Service Report

Report Date : 24 March 2023

Customer : Emitraco Investama Mandiri
Project No. : 020-23-ETO / Ex 695-22-ETO

Machine Specification : DC Motor 234kW 400V 636A 1080-2500RPM

SN : 05-041 761

PT Rotary Electrical Machine Service

Taman Tekno BSD, Blok A1 No 53-55
Tangerang, 15314
+62 (21) 75881804 / 75881805
www.rems.co.id
CUSTOMER : Emitraco Investama Mandiri
PROJECT NO : 020-23-ETO

General Service Report

SCOPE OF WORK

x. Abnormal / Fault Finding

1. Bad Surge Field Stator Windings (Following Previous Data 695-22-ETO)
2. Bad Insulation Series Stator Windings (Following Previous Data 695-22-ETO)
3. Bad Surge - Low Insulation Armature Rotor Windings and Damage Wedges
(Following Previous Data 695-22-ETO)
4. Bad Carbon Brush
5. Damage Terminal Block
6. NDE Bearing Housing is Maximum Tolerance
7. DE Journal Bearing Is Undersize
8. Wavy and Scrathed Surface of Commutator Rotor
9. Damage Oil Seal

xx. Action and Suggestion

1. Field Windings -Stator Rewindings
2. Series Windings - Stator Rewindings
3. Interpole - Reinsulation Stator Windings
4. Armature-Rotor Rewindings
5. Replace New Carbon Brush Type as Existing Qty: 20pcs
6. Replace New Terminal Block Type as Existing
7. Replace New Bearing DE-NDE Side are 6320 C3 -1pcs and 6218 C3 -1pcs
8. Skimming,Undercuting and Bevelling of Commutator Rotor
9. Rebushing NDE Bearing Housing
10. Repair DE Journal Bearing
11. Replace New Oil Seal Type: SC 110,130,12 Qty: 1pcs
12. Dynamic Balancing Rotor

xxx. Action has Been Taken

1. Mechanical Inspection
2. Taking Data-Stripping Stator-Rotor Windings
3. Cleaning Core Stator-Rotor
4. Start Rewind Stator-Rotor
5. In Process After Rewind Stator-Rotor
6. Varnish - Oven Stator Windings
7. Banding,Varnish - Oven Rotor Windings
8. In Process After VArnish Stator-Rotor
9. Rebushing NDE Bearing Housing
10. Repair DE Journal Bearing
11. Skimming,Undercuting and Bevelling of Commutator Rotor
12. Dynamic Balancing Rotor
13. Replace New Bearing DE-NDE Side are 6320 C3 -1pcs and 6218 C3 -1pcs
14. Replace New Oil Seal Type: SC 110,130,12 Qty: 1pcs
15. Replace New Carbon Brush Type as Existing Qty: 20pcs
16. Replace New Terminal Block Type as Existing
17. Motor Reassembly
18. Test Run No Load
19. Motor Painting
 REMS/Form/201-10
Revision : 1
ELECTRICAL INITIAL INSPECTION REPORT
MACHINE NAME PLATE

Project No. 020-23-ETO Customer Emitraco Investama Mandiri

Inspector Verification
QC Electrical / Field Engineer Supervisor
Inspection date Name / Signature Approval date Signature
26-Jan-23 Andri.S 26-Jan-23 R. Pradana
Machine Name Plate
Machine Type DC Motor
Manufactured by LDW
Serial Number 05-041 761
Type / Model GC 28.12-M2
Catalog No. -
-
kW 234
Voltage Primary 400
Ampere Primary 636
Voltage Secondary 260 / 74
Ampere Secondary 14.2 / 4
Phase -
RPM 1080 / 2500
Frequency -
Power Factor (Cos Q) -
Poles Number -
Insulation Class H
Stator Frame -
Bearing Drive End -
Bearing Non Drive End -
Temperature Rise -
Ambient Temperature 40O
Design -
Rating Service / Duty S1
Service Factor -
Code -
International Standard Use -
IP (International Protection) 23
IC (International Cooling) 06
IM (International Mounting) -
-
Tacho Gen.Voltage & RPM -
Tacho Gen. type & sn. -
Space heater -
Machine Weight 1.51
Machine Application / Use -

Remarks / Notes
 Rems/Form/201-13
Revision : 0
ELECTRICAL INITIAL INSPECTION REPORT
DC MOTOR / GENERATOR

Project No. Customer

020-23-ETO Emitraco Investama Mandiri

Inspector Verification
QC Electrical / Field Engineer Supervisor
Inspection date Name / Signature Approval date Signature
17-Aug-22 Andri.S 17-Aug-22 R. Pradana
DC Motor / Generator Data
Manufactured by kW / HP Voltage Ampere Ext.Voltage Ext.Ampere RPM
LDW 234 400 636 260 / 74 14.2 / 4 1080 / 2500
Serial Number Type / Model Room temp Humidity
o
05-041 761 GC 28.12-M2 32 C 56 %
Electrical Measurement Records
Stator Windings Low Resistance ( Ohm - milliOhm )
Test Point Total Resist. Connection Pole No.1 Pole No.2 Pole No.3 Pole No.4 Pole No.5 Pole No.6
Field 9.79 Paralel 2.5 2.6 2.5 2.4
Interpole + 12.8 mΩ Seri-Paralel 4.04 mΩ 4.06 mΩ 4.08 mΩ 4.07 mΩ
Series 7.26 mΩ 7.25 mΩ 7.41 mΩ 7.81 mΩ
Insulation Resistance / Mega Ohm
Test Point Test Voltage Total Insul.R Pole No.1 Pole No.2 Pole No.3 Pole No.4 Pole No.5 Pole No.6

Field -E 500 V 8.72 - - - - - -

Interpole-E 500 V 2.92 43.5 27.9 20.8 36.5 - -
Series-E 500 V 2.92 >100 67.1 >100 28.2 - -
Fld-Series 500 V 7.27 - - - - - -
Armature-E 500 V 4.7

Brush hld.- E 500 V 36.2

Armature Windings Test
Test Method, please cross 1.Voltage Drop T / 2.Baker Surge Bar-bar T / 3. DLRO Low Resistance T
Method 1 Test Voltage V Test amps A Test Results GOOD / BAD WINDINGS
Method 2 Peak Voltage V Test Results GOOD / BAD WINDINGS
Method 3 Resistance b-b 1.38 m Ohm Test Results GOOD / BAD WINDINGS
Voltage Drop Test Stator Windings P1 P2 P3 P4 P5 P6 P7 P8
Shunt Winding Voltage test 16 VAC VD per pole 2.47 V 2.48 V 2.36 V 2.39 V V V V V
Interpole Winding Voltage test 34 VAC VD per pole 1.79 V 1.80 V 1.80 V 1.80 V V V V V

Shunt Winding Voltage test 60 VDC VD per pole 0.41 V 0.41 V 0.41 V 0.41 V V V V V

Interpole Winding Voltage test 62 VDC VD per pole 0.24 V 0.24 V 0.24 V 0.24 V V V V V
Protection Device & Asseccories / Ohm
Windings PT100 / Thermistor Bearing PT 100 Heaters
Pole No. 1 Pole No. 2 Pole No.3 Pole No.4 NDE DE H1 H2 H3
184.6 - - - - - 246.3 - -
Test Results & Electrical Parts Visual Inspection (please cross)
Shorted to Ground of FIELD / INTERPOLE / ROTOR Windings Burnt-out Coil / Overload / Overheat
Shorted circuit FIELD / INTERPOLE / ROTOR Windings Burnt-out Cable Lead / Terminals
Open Circuit of FIELD / INTERPOLE / ROTOR Windings Worn out CARBON BRUSHES/COMMUTATOR
Shorted to Ground COMMUTATOR √ Bad Rotor Banding Tape
Shorted circuit bar-bar COMMUTATOR Bad Space Heaters / Thermistor
Flash over COMMUTATOR / BRUSH HOLDER / CARBON B √ Missing Electrical Parts
Scratched Core / Damaged Core & Laminations √ Others .....................................................
Inspection Comments & Electrical Parts Need to be Ordered / Replaced

1. Field and Series -Stator Rewindings

2. Interpole Insulation Resistance Low - Reinsulation Stator Windings
3. Armature-Rotor Insulation Resistance Low and Damage Wedges - Recommended to Rewindings
4. Damage Terminal Block
5. Bad Carbon Brush
(Following Previous Data 695-22-ETO)
 REMS/Form/202-11
MECHANICAL INSPECTION REPORT Revision : 1

ROLLING BEARING HOUSING

Machine data
Project no. Customer
kW / HP Serial number
020-23-ETO Emitraco Investama Mandiri 234 05-041 761

INITIAL AFTER REPAIR

Inspected Date Inspected By Repaired Date Repaired By
25-Jan-23 Kahfi 06-Mar-23 Satimin
Verified Date Verified By Verified Date Verified By

25-Jan-23 R. Pradana 06-Mar-23 R. Pradana

Bearing Housing / Endshield Data DE NDE

Bearing Type (Ball / Roller) Deep Groove Ball Deep Groove Ball

Bearing Part Number 6320 C3 6218 C3

Bearing Housing Bore Diameter (mm) Ø 215 Ø 160

Housing Fits Tolerance Standard Class H6 H6

Bearing Housing Specified Value (1/1000 mm) 0 +29 0 +25

International Standard Reference ABMA Std. 7 ABMA Std. 7

MEASUREMENT POINTS

DRIVE END (DE)

Measurement Point INITIAL AFTER REPAIR Inspection Notes
Ref: ABMA stds.7:1995, Bearing Housing Fits
Dia A-A 1 Ø 215 + 0.010 Ø
(mm) 2 Ø 215 + 0.010 Ø

Dia B-B 1 Ø 215 + 0.015 Ø Good Condition

(mm) 2 Ø 215 + 0.015 Ø

Ovality

NON DRIVE END (NDE)

Measurement Point INITIAL AFTER REPAIR Inspection Notes
Ø Ø Ref: ABMA stds.7:1995, Bearing Housing Fits
Dia A-A 1 160 + 0.020 160 + 0.005
(mm) 2 Ø 160 + 0.030 Ø 160 + 0.005 Before : Ovality & Max Tolerance, Need to
1 Ø 160 + 0.010 Ø 160 + 0.005 Rebushing
Dia B-B
(mm) 2 Ø 160 + 0.030 Ø 160 + 0.010 After : Good Condition

Ovality
 REMS/Form/202-12
MECHANICAL INSPECTION REPORT Revision : 1

ROLLING BEARING JOURNAL SHAFT

Project no. Customer kW / HP Serial number
020-23-ETO Emitraco Investama Mandiri 234 05-041 761

INITIAL AFTER REPAIR

Inspected Date Inspected By Repaired Date Repaired By
25-Jan-23 Kahfi 18-Feb-23 Satimin
Verified Date Verified By Verified Date Verified By
25-Jan-23 R. Pradana 18-Feb-23 R. Pradana
Bearing Journal Shaft Data DE NDE
Bearing Type (Ball / Roller) Deep Groove Ball Deep Groove Ball
Bearing Part Number 6320 C3 6218 C3
Bearing Journal Shaft Diameter (mm) Ø 100 Ø 90
Journal Shaft Fits Tolerance Standard Class k5 k5
Bearing Journal Shaft Specified Value (1/1000 mm) +18 +3 +18 +3
International Standard Reference ABMA Std.7 ABMA Std.7
MEASUREMENT POINTS

DE Bearing Journal INITIAL AFTER REPAIR Inspection Notes

Dia A-A 1 Ø 100 - 0.010 Ø 100 + 0.010 Ref: ABMA stds.7:1995, Bearing Journal Shaft Fits
(mm) 2 Ø 100 - 0.010 Ø 100 + 0.020
Dia B-B 1 Ø 100 0.000 Ø 100 + 0.020 Before : Undersize, Need To Repair
(mm) 2 Ø 100 - 0.010 Ø 100 + 0.015 After : Good Condition
Ovality
NDE Bearing Journal INITIAL AFTER REPAIR Inspection Notes
Dia A-A 3 Ø 90 + 0.010 Ø Ref: ABMA stds.7:1995, Bearing Journal Shaft Fits
(mm) 4 Ø 90 + 0.010 Ø
Dia B-B 3 Ø 90 + 0.005 Ø Good Condition
(mm) 4 Ø 90 + 0.010 Ø
Ovality
COUPLING SEAT INITIAL AFTER REPAIR Inspection Notes
Dia A-A 5 Ø 95 + 0.020 Ø Ref: IEC stds.60072-1,C.1.4 Shaft Extens. dia. Tol.
(mm) 6 Ø 95 + 0.020 Ø
Dia B-B 5 Ø 95 + 0.015 Ø Good Condition
(mm) 6 Ø 95 + 0.010 Ø
Ovality
COUPLING INNER BORE INITIAL AFTER REPAIR Inspection Notes
Dia A-A 5-a Ø Ø Identifikasi letak coupling dari ujung shaft :
(mm) 6-a Ø Ø = - mm
Dia B-B 5-b Ø Ø (+ jika letak coupling keluar dari ujung shaft)
(mm) 6-b Ø Ø ( - jika letak coupling kedalam dari ujung shft)
Ovality
FAN SEAT INITIAL AFTER REPAIR Inspection Notes
Dia A-A 7 Ø Ø Ref: IEC stds.60072-1,C.1.4 Shaft Extens. dia. Tol.
(mm) 8 Ø Ø
Dia B-B 7 Ø Ø
(mm) 8 Ø Ø
Ovality
FAN INNER BORE INITIAL AFTER REPAIR Inspection Notes
Dia A-A 7-a Ø Ø Cooling fan material:
(mm) 8-a Ø Ø
Dia B-B 7-b Ø Ø
(mm) 8-b Ø Ø
Ovality
 Rems/Form/202-16
MECHANICAL INSPECTION REPORT Revision : 0

COMMUTATOR MEASUREMENT
Project No. Customer
020-23-ETO Emitraco Investama Mandiri

Inspector Verification
Receiving Finishing
QC Mechanic QC Mechanic
Inspection date Signature Inspection date Signature
25-Jan-23 Kinan 15-Mar-23 Satimin

Workshop Supervisor Workshop Supervisor

Approval date Signature Approval date Signature
25-Jan-23 R. Pradana 15-Mar-23 R. Pradana

Inspection Measurements
5
4 3 2
6 1
B

A A Ø

M
C B
R
L
Measurement unit : mm
DIA. ØA-A Ø B- B RUN OUT VISUAL Acceptance Criteria @/ Standard

1 192.800 192.750 G
1. ≤ 0.5mm (Ø A-A & ØB-B)
RECEIVING

2 208.600 208.630 W/S

3 208.660 208.690 W/S

2. ≤ 0.075mm (Run Out)
4 208.700 208.740 W/S

5 285.500 285.500 G 3. VISUAL :

1 192.800 192.750 G - G = Good Condition.
FINISHING

2 208.350 208.350 G - W = Wavy Surface.

3 208.340 208.340 G - S = Scratched Surface.
4 204.340 208.340 G
5 285.500 285.500 G
LENGTH Acceptance Criteria @/ Standard

L R C M
Receiving - 20 209.5 9.5 ± 0.5mm
Finishing - 20 209.5 9.5

Notes : Before: Scratched Surface, Need to Skimming, Undercutting and Beveling,

After : Good Condition
 REMS/Form/202-23
MECHANICAL INITIAL INSPECTION REPORT Revision : 1

TOTAL INDICATED RUNOUT (TIR)

PROJECT NO CUSTOMER INSPECTION BY DATE
020-23-ETO Emitraco Investama Mandiri Arik 16-Mar-23
MACHINE DATA KW/HP VOLTS AMP RPM ROTOR SERIAL NO. / ID VERIFY BY DATE
DC Motor 234 400 636 1080 / 2500 05-041 761 R. Pradana 16-Mar-23

TITIK PERIKSA / UKUR

SUDUT
1 2 3 4 5 6 7 8 9 10 11 12 13
0° 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

90° 0.050 0.030 0.000 0.000 0.000 0.020 N/A N/A 0.010 0.000 0.000 N/A N/A

180° 0.030 0.050 0.010 0.000 0.000 0.010 N/A N/A 0.010 0.000 0.000 N/A N/A

270° 0.050 0.040 0.000 0.000 0.000 0.010 N/A N/A 0.010 0.000 0.000 N/A N/A

TIR 0.050 0.050 0.010 0.000 0.000 0.020 0.000 0.000 0.010 0.000 0.000 0.000 0.000
Shaft Extension
100.00 90.00
Diameter (mm)
Permissible shaft
0.070 0.070
extension runout

Notes
Permisible shaft extension runout:
1. Standard reference : IEC Stds. 60072-1, C.1.6
2. Standard reference : NEMA Stds. MG 1, 4.9.7

Rotor Run Out - In Tolerance

 MECHANICAL BALANCING REPORT
ROTOR

Project No. 020-23-ETO Customer Emitraco Investama Mandiri

Inspector Verification
Balancing Operator Supervisor
Inspection date Name / Signature Approval date Signature
16-Mar-23 Arik 16-Mar-23 R. Pradana

Balancing Result

Dynamic Balancing Rotor - In Tolerance

 MECHANICAL BALANCING REPORT
ROTOR

Project No. 020-23-ETO Customer Emitraco Investama Mandiri

Inspector Verification
Balancing Operator Supervisor
Inspection date Name / Signature Approval date Signature
16-Mar-23 Arik 16-Mar-23 R. Pradana

Balancing Result

Dynamic Balancing Rotor - In Tolerance

 Rems/Form/201-32
Revision :
ELECTRICAL FINAL TEST REPORT
DC MOTOR / GENERATOR
Project No. Customer Room temp Humidity

020-23-ETO Emitraco Investama Mandiri 31o C 58 %

Inspector Verification
QC Electrical Workshop Supervisor/Field Eng
Test date Name / Signature Approval date Signature

21-Mar-23 Rizal 21-Mar-23 R. Pradana

DC Motor / Generator Data
Manufactured by kW / HP Voltage Ampere Ext.Voltage Ext.Ampere RPM Description
LDW 234 400 636 260 / 74 14.2 / 4 1080 / 2500
Serial Number Type / Model -

05-041 761 GC 28.12-M2 -

Electrical Measurement Records
Stator Windings Res/ Ω - milliΩ Ins Res/ Giga Ohm HI-POT Test Polarization Index Test
Test Point Total Resist Connection Test Volt to E Total Ins.R Test Voltage Leakage Currents PI Volt R1 " R10" PI reading

Field 13.45 Ω Seri 500 V 1.576 kV micro A 500 1576 GΩ 2.90 GΩ 1.84
Interpole 233.2 mΩ Pararel 500 V 665 MΩ V micro A 500 665 MΩ 1.405 GΩ 2.11
Series V V micro A

Field series V V micro A

Armature 500 V 665 MΩ V micro A 500 665 MΩ 1.405 GΩ 2.11

Armature Windings Test
Test Method, please cross 1.Voltage Drop T / 2.Baker Surge Bar-bar T / 3.DLRO Low Resistance T
Method 1 Test Voltage V Test amps A Test Results GOOD / BAD WINDINGS
Method 2 Peak Voltage V Test Results GOOD / BAD WINDINGS
Method 3 Resistance b-b 1.36 mili Ohm (see Form 201-21) Test Results GOOD / BAD WINDINGS
Protection Device & Asseccories / Ohm Bearing Lubricant type
Windings PT100 / Thermistor Bimetal Bearing PT 100 Heaters
Pole No. 1 Pole No. 2 Pole No.3 Pole No.4 NDE DE H1 H2 H3 Grease
- 247
Electrical Test Run Records
Bearing temp Vibration (mm/s)-RMS
Exciter Exciter Armt Armt Motor
Time RPM DE NDE Remarks
Volts Amp Volt Amps temp DE NDE
Ver Hor Axi Ver Hor Axi
5 205 13.4 176 6.6 540 31 40 40 0.47 0.54 0.84 0.57 0.30 0.63 Direction :
10 205 13.3 335 10 1018 32 41 40 0.47 0.54 0.84 0.57 0.30 0.63 - Clockwise /
15 136 8.7 400 10.5 1507 32 42 40 0.47 0.54 0.84 0.57 0.30 0.63 - Counter clockwise
20 92 6.1 403 11.7 2016 35 44 42 0.47 0.54 0.84 0.57 0.30 0.63 From DE

25 76 4.9 402 12.5 2478 35 44 42 0.47 0.54 0.84 0.57 0.30 0.63

TEST RESULT & NOTES

Machine test result : Fail Description (please fill-up if the machine test result fail)
√ Good Vibration too high Rotating parts looses (fan , pulley)
Fail Rotor unbalance Rotating parts scratched
To be retested Bearing Noisy Electrical Failure
√ OK Tested Mechanical Noisy Others .....................................................
………………..
 ELECTRICAL SURGE TEST REPORT

Project No. 020-23-ETO Customer Emitraco Investama Mandiri

Inspector Verification
QC Electrical / Field Engineer Supervisor
Inspection date Name / Signature Approval date Signature
21-Mar-23 Rizal 21-Mar-23 R. Pradana

Result

Final Surge Field - Stator Coils are Good Windings

 ELECTRICAL SURGE TEST REPORT

Project No. 020-23-ETO Customer Emitraco Investama Mandiri

Inspector Verification
QC Electrical / Field Engineer Supervisor
Inspection date Name / Signature Approval date Signature
21-Mar-23 Rizal 21-Mar-23 R. Pradana

Result

Final Surge Interpole - Stator Coils are Good Windings

 BAR TO BAR ROTOR TEST REPORT

Project No. Customer KW/HP Volts Amps

020-23-ETO Emitraco Investama Mandiri 234 400 636
Quality Control Verification
QC Electrical / Tester / Field Engineer Test Results
Signature Date
√ Good Coils
Andi. S 15-Mar-23
Open Circuit
Supervisor
Shorted Circuit
Signature Date Others (please explain in test notes)
R. Pradana 15-Mar-23
Test Notes :
Room Temperature Humidity Final Bar to Bar
o
30 C 72 % IR = 1.33 GΩ (500V)
 TITLE : 020-23-ETO
MACHINE INFO : DC Motor 234kW 400V 636A 1080-2500RPM
CUSTOMER : Emitraco Investama Mandiri

Arrival Unit Motor Frame Stator Condition

Rotor Condition DE-NDE Endshield Condition

DE-NDE Journal Condition Core Field Condition

 TITLE : 020-23-ETO
MACHINE INFO : DC Motor 234kW 400V 636A 1080-2500RPM
CUSTOMER : Emitraco Investama Mandiri

Taking Data Armature Rotor Return Taking Data Armature Rotor

Red Oxide Frame Stator & Core Field Cleaning Core Rotor

Cleaning Raiser Commutator Rewindings Field Process

 TITLE : 020-23-ETO
MACHINE INFO : DC Motor 234kW 400V 636A 1080-2500RPM
CUSTOMER : Emitraco Investama Mandiri

Install Field Winding to Frame Stator Reinsulation Coil Interpole

Install Interpole Winding to Frame Stator Rewindings Coil Series Process

Connection Process In Process Before Varnish Stator Windings

 TITLE : 020-23-ETO
MACHINE INFO : DC Motor 234kW 400V 636A 1080-2500RPM
CUSTOMER : Emitraco Investama Mandiri

Red Oxide Core Rotor Arivall New Coils Armature

Install Equalizer Rotor Start Rewind Rotor

Return Rewind Rotor Finish Rewind Rotor

 TITLE : 020-23-ETO
MACHINE INFO : DC Motor 234kW 400V 636A 1080-2500RPM
CUSTOMER : Emitraco Investama Mandiri

Tighwelding Commutator Rotor Varnish Stator - Rotor

Banding Rotor Process Oven Stator - Rotor

Skimming - Bevelling Commutator Process Make Ring Rebushing

 TITLE : 020-23-ETO
MACHINE INFO : DC Motor 234kW 400V 636A 1080-2500RPM
CUSTOMER : Emitraco Investama Mandiri

Dynamic Balancing Rotor Motor Reassembly - Install New Bearing

Install New Carbon Brush Install New Terminal Block

Test Run No Load - Voltage & Ampere Exciter Test Run No Load - Voltage & Ampere Armature
 TITLE : 020-23-ETO
MACHINE INFO : DC Motor 234kW 400V 636A 1080-2500RPM
CUSTOMER : Emitraco Investama Mandiri

Test Run No Load - RPM Check Test Run No Load - DE & NDE Axial Point

Test Run No Load - DE & NDE Vertical Point Test Run No Load - DE & NDE Horizontal Point

Test Run No Load - Temperature Check