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THE WAY OUT OF A COSTLY REWIND

If the machine does not quickly react to Process 1, it can be assumed that there is an internal problem, which needs Process 2 to root out the deep-seated trouble. Process 2 means taking the machine to the factory, but even so it takes less time and costs less money than conventional services and gives you a completely revitalized machine.

When the machine arrives we carry out a thorough examination and dielectric assessment to trace the problem. The motor is then steam cleaned to remove surface contamination, like salts or loose varnish and paint. 

The cross section show shows how dirty the surface can become on a motor in general use.

Following the examination and steam cleaning, the machine is moved to the specially designed Ayrodev oven for drying and stabilization of the insulation system.

While the motor is in the oven we are able to monitor the air temperature, the conductor temperature, I.R, Tan Delta, and capacitance, which when drawn out are represented in the graphs.

   It will be noticed that stabilization point is reached and the readings are monitored to contain three consecutive readings at temperature. It also indicates that the winding has been completely dried out and the latent potential in the machine has been fully utilized.

Stabilizing Bake

The capacity and Tan delta are high initially and the insulation value low due to the presence of water from steam cleaning. As the job warns up there is a drop in the values, indicating water removal.

The Peak in capacity indicates post-curing of the original varnish. All values stabilize indicating complete cure and dryness.

Varnish Bake

These curves are much flatter confirming that the stabilizing bake was effective, but there is a typical peak reversal indicating good curing of the varnish and again complete stability is achieved.

The Machine is removed to be flood dipped. Wherever possible the machine is lowered into the dip in the vertical position so that the varnish penetrates the winding. After primary drainage the motor is returned to the oven. It is now that the Ayrodev oven comes into its own. You can see the difference between the Ayrodev technique and the conventional oven. As the heat seal moves down the winding, the varnish flashes off the solvent, leaving a solid coat of insulation varnish throughout the machine. Again we monitor the air temperature, winding temperature, I.R, capacitance and Tan Delta.

We reach stabilization point when the machine has been fully cured and sealed. Even in high voltage machines we have managed to maintain stable insulation readings over a 5 ½ year period. As the motor is removed from the oven it is coated with Devolac anti-tracking enamel, final readings are taken, and a report prepared for the customer.  Process Two can sometimes even improve upon the manufacturer’s original figures. Indeed a major tanker fleet now sends all its new engine room and deck machines to Ayrodev for stabilization and treatment before going into service.

So now, for the first time, insulation can be stabilized, giving machines a new lease of life—often better than new for a fraction of the cost of a rewind. Machines up to 11 KV and 5000 hp have been successfully revitalized and once stabilized the new values have been maintained in service. And this applies not just to the temperate climate of Britain but also to the heat and humidity of Hong Kong. As good as Processes One and Two are, they are limited by the original quality of the machine.

What happens if a rewind is required? Go to:

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