Shop and Service Center – Motors

BackgroundWestinghouse’s Nuclear Component Repair Center (NCRC) in Madison, Pennsylvania (USA), provides the nuclear industry access to the most experienced quality and safety-conscious resources for pump, motor and component engineering and repair services. The NCRC has a large and well-equipped repair machine shop for working on contaminated equipment and supporting a full scope of services.An in-house engineering group, experienced machinists, repair specialists, and mechanical and electrical inspectors certified to American National Standards Institute standards support all repair/refurbishment services. Services provided meet 10CFR50 Appendix B and ISO 9001 quality standards.

DescriptionThe NCRC is a fully equipped 8,000 square-foot facility, providing a complete range of services for contaminated and safety-related motors of both Westinghouse and non-Westinghouse designs. With a 10CFR50 Appendix B program, ISO 9001 certification and the Nuclear Procurement Issues Committee approval, Westinghouse fully understands the design responsibility and service reliability required by safety-related and critical service nuclear components.

Auxiliary Motor Service Capabilities• Maintenance/repair of motors from all

manufacturers including Westinghouse, Reliance, Siemens-Allis, Allis-Chalmers, Electric Machinery and General Electric(Alliance Agreement), from fractional horsepower up to 13,000 horsepower used in both pressurized water reactor and boiling water reactor nuclear plants

• Safety-related, seismically and environmentally qualified refurbishments and rewinds

• Contaminated and non-contaminated services• Typical safety-related auxiliary motors repaired

at the NCRC include: – Safety injection (SI) – Residual heat removal (RHR) – Essential service water (ESW) – Containment spray (CS) – Containment fan (CF) – Component cooling (CC) – Auxiliary feed water (AFW)

Other motors which are serviced through the NCRC are:

– Reactor recirculating pump – Heater drain pump – Hotwell pump – Control rod drive – Emergency diesel generator (EDG) fuel oil transfer pump

– Compressor• Original equipment manufacturer (OEM) parts

and drawings• Reverse engineering using computer

measuring machine, laser scanning and X-ray fluorescence material analysis

• Stator rewinds with qualified insulation systems (Westinghouse/Reliance/Howden North America Inc.)

Nuclear Component Repair Center Auxiliary Motor Services

Dyno testing of a 2,000-hp motor

Nuclear Services / Field Services

Westinghouse Electric Company1000 Westinghouse DriveCranberry Township, PA 16066

www.westinghousenuclear.comDecember 2011 NS-FS-0058

©2015 Westinghouse Electric Company LLC. All Rights Reserved

• Vibration data acquisition and analysis using IOtech, Computational Systems, Inc., and automated diagnostics for rotating equipment

• Infrared thermography• Dynamic balancing through 44,000 pounds• Load testing through 2,815 horsepower horizontal/1,350

horsepower vertical• No-load testing through 13,800 VAC• Virtual witness of motor testing from customer’s home

or officeStandard Scope of ServiceWhen an auxiliary motor is serviced at the NCRC, the following standard work scope is performed:• Receipt Inspection

– Visual inspection – Stator electrical testing (insulation resistance, polarization index (PI), and winding resistance measurements)

– Auxiliary instrument testing – Mechanical tests (air gap, endplay, shaft-extension total indicated runouts [TIRs], etc.)

– No-load testing (upon request)• Motor disassembly• Hot water cleaning/decontamination of components • Oven drying of motor and stator• Rotor total indicated runouts• Visual and electrical inspection of stator• Bearing inspection and replacement• Main leads replacement (as required)• Stator rewind (as required)• Motor reassembly• No-load test run

BenefitsIn addition to quality of execution and state-of-the-art processes, Westinghouse provides additional value by assigning a project manager to be the single point of contact with the customer. The project manager functions as the direct interface for all technical and commercial issues for every repair project.

ExperienceWestinghouse’s extensive refurbishment expertise is also used on non-Westinghouse pumps and motors. Westinghouse has accumulated decades of motor design and qualification experience and is strategically aligned with partners that provide access to motor design and upgrade expertise of other OEMs such as General Electric, TECO/Westinghouse Motor Company, Reliance Electric and Howden North America Inc. Using human performance tools along with the ingrained practice of the Institute of Nuclear Power Operations principles for a strong nuclear safety culture in the work control processes, Westinghouse provides value added that supports life-cycle management while minimizing the risk of forced outages.

600-hp auxiliary motor

BackgroundWith the new high-power motor test system, Westinghouse has expanded full functional testing capabilities for the nuclear industry. With the addition of the following upgrades, Westinghouse is even better able to serve its customers.• Overall motor power range up to 15,000

horsepower (hp)• Live web broadcast of the test in real-time• Sound-isolated control room• In-house testing of Westinghouse and other

OEM reactor coolant pump motors

DescriptionThe high-power motor test system is capable of testing and monitoring up to a 15,000-horsepower (hp) motor at no load or a 3,000-hp motor at full load.The high-power motor test system is designed using components from the leading testing manufacturers in the industry. This state-of-the-art system offers customers a “one-stop shop” to handle a variety of testing needs, from the smallest auxiliary motors to the largest reactor coolant pump motors in the nuclear industry, such as a pressurized water reactor (PWR) reactor coolant pump (RCP) motor or a boiling water reactor (BWR) primary coolant pump motor.The test system uses Microsoft Windows®-based data collection software, which provides the customer with complete documentation in a user-friendly report format for each motor tested. The report includes detailed information, including the following:temperature data (such as bearing, stator winding, cooling water and oil temperature), power data (such as voltage, current and watts), and vibration data in any customer-required unit or format (such as acceleration, velocity, displacement and speed). The data are stored electronically for quicker test-report generation and future retrieval.

The system can provide two motor-starting methods: full-voltage and reduced-voltage (“soft-start”), depending on customer requirements. Reduced-voltage starting is a great option to reduce the risk of damage when starting a motor in an unknown, as-received condition. Additionally, voltage output through 14,100 VAC (voltage alternating current) is available for customer-specified,over-voltagetesting.

BenefitsIf requested, this system also has the capability for customers to virtually view the testing and data collectionfromtheirhomeoroffice.Westinghouse provides the nuclear industry access to experienced quality and safety-conscious resources for pump, motor and component engineering, repair and testing services. The new high-power motor test system continues that tradition by providing customers with a reliable and versatile avenue for tracking testing and data collection.

High-power Motor Test System

Main power cabinet

Nuclear Services / Field Services

Westinghouse Electric Company1000 Westinghouse DriveCranberry Township, PA 16066

www.westinghousenuclear.comDecember 2010 NS-FS-0132

©2015 Westinghouse Electric Company LLC. All Rights Reserved

Windows® is a registered trademark of the Microsoft Corporation

Customers have the option to witness motor testing and data collection in the new, state-of-the-art control room. Thecontrolroomisdesignedasafull-serviceoffice,providing the customer with a comfortable environment to view the test and data collection on multiple screens. TheofficeiswiredforInternetandphoneaccess,allowingcustomers to stay connected with day-to-day activities as well.

ExperienceWestinghouse has experience with a wide range of Westinghouse and non-Westinghouse reactor coolant pump motors.Westinghouse has successfully tested motors up to 11,000 hp. At this time, the Westinghouse test set is capable of no-load testing of motors of up to 15,000 hp using a reduced voltage (“soft start”) starting method. Westinghouse can perform load tests using a hydraulic (water brake) Dynamometer for both horizontal and vertical motors.

State-of-the-art control room

Non-Westinghouse reactor coolant pump motorsetupforfinalperformancetest

Westinghouse reactor coolant pump motorafterfinalperformancetest