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KRPC Rewinding Workshop Establishment Committee Reports

To:

The Executive Director Operations (EDO)

Task:

KRPC Rewinding Workshop Establishment

Date:
Subject:

26th August, 2014


Modalities for Establishment of KRPC Rewinding
Workshop (a follow-up of the fact finding visit to
WRPC Electric motor rewinding workshop)

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

KRPC Rewinding Workshop Establishment Committee Reports

workspace within KRPC and recommend essential


resources for setting up electric motor rewinding
workshop.

KRPC Rewinding Workshop Establishment Committee Reports

1.0

BACKGROUND

The burning of electric motors stator windings have become so


alarming, especially during rainy season that it became a great
concern to KRPC management. KRPC at the moment has no rewinding
facilities to take care of burnt stator coils; hence, the intervention of
third parties has been the practice.
In view of this, the management of KRPC Limited assigned four (4 Nos.)
maintenance staff to visit WRPC rewinding workshop for fact finding.
Following the fact finding report, six (6 Nos.) member committee was
set up with the terms of reference based on the modalities for the
establishment of a similar workshop in KRPC limited.
2.0

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

6. Okey, Williams (Reporting)

(18995)

MTCE.

3.0

TERMS OF REFERENCE

The following are the committees terms of reference;


1. Locate appropriate workspace within KRPC.
3

KRPC Rewinding Workshop Establishment Committee Reports


2. Compile major equipment required and their specifications.
3. Hand tools and their specifications.
4. Comprehensive list of consumables.
5. Number of man power required.
6. Rewinding workshop man power and skill required.
7. Contact vendors on latest version of equipment and hand tools
for rewinding workshop.
8. Fashion out modalities for manpower training for KRPC rewinding
workshop.
9. Summit committee report within three (3) weeks.
The KRPC Rewinding Workshop Establishment committee carried out
the said assignment and hereby presents its reports.
4.0

ANALYSIS OF ELECTRIC MOTOR REWINDING PROCESS

Failed electric motors are brought to the maintenance workshop for


insulation resistance improvement, overhauling and subsequent stator
coil rewinding if found burnt. The overhaul maintenance team verifies
the integrity of the motor by conducting appropriate test. All electric
motors with low or zero insulation resistance pass through the process
of insulation resistance improvement. When insulation resistance of
any electric motor remains at zero (0) Ohms, the electric motor is then
considered burnt. Hence, the need for coil rewinding or replacement
arises.
Careful studies show that rewinding of electric motors and other
electrical machines go through the stages illustrated in the sequence
shown below.

KRPC Rewinding Workshop Establishment Committee Reports

Electric Motor rewinding process


5.0

REQUIRED RESOURCES

After a careful analysis of the processes involved in repair and


rewinding of burnt electric motors, the committee identified some key
resources needed for the setting up and running of KRPC rewinding
outfit.
In order to ensure efficient establishment, operation and management
of the proposed KRPC electric motor rewinding workshop, the following
resources would be required.
1. The winding workshop (Workspace).
2. 240V - 3.3KV ac power supply.
3. Overhead crane.
4. Skilled and experienced personnel.
5. Coil winding equipment and tools.
6. Manpower (HR) and training.
7. Succession planning.
6.0

AVAILABLE RESOURCES

KRPC Rewinding Workshop Establishment Committee Reports


KRPC Electric Motor Rewinding Workshop Establishment Committee
also identified some existing resources that will encourage the
establishment of this workshop within the possible short time.
1. 14.5m x 9.7m workspace (For conversion).
2. 2 ton Overhead crane (Need to procure only the hoist of 10 0r 30
tons).
3. Two 1600KVA, 3.3KV/415V transformers i.e. 20 TRP-9 & 20 TRP10 (Requires a circuit cubicle and associated control accessories).
7.0

LOCATION OF WORKSPACE

Concerning where to situate the rewinding workshop, suggestions,


deliberation, site visitation and resolutions were reached after the
following considerations were made;

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.

KRPC Rewinding Workshop Establishment Committee Reports

7.1

Why the Choice of LAB Fabrication Workshop?

Well defined emergency exits

Nearness to muster clearly defined point

Properly maintained conveniences

Easy accessibility
7

KRPC Rewinding Workshop Establishment Committee Reports

An existing drain/sewage system.

Presence of an existing 2 tons overhead crane upgradable to not


less 30 tons

Nearness to main Power supply i.e. transformer yard (reduced


cabling cost)

Availability of office space (Rooms 050 tagged Material central


Tools Store, 051 with no tag & 052 tagged Plant Engr.)

Existing air, water and steam lines

8.0 RECOMMENDED
SPECIFICATIONS

EQUIPMENT/MACHINES

AND

THEIR

For the purpose of setting up an electric motor rewinding workshop,


the under listed equipment/machinery were thus recommended for
procurement.
Table Showing Coil Winding Equipment
S/NO EQUIPME SPECIFICATION
.
NT
DESCRIPT
ION
1.

Manual
Motor Coil
Winding
Machine.

2.

Multipurpose
Heavy Duty
Motor Coil
Winding
Machine.

3.

SAMATIC
2780
Automatic
Random Coil
Winding
Machine.

Full Manual (Range) with


counter, hand wheel
operated, Winding
capacity for 1/8Hp to
40Hp coil (All copper
wire range)
Heavy duty winding
machine; Auto pedal
operation; pitch
diameter: 400mm, 2h.p,
3-phase motors, D.C
Brake & Rectifier shaft
extension of 250mm,
Speed: 0 to 100 RPM by
variable speed drive.
Power supply: 240V or
415V/50Hz
Model: SAMATIC 2780;
Pulling power for more
than 20 wires of AWG
#12 in parallel; Built in
wire tensioner; winding
speed of 35 to 250 rpm;
coil size of 2 inches to

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

KRPC Rewinding Workshop Establishment Committee Reports

4.

Stator Lifting
Table SLT1400-TT

5.

Heavy-Duty
Bench-Type
Undercutter
Model H-9

6.

ABT Brazing
machine and
tongs.

43.8 inches; learning


mode, counter, etc.
Power supply:
240V/50Hz single phase
or 415V/50Hz three
phase.
Robust Lifting Tables
with integral hydraulic
power supplies; Foot
pedal operation, rotating
table; Platform
Size:1350 x 800mm;
Turntable Diameter:
700mm;
Closed height: 310mm;
Safe Working Load: 1400
Kg; fully safety features
incorporated.
Maximum between
centers: 32, V-supports
35.
Takes armatures 12
diameter on centers or
17 on V-supports.
Handles commutators
up to same diameters as
armatures.
Dimensions with
bench: 4 L., 2 W., 5 H.
V-supports vertically
adjustable.
Motor: 1/2 h.p., 3450
r.p.m.
Model: WH-BU Brazing
Unit.
Electrical supply:
240V single phase 50Hz,
13amp.
Brazing capacity:
Can braze copper strip
up to a maximum cross
sectional area of
200mm2

WHITELEGG
MACHINES.

See
Appendix
XV

MARTINDALE

See
Appendix
XX

WHITELEGG
MACHINES.

See
Appendix V

KRPC Rewinding Workshop Establishment Committee Reports


7.

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

KRPC Rewinding Workshop Establishment Committee Reports

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

Table Showing Recommended Electric Motor Test Equipment


S/ NO
1.

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

Model MIT 1525, 15KV


Megger
Insulation
Resistance Tester.
Voltage input range :
90-264 V rms, 47-63 Hz,
200VA. Battery: 11.1 V,
5.2Ah Li-ion batteries,
meet IEC 62133:2003,
MIT1525 has 2 battery
packs
Model: FLUKE 190
204/AM
Oscilloscope;
Four 200 MHz Scope
Inputs (BNC), 4-chan,
2.5GSPS.
5-in-1 data collector for
machine
condition
monitoring;
1. Vibration
2. Temperature
3. RPM
4. Bearing condition
and
5. Cavitation.
Model: MS2108.
DC Current:
Range- 600A to 0.1A

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

KRPC Rewinding Workshop Establishment Committee Reports

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

Accuracy (3.0% of rdg+10


digits)
Max.
Input
current600A DC.
AC Current:
Resolution- 0.01A at 66A
& 0.1A at 600A.
Accuracy
(3.0%
of
rdg+10digits).
Max.
input
current600A
Frequency range- 40 to
400Hz.
1. Engine Mounting Test
Stand;
2. Material: HT200-250,
3. Hardness: HB 170240;
4. Wear-resisting.
5. Flatness accuracy
according
to
DIN876.
6. T-slots according to
DIN650.
Dimension: 2.5m x 1.5m
x 0.3m T-slot surface
plate
Mode: Motor Analyzer
X. The X Model offers
a 4000V-dc power
source. Turn-to-turn by
probe
Variable
Voltage:
011KV/ 50Hz, 3-; 0150KW motor capacity
for 415V motors and
2000KW
for
3.3KV
motors.
Adjustable overload
protection;
Variable DC Output: 0600V
Panel mounted voltage,
current, frequency
function indicators.
( this specification is for
KRPC test Lab demand
thus a customized panel
is required)

12

ZHGONGBO
HEAVY
INDUSTRY

See picture
on page 16
and
attachment
s

WHITELEGG
MACHINES

See
Appendix IV

Contact KAY PEE


CORPORATION
On: +(91)8377802180,
+(91)9328908676;
+(91)982475606.
E-meail:
kaypeecorporatio
n@gmail.com

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

KRPC Rewinding Workshop Establishment Committee Reports


8.

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

RECOMMENDED HAND TOOLS

The table that follows captures the recommended hand tool required
when carrying an electric motor rewinding tasks.
S/No
.

Tools Description

1.

CM.110A Metric Set


with 12-point sockets
and riveting hammer
701A Multi-function
Tester (DIN57105)

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

10. 841.4 Sheathed


Electricians Scissors.

Specification

Manufacturer/M
odel

Quantit
y

See page 434 of


F96 FACOM tools
catalogue.
See page 462 of
F96 FACOM tools
catalogue.
See page 472 of
F96 FACOM tools
catalogue.
See page 472 of
F96 FACOM tools
catalogue.
See page 472 of
F96 FACOM tools
catalogue.
See page 465 of
F96 FACOM tools
catalogue.
See page 434 of
F96 FACOM tools
catalogue.

FACOM/CM.110A

FACOM/701A

FACOM/390.16VS
E

FACOM/391.16VS
E

FACOM/190.16VS
E

FACOM/CM.E18

FACOM/CU.110A

See page 452 of


F96 FACOM tools
catalogue
See page 452 of
F96 FACOM tools
catalogue
See page 288 of
F96 FACOM tools
catalogue.

FACOM/162

FACOM/162.2

FACOM/841.4

13

KRPC Rewinding Workshop Establishment Committee Reports


11. 841.9 Multipurpose
Scissors.
12. 840.4A Senior
Pocket Knife
13. STU Set of 9 files
14. Digital Micrometer
Screw Gauge. (Refer
to Appendix XVI)
15. Analog Micrometer
Screw Gauge. (Refer
to Appendix XVII)
1

Key Pulling Pliers

6.

See page 288 of


F96 FACOM tools
catalogue.
See page 289 of
F96 FACOM tools
catalogue.
See page 293 of
F96 FACOM tools
catalogue.
Fowler
Digital
Micrometers - 0 100mm - .001mm Premium Ratchet
Fowler
Standard
Micrometers - 0 100mm - Metric Sets
Clamping range: 035mm
Weight: 2Kg. (See
image on page 16
0f this reports.

FACOM 841.9

FACOM/840.4A

FACOM/STU

WESTPORT
CORPORATION

WESTPORT
CORPORATION

DUDEK
Fertigung
ssysteme

List of special Martindale motor repair hand tools


The under listed special tools can be procured directly from Martindale
through the following contact. Also, see MARTINDALE tools catalogue
on appendix XIV-(a up to l).
MARTINDALE
1375 Hird Avenue, Cleveland, OH 44107,
Phone: (216) 531-8567 / USA & Canada (800) 344-9191
E-Mail: sales@martindaleco.com
Web Site: www.martindaleco.com
S/No
.

Tool Description

Quantity

1.

Adjustable Slot Scraper

2.

Commutator Slotting Files

3.

Mini-Bar Mica Hand Saw

4.

Electricians Knife

2
14

KRPC Rewinding Workshop Establishment Committee Reports

5.

Wedge Drivers

6.

Handle-Type Coil Tampers

7.

Coil Tamping Pliers

8.

Internal Coil Tampers

9.

Armature Wedge Remover

10. Slot Cleaning Brushes

11. Winders Shears

12. Armature Air Gap Gauge

13. Lamination Tooth Straighteners

14. Winders Horn

15. Winders Lacing Hook

16. Hand Held Wire Stripper

17. Martindale Automatic Wire Stripper

18. Martindale Handy Wire Stripper

19. Wire Skinner and Straightener

20. Twin Wheel Wire Stripper

21. Martindale Bearing Tool Sets

22. Hand Knurling Tool

23. Repairmans Stethoscope

24. Rawhide and Nylon-Faced Hammers

15

KRPC Rewinding Workshop Establishment Committee Reports

25. Rawhide Mallets

26. trucothane DEAD BLOW Hammers

Below are pictorial appearances of some special electronic measuring


devices and mechanical equipment as specified on pages 9, 10 and 12;

Oxyacetylene Gas cylinders and welding Kits (For heating up


rusted electric motor couplings)

Megger MIT1525 (1002-909) 15KV Insulation Resistance Tester

16

KRPC Rewinding Workshop Establishment Committee Reports

Fluke 190-204 Scopemeter (For testing stator winding


connections)

Prototype of required motor test panel (find specifications on


page 10)

17

KRPC Rewinding Workshop Establishment Committee Reports

Whitelegg COV-15 Curing Oven (For heat treatment of motor


coils)

Motor Engine Test Mounting Stand or Test Bay (For mounting


electric motors during test run).

18

KRPC Rewinding Workshop Establishment Committee Reports

10.0 LIST OF CONSUMABLES


The consumables needed for rewinding electric motors, transformers
and solenoids in KRPC are as tabulated (which will be codified by
supply chain management department).
S/
N
1
2
3
4
5
6

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

KRPC Rewinding Workshop Establishment Committee Reports


7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

Copper Winding Wire


Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Copper Winding Wire
Leatheroid Insulation (Class
Leatheroid Insulation (Class
Leatheroid Insulation (Class
Insulation Sleeve (Class F)
Insulation Sleeve (Class F)
Insulation Sleeve (Class F)
Insulation Sleeve (Class F)
Insulation Sleeve (Class F)
Insulation Sleeve (Class F)
Insulation Sleeve (Class F)
Insulation Sleeve (Class F)
Insulation Sleeve (Class F)
Insulation Sleeve (Class F)
Insulation Sleeve (Class F)
Insulation Varnish, Oven
(Class F)
Binding Tape (Fibre Glass)
Scotch Cast
Emery cloth or sand paper

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

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KRPC Rewinding Workshop Establishment Committee Reports


49
50
51

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

2. Two (2 Nos.) Electrical Engineers.


3. Four (4 Nos.) In-house Electrical Technicians.
4. Three (3 Nos.) Externally sourced Experienced and Professional
Re-winders.
12.0 NUMBER OF MANPOWER REQUIRED
Apart from Superintendent Electrical/Instrument Workshop, required
number of manpower is Nine (9). See the organogram presented
below.

Proposed organizational structure of the rewinding workshop


13.0 TRAINING REQUIREMENTS/MODALITIES FOR MANPOWER
TRAINING
After a session of suggestions and useful deliberations, the under-listed
recommendations were made;

21

KRPC Rewinding Workshop Establishment Committee Reports

Three weeks theoretical training on electric motor rewinding by


reputable consultants

Three weeks of practical training.

Two weeks of a follow-up practical training by the workshop


instructor.

14.0 FACTS FOR MANAGEMENT CONSIDERATION


The committee agreed to list out the following facts for management
to consider;
1. At the moment, KRPC has no rewinding workshop
2. Rewinding of burnt stator windings by the third parties is not cost
effective.
3. Rewinding in KRPC workshop using KRPC staff will be more
reliable.
4. Conformity to coil winding standards is guaranteed if executed
in-house.
5. Supervision of rewinding jobs within KRPC rewinding facility will
be made easier.
6. Rewinding workshop, if established in KRPC, will enhance
revenue generation.
15.0 RECOMMENDATION
After considering critical need for safety, cost effectiveness, reliability
and conformity to standard practices in the rewinding of electric motor
coils, the committee recommends that KRPC management should
please consider;
1. Establishment of electric motor coil rewinding workshop in KRPC.
2. The located workspace of 14.5 x 9.7m in LAB fabrication
workshop.
3. Procurement of the identified machines (with their spare parts)
and install them.
4. Training of staff on the use of coil winding equipment and
identified hand tools for proper tools audit.
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5. Engagement of at least three (3 Nos.) labour support staff for
rewinding jobs under the supervision of the superintendent.
6. Training of KRPC maintenance staff on basic Electric motor
theory and practice by reputable consultants, like Messrs.
Applied Engineering Technology Initiative (AETI) Limited, Lagos;
who has industrial training facilities and the required capability
(see attachments).
7. Practical training of KRPC electrical maintenance staff on handson basic rewinding in WRPC.
8. Invitation of WRPC rewinding engineers to follow up the handson training in the established KRPC workshop.
16.0 COMMITTEES SOURCES OF INFORMATION.
1. Internet and Interactive deliberations between members.
2. WRPC fact finding report.
3. Visit to some rewinding workshops in Kaduna.
4. Messrs. TomGray Engineering Services. Phone: (080) 25011203; (070) 676-95354.
5. Messrs. Baken Nigeria Limited. Phone: (080) 378-78947
6. Messrs. Harry Engineering Tech. Nig. Limited. Phone: (080)
334-98453; (080) 996-31584.
16.0 LIMITATION
In the course of this assignment, the committees findings were limited
in terms of prices of equipment and tools but the invited companies
supplied prices of some equipment as can be seen in the vendor
submissions attached.
17.0 ATTATCHMENTS
1. Appendix I to XX.
2. Layout of LAB Workshop/technical Building (Page 55).
3. Picture of Electric Motor Test Benches (Prototype & WRPC).
Page 56.
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4. Electric Motor Test Panels (Page 57).
5. Image of Electric Motor Testing stand or Test Bay Page58)
6. Drawing/dimension of rewinding workbench (Page 59).
7. Submission by local suppliers.
8. Recommended training consultant course list.
18.0 ENDORSEMENT BY COMMITTEE MEMBERS
NAME

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.

KRPC Rewinding Workshop Establishment Committee Reports

APPENDICES
Appendix I -

Manual Motor Coil Winding Machine

Appendix II -

Multipurpose Heavy Duty Coil Winding Machine

Appendix III-

SAMATIC 2780 Automatic Random Coil Winding

Machine
Appendix IV

Motatest

Multifunction

Tester

for

Electric

Motors
Appendix V -

WH-BU Brazing Unit

Appendix VI

SAS-280 Semi-automatic Soldering Machine

Appendix VII

Posi Lock 100 Ton Hydraulic Grip Pullers

Appendix VIII

Model: TIH 220m SKF Induction Bearing Heater

Appendix IX

Model: MS2108 MASTECH Clamp Meter

Appendix X -

Model: MIT1525 Megger Insulation Resistance Tester

Appendix XI-a/b - VIBROTIP (5-in-one) Machine Condition Trending Data


Collector
Appendix XII

Arbors for Rewinding machines

Appendix XIII

DUDEK Stator Holding Rings Type-D

Appendix XIV-(a-l) -

Martindale Motor Repair Hand Tools Catalogue

(12 pages)
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Appendix XV

Stator Lifting Table SLT-1400-TT

Appendix XVI

Fowler

Digital

Fowler

standard

Appendix XVIII

Whitelegg Curing Oven (Model: COV-15)

Appendix XIX

Fluke 190-204 Scopemeter Specification

Appendix XX

Heavy Duty Bench-Type Undercutter Model H-9

Micrometers

(0-100mm)

Premium Ratchet
Appendix XVII

Micrometers

(0-100mm)

metric-sets

by Martindale
APPENDIX I

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APPENDIX II
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APPENDIX III
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APPENDIX IV
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APPENDIX V

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APPENDIX VI

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APPENDIX VII

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APPENDIX VIII
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APPENDIX IX
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APPENDIX X
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APPENDIX XI-a

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APPENDIX XI-b

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APPENDIX XII

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APPENDIX XIII

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APPENDIX XIV -a

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APPENDIX XIV b

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APPENDIX XIV-c

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APPENDIX XIV-d

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APPENDIX XIV-e

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APPENDIX XIV-f

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APPENDIX XIV-g

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APPENDIX XIV-h

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APPENDIX XIV-i

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APPENDIX XIV-J

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APPENDIX XIV-K

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APPENDIX XIV-L

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APPENDIX XV

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APPENDIX XVI

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APPENDIX XVII
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APPENDIX XVIII

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APPENDIX XIX

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APPENDIX XX

61