
3.
SAMATIC
2780
Automatic
Random Coil
Winding
Machine.
MANUFACTU
RER
QTY
REFEREN
CE
B.M.P.
EQUIPMENT,
MUMBAI.
See
Appendix I
B.M.P.
EQUIPMENT,
MUMBAI.
See
Appendix II
JENLORS
SAMATIC
WINDING
MACHINES.
See
Appendix III
4.
Stator Lifting
Table SLT1400-TT
5.
Heavy-Duty
Bench-Type
Undercutter
Model H-9
6.
ABT Brazing
machine and
tongs.
WHITELEGG
MACHINES.
See
Appendix
XV
MARTINDALE
See
Appendix
XX
WHITELEGG
MACHINES.
See
Appendix V
8.
SAS-280
Semiautomatic
Soldering
Machine
100 Ton
Hydraulic
Grip Pullers
Power: AC 220V 50 / 60
HZ
AIR SUPPLY 4kg/cm2
Dimension of Soldering
Pot
100(W)*200(L)*50(T)mm
Power Consumption
1600W.
Soldering Temperature:
600max
Weight: 100kg
DIMENSION:
700(W)*700(L)*870(H)m
m
Function:
1.soldering pot made by
Titanium, meet lead-free
procedure/standard.
2.Fixture for multi
Bobbins, adjustable
angle from 0~360
EPH-Series, Posi Lock
with thee jaws; Model
number: EPH-1003E
(Metric); capacity of
pulling up to 100 tons.
Roller cart with
power lift
Adjustable jaw
tips
Puller easily
detaches from
cart
Self-contained
unit
SHINING SUN
ENTERPRISE
CO.,LTD.
See
Appendix VI
ENERPAC
See
Appendix VII
Locally sourced
1 set
WHITELEGG
MACHINES
See picture
on page 14
&
attachment
s
Appendix
XVIII and
picture on
page 15
9.
Oxyacetylene
Gas Welding
Machine
10.
Heavy Duty
Motor Curing
Oven
Puller height
range 26.5" 66.5"
50Kg Oxy-acetylene
Cylinders 1 set of
cylinders and welding
kits
Model: COV -15
Whitelegg oven.
Internal Dimensions:
200x200x200cm.
External Dimensions:
308x249x236cm.
Power rating: 32KW.
Power supply: 240V/50-
10
11.
SKF
induction
Bearing
Heater (TIH
220m)
12.
Arbors
13.
Work
Benches
60Hz.
Model: TIH 220m; Power
Supply: 220V/50-60Hz;
Sliding arm for large
yoke; Bearing diameter:
from 60mm to a max.
weight of 300kg
Winding Arbors;
Types:
Aluminium type sets, AJ1A set, AJ-2 Aluminium
types, H-type Rubber
type, Diamond Type,
Concentric H UN6/15/2
Dimesions: 3000mm(L)
by 1200mm(W) by
700mm(H),
Top seasoned wood
75mm thickness and
Rubber mat.
SKF
See
Appendix
VIII
WHITELEGG
MACHINES
or
B.M.P.
EQUIPMENT,
MUMBAI.
2
each
See
Appendix XII
To be
constructed inhouse.
See
Diagram
attached on
page 59
EQUIPMENT
DESCRIPTIO
N
Megger
Insulation
Resistance
Tester
(model:
MIT1525)
2.
Fluke
190
Series
Scopemeter
3.
VIBROTIP
Machine
condition
trending
data
collector
4.
MASTECH.
Digital Clamp
Meter
SPECIFICATION
MANUFACTURE
R
QTY
REFERENC
E
MEGGER
See
Appendix X
and picture
on page 14
FLUKE
INDUSTRIAL B.V.,
NETHERLANDS.
PRUFTECHNIK
See
Appendix
XIX
and
picture
on
page 14
See
Appendix
XI-a/b
MASTECH
11
See
Appendix IX
5.
6.
7.
Motor Engine
Mounting
Testing Stand
s Plate With T
Slots
(Test
Bay).
Motatest
Multifunction
tester for
electric
motors
Electric
motor Test
Panel or
Bench
12
ZHGONGBO
HEAVY
INDUSTRY
See picture
on page 16
and
attachment
s
WHITELEGG
MACHINES
See
Appendix IV
See
attachment
for
prototype
from WRPC.
(Recommen
ded
for
KRPC)
&
Available
type from
KAY PEE
CORPORATI
ON (Not
match our
requirement
). See
attachment
on pages
57 & 58
Stator
Holding Rings
Type D
9.0
Electrical Turntable,
reinforced construction;
Power Supply:
415V/50Hz. 4 Clamping
brackets with two fixing
screws (3 pieces). A set
of clamping sheers (3
pieces). Support tables
for tooling. Standard
machine colour:
blue/yellow. Size: D1800. Max. clamping
weight: 5000Kg.
DUDEK
fertigungssystem
e.
See
Appendix
XIII
The table that follows captures the recommended hand tool required
when carrying an electric motor rewinding tasks.
S/No
.
Tools Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
390.16VSE End
nippers (Cutting pliers
for copper wire)
391.16VSE Diagonal
cutters (Cutting pliers
for copper wire)
190.16VSE End
nippers (Cutting pliers
for hard wire)
CM.E18 Metric set of
95 tools
CU.110A Inch set of 86
tools with 12-point
sockets and engineers
hammer
162 Automatic Cutting
Stripper
162.2 Dual stripper
Specification
Manufacturer/M
odel
Quantit
y
FACOM/CM.110A
FACOM/701A
FACOM/390.16VS
E
FACOM/391.16VS
E
FACOM/190.16VS
E
FACOM/CM.E18
FACOM/CU.110A
FACOM/162
FACOM/162.2
FACOM/841.4
13
6.
FACOM 841.9
FACOM/840.4A
FACOM/STU
WESTPORT
CORPORATION
WESTPORT
CORPORATION
DUDEK
Fertigung
ssysteme
Tool Description
Quantity
1.
2.
3.
4.
Electricians Knife
2
14
5.
Wedge Drivers
6.
7.
8.
9.
15
16
17
18
MATERIAL DESCRIPTION
SIZE
QUANTITY
Copper
Copper
Copper
Copper
Copper
Copper
0.25mm
0.30mm
0.35mm
0.40mm
0.45mm
0.50mm
50Kg
50Kg
50Kg
50Kg
50Kg
100Kg
Winding
Winding
Winding
Winding
Winding
Winding
Wire
Wire
Wire
Wire
Wire
Wire
19
F)
F)
F)
Bake
0.55mm
0.60mm
0.65mm
0.70mm
0.75mm
0.80mm
0.85mm
0.90mm
0.95mm
1.00mm
1.05mm
1.10mm
1.12mm
1.20mm
1.25mm
1.30mm
1.35mm
1.40mm
1.45mm
1.5omm
1.55mm
1.60mm
1.65mm
1.70mm
0.20mm
0.30mm
0.40mm
1mm
2mm
3mm
4mm
5mm
6mm
8mm
10mm
12mm
15mm
20mm
100Kg
100Kg
100Kg
50Kg
100Kg
100Kg
100Kg
100Kg
100Kg
100Kg
100Kg
100Kg
100Kg
100Kg
100Kg
100Kg
100Kg
100Kg
100Kg
100Kg
100Kg
100Kg
100Kg
50Kg
200m
200m
200m
100m
100m
100m
100m
100m
100m
100m
100m
100m
100m
100m
50Ltr
300m
20
Polyester tape
SKF Bearings of all sizes and
types
Oxyacetylene gas
11.0 REWINDING
REQUIRED
WORKSHOP
50Kg
MANPOWER
AND
SKILL
With reference to WRPC fact finding report and absence of staff during
annual, compassionate or sick leave, the following are the
recommended personnel required;
1. One (1 No.) Superintendent
electrical workshop.
Existing
superintendent
of
21
ID NO.
DANIEL SENCHI
(chairman)
13906
AKINBODE O. F.
90372
ADEBAYO AMOS
13234
NASIR MAHAMMAD
74073
FRANK ITUA
17332
OKEY WILLIAMS
(Reporting)
18995
24
SIGN.
APPENDICES
Appendix I -
Appendix II -
Appendix III-
Machine
Appendix IV
Motatest
Multifunction
Tester
for
Electric
Motors
Appendix V -
Appendix VI
Appendix VII
Appendix VIII
Appendix IX
Appendix X -
Appendix XIII
Appendix XIV-(a-l) -
(12 pages)
25
Appendix XVI
Fowler
Digital
Fowler
standard
Appendix XVIII
Appendix XIX
Appendix XX
Micrometers
(0-100mm)
Premium Ratchet
Appendix XVII
Micrometers
(0-100mm)
metric-sets
by Martindale
APPENDIX I
26
APPENDIX II
27
APPENDIX III
28
APPENDIX IV
29
30
31
APPENDIX VI
32
APPENDIX VII
33
APPENDIX VIII
34
APPENDIX IX
35
APPENDIX X
36
37
38
39
40
41
42
43
44
45
46
47
48
49
APPENDIX XIV-i
50
APPENDIX XIV-J
51
APPENDIX XIV-K
52
APPENDIX XIV-L
53
APPENDIX XV
54
APPENDIX XVI
55
APPENDIX XVII
56
57
58
59
60
61