After a successful first test start, the coupling between the driving and driven machine should be coupled, and the machine can be restarted.
5.7.1 Supervision during the first run
During running the machine the first time, it is verified that the machine functions as expected.
The vibration level, the temperature of the windings and bearings, and other equipment are monitored frequently. If the machine functions as expected, the machine can be left running for a longer time.
Check the operating load of the machine by comparing the load current with the value given on the rating plate of the machine.
Record the temperature readings given by the temperature detectors placed in the windings and possibly in the bearings. Check the temperatures frequently to ensure that they remain below the limits. Continuous temperature monitoring is recommended.
NOTE: If resistance temperature detector (RTD, Pt-100) or equivalent is not available, the surface temperature of the bearing area shall, if possible, be measured. The bearing temperature is approximately 10°C (20°F) higher than the surface temperature.
In case of any deviations from expected normal operation, e.g. elevated temperatures, noise or vibration, shut down the machine, and find the reason for the deviations. If necessary, consult the manufacturer of the machine.
NOTE: Do not disengage any protective devices during running of the machine, or during search for a reason for unexpected function of the machine.
5.7.2 Checks during running of the machine
During the first days of running, it is important to keep a close surveillance of the machine in case of any changes in vibration or temperature levels or abnormal sounds should occur.
5.7.3 Bearings
The rotating electrical machines manufactured by ABB are equipped with either rolling or sleeve bearings.
***Following chapter for bearing type: Rolling bearing
5.7.3.1 Machines with rolling bearings
In case of a newly installed machine or a machine, which has been out of service for more than 2 months, inject new grease into the bearings immediately after start-up. New grease must be injected when the machine is running, and is injected until old grease or excess new grease is discharged through the lubrication channel in the bottom of the bearing housing, see Figure 5-1 Example of lubrication channel through bearing arrangement of horizontal machine.
Figure 5-1 Example of lubrication channel through bearing arrangement of horizontal machine
NOTE: The re-lubrication interval will never be longer than 12 months.
The type of original grease used is found on the bearing plate on the machine. Acceptable types of grease can be found in Chapter 7.5.3 Rolling bearings.
The temperature of the bearings will initially increase because of the excess grease. After few hours, the excess grease will be discharged through the lubrication valve and the temperature of the bearing will return to normal running temperature.
If available, and after the machine has been running for several hours, measure the vibrations or SPM-values from the SPM-nipples, and record the values for future reference use.
D-END N-END
***Following chapter for bearing type: Sleeve bearing
5.7.3.2 Machines with sleeve bearings
Verify that no rotating parts rub against any stationary parts. Verify through the oil sight glass that the oil level inside bearing is correct. The correct oil level is in the middle of the oil sight glass, but as long as the oil level is within the oil sight glass, the level is acceptable.
Check the temperature and the oil level of the bearings continuously in the beginning. This is particularly important for self-lubricating bearings. If the temperature of the bearing suddenly rises, the machine should be stopped immediately, and the reason for the temperature rise must be found before the machine is re-started. If no logical reason is found from the measurement equipment, it is recommended that the bearing is opened, and its condition verified. If the machine is under warranty, the manufacturing factory must always be contacted before any action is taken.
For self-lubricating bearings, the rotation of the oil ring is verified through the inspection window on top of the bearing. If the oil ring is not rotating, the machine must be stopped immediately, as a stopped oil ring will result in bearing failure.
For flood-lubricated machines, the oil supply pressure is adjusted with the pressure valve and orifice. The normal supply pressure is 125 kPa ± 25 kPa (18 psi ± 4 psi). This gives the right flow of oil to the bearing. Using higher supply pressure gives no additional benefit, but can cause bearing oil leakages. The rate of oil flow is also specified on the dimensional drawing.
NOTE: The lubrication system should be constructed so that the pressure inside the bearing is equal to the atmospheric (outside) pressure. Air pressure entering the bearing from either inlet or outlet oil pipes will cause bearing oil leakages.
5.7.4 Vibrations
For a comprehensive discussion on vibrations, see Chapter 7.4.2 Vibration and noise.
5.7.5 Temperature levels
The temperatures of the bearings, stator windings and cooling air should be checked when the machine is running.
The winding and bearing temperature may not reach a stable temperature until after several (4-8) hours, when running at full load.
The stator winding temperature depends on the load of the machine. If full load cannot be obtained during or soon after commissioning, the present load and temperature should be noted and included in the commissioning report.
Recommended settings for alarm and trip levels see main connection diagram and Chapter 7.4.3.3 Evaluation.
***Following chapter for cooling type: Air-to-air and air-to-water 5.7.6 Heat exchangers
Prior to start, check that the connections are tight and there is no leakage in the system. After running the machine for some time, the cooling system should be checked. Verify that the cooling fluid, where applicable, and air is circulating without any obstruction.
***Following chapter for rotor type: Slip rings 5.7.7 Slip rings
Check that the brushes on the slip rings are not sparking.