M/s. BASAI STEELS PVT. LTD.

CETHAR VE SSE LS LIMITED

1 X 80 TPH AFBC BOILER (BH048)

TABLE OF CONTENTS

SL. NO. DESCRIPTION PAGE NO.

VI. OTHERS:

FLOW NOZZLE 003

GEARED MOTOR 017

LIST OF MOTORS 029

DISC SPRING 038

SPRING HANGER 067

STRAINER 079
OTHERS
 DATA SHEET

FLOW NOZZLE
DESCRIPTION SPECIFICATION

GENERAL DATA:

MAKE M/S. INSTRUMENTATION LIMITED.

QUANTITY 1 NO.

APPLICATION FOR STEAM LINE

TAG NO. B1-FE201

DESIGN CODE BS1042

TAPPING DETAILS D & D/2

END CONNECTION BUTTWELD

FLOW NOZZLE MOUNTING WELD – IN

LINE SIZE 200 NB

PIPE SIZE DIA 219.1 X 23.01 THK.

PIPE MATERIAL SA335 P11

MATERIAL OF CONSTRUCTION (NOZZLE) SS 316

OPERATING DATA:

MEDIUM SUPERHEATED STEAM

FLOW 96,000 Kg/hr (MAX.), 80,000 Kg/hr (NOR.)

PRESSURE 72.00 Kg/cm² (g) (MAX.), 67.00 Kg/cm²(g) (NOR.)

TEMPERATURE 505°C (MAX.), 500°C(NOR)

DIFFERENTIAL PRESSURE 10000 MMWC

FLOW DIRECTION HORIZONTAL

TESTING AS PER IBR

TRANSMITTER TAPPING SIZE 15 NB, SOCKET WELD

ASSEMBLY LENGTH 1.76 M

NO. OF PAIR OF TAPPINGS 2

SUPPLIER’S ADDRESS:
M/s. INSTRUMENTATION LIMITED,
KANJIKODE WEST,
PALGHAT - 678 623.
KERALA STATE.
 DATA SHEET

GEARED MOTOR

DESCRIPTION SPECIFICATION

GENERAL DATA:

MAKE M/S. IC-BAUER

QUANTITY 5 NOS. 2 NOS 2 NOS

APPLICATION DRAG CHAIN ASH FEEDERS HP & LP DOSING

FEEDERS (AGITATOR)

TAG NO. B1-GM401 TO B1-GM406 & B1-GM501 &

B1-GM405 B1-GM407 B1-GM001

TYPE OF MOUNTING FOOT MOUNTED FOOT MOUNTED FOOT MOUNTED

MODEL NO.

TYPE OF MOTOR SQUIRREL CAGE INDUCTION MOTOR (TEFC)

MOTOR RATING 2.2 KW 0.37 KW 0.25 KW

OUTPUT SPEED 34 RPM 30.5 RPM 30.5 RPM

AMBIENT TEMPERATURE 50°C 50°C 50°C

POWER SUPPLY 415 V, ±10%, 50 HZ ±5% AC, 3 PHASE

DUTY CONTINUOUS CONTINUOUS CONTINUOUS

INSULATION CLASS FOR ‘F’ ‘F’ ‘F’

MOTOR

CABLE ENTRY SIDE SIDE SIDE

TYPE OF STARTING LT / DOL LT / DOL LT / DOL

PROTECTION IP 55 IP 55 IP 55

SUPPLIER’S ADDRESS:
M/S INTERNATIONAL COMBUSTION (INDIA) LTD ,

107/1, PARK STREET,

KOLKATA - 700 016. WEST BENGAL.

 DATA SHEET

LIST OF MOTORS

DESCRIPTION SPECIFICATION

GENERAL DATA:

MAKE M/s. SIEMENS LTD.

TYPE SQUIRREL CAGE INDUCTION MOTOR

POWER SUPPLY 415 V ± 10%, 3 PHASE, 50 HZ, ± 5% AC

TEMPERATURE 50°C

ENCLOSURE TEFC

PROTECTION IP 55

INSULATION CLASS “F”

DUTY CONTINUOUS

TYPE OF MOUNTING HORIZONTAL FOOT MOUNTED

APPLICATIONS
FULL LOAD
DESCRIPTION QTY. CAPACITY SPEED CURRENT FRAME NO. OF TYPE OF
(NOS) (KW) (RPM) (AMPS) SIZE POLES STARTING

FD FAN 1 370 1488 643 1LA8 357-4 4 VFD/ STAR DELTA

ID FAN 1 160 988 278 1SEO 356-6 6 VFD/ STAR DELTA

PA FAN 2 75 1485 130 1SEO 281-4 4 STAR DELTA

BED ASH 1 55 1480 96 1SEO 254-4 4 STAR DELTA

COOLER FAN

FEED PUMP 4 250 2900 435 1SEO 356-2 2 STAR DELTA

HP & LP 4 0.37 1440 0.64 1LAO 073-4 4 D.O.L

DOSING

POCKET 10 1.5 1440 2.6 1LAO 096-4 4 VFD

FEEDER

SUPPLIER’S ADDRESS:
M/S. KUMARAN TRADERS ,
10, TAMIL SANGAM BUILDING, W.B.ROAD,
TRICHY – 620 008.
s

Installation . Operation .
Maintenance Instructions

Superbreed Motors ! WARNING

Supply Voltage is hazardous and can
cause Electric Shock and burns.

Type - 1LA0/1SE0 MOTORS Disconnect Power before proceeding

with any work on this equipment.

FRAME SIZES 160M TO 355L

Types of Construction:

General Note
WARNING
The data and recommendations specified in all
the instructions supplied, and in all other related
instructions, must always be observed in order
to avoid hazardous situations and the risk of
possible injury or damage.
Furthermore, the pertinent national, local and
plant-specific regulations and requirements
should be kept in mind!
Special designs and other versions may vary in
technical details! If in doubt, be sure to contact
the manufacturer, quoting the type
designation and serial number, or have
maintenance work done by one of SIEMENS
Service Centers.
WARNING
The waste generated during operation &
maintenance of the motor should be done as
per the applicable local environmental
legislations.
• Waste grease & Greased cloth to be collected
as hazardous waste and sent to hazardous
waste disposal facility for incineration.
• Waste copper windings to be collected as
hazardous waste and sent to registered
recyclers approved by the respective State
Pollution Control Board.
1 Description
1.1 General
The superbreed motors are three phase cage induction
motors; totally enclosed fan cooled (TEFC) type for low
voltage supply. General-purpose motors type 1LA0
conform to IS: 325. The motors comply with the type of
protection IP55 in accordance with IS 4691. The degree
of protection of the motor is specified on the rating plate.
IMB3 is the standard mode of construction. All other
constructions are given on customer request.
Unless otherwise specified, the rated outputs apply to
continuous duty (S1) at a frequency of 50 Hz, an ambient
temperature of 45° centigrade and site altitude not
exceeding 1000m above mean sea level.
1.2 Terminal box
The terminal box conforms to type of protection IP55 in
accordance with IS: 4691.
For foot-mounted motors, the terminal box is provided
on the top with cable entry from RHS (as seen from DE)
as a standard feature. If specifically ordered, terminal box
2
position on the right or the left-hand side (when viewed
from the drive end) can be supplied.
In order to provide for different directions for cable entry,
the orientation of the terminal box can be altered in steps
of 90°. The larger terminal boxes are normally provided
with detachable inclined
cable gland plate that also can be rotated in steps of 180°.
2 Operation
WARNING
Before starting any work on the machine, be sure to
isolate it from the power supply.
2.1 Inspection, Storage & Transport
The motors should always be lifted at the lifting
eyebolt(s) during transport.
WARNING
For lifting assembled machine sets (such as built-on
gearboxes, fan units), always use the lifting eyebolt(s)
or lifting pegs provided on both the units! Machine
sets should not be lifted by suspending the individual
machines! Check the lifting capacity of the hoist!
NOTE: The motors should not be lifted using the centre
holes on the shaft DE and NDE, because the weight of
the motor shall harm the bearing and reduce its
performance and operational life.
The bearings should be regreased, if the motors are
stored for more than 18 months prior to commissioning
under favorable conditions (kept in a dry place free from
dust and vibration).
Under unfavorable conditions, this period is considerably
shorter than above.
Check the packing of the motor on arrival and in case
any damage is observed, please report to the nearest
Siemens office.
Make sure that the right type of motor as ordered has
arrived. The motor nameplate provides relevant
information.
If the motor is not installed immediately, it should be
stored in a dry and vibration free room.
The rotor of the motor with cylindrical roller bearing or
angular contact ball bearings is axially locked in position
with the help of sheet steel rotor locator at the shaft
extension. This is to prevent damage to the bearing due
to standstill vibrations during transport. Do not remove
this rotor locator until the motor is being coupled to the
driven equipment. In special cases where the motor is to
be transported after the fitting of the transmission
elements like coupling/pulley, other suitable
arrangements to secure the rotor must be made.
Motors of vertical type of construction with angular
contact ball bearing (2 pole motors of frame 315 and
above) should be transported in vertical conditions only.
If horizontal transportation is a must, lock the rotor axially
in position with the help of the rotor locator.
If the motors are kept in stock (for more than 3 months)
prior to commissioning, rotate the rotor for 10 to 15
revolutions every fortnight. For those motors supplied
with rotor locator, remove the locator, do the above
operation and reassemble the rotor locator in its place.
2.2 Mounting
All standard motors upto frame size 315M (except 2 pole
motors of frame 315M) are suitable for horizontal as well
as vertical mounting. i.e. Standard foot mounted motors
can be used in IM-B3, B6, B7, B8, V5, V6 constructions
or flange-mounted motor can be used in IM-B5, V1, and
V3 constructions. All motors which have a shaft extension
pointing upwards (V6 construction) must have a means
(provided by the user) of preventing the ingress of dust
and of liquids along the shaft.
Whenever the foot mounted motors have facility for
mounting with alternative fixing distances corresponding
to S&M or M&L frame designations, two holes are
provided on the mounting feet at the non-drive end.
Corresponding letters S, M, L are indicated near the fixing
holes on the mounting feet.
2.3 Installation
After installation, screwed-in lifting eyebolt(s) should
either be removed or tightened down.
Remove rotor locator (when provided) from shaft
extension. Check the free running of the rotor by rotating
the shaft by hand.
The shaft extension of the motor is coated with an
anticorrosion agent. To remove this coating use kerosene
/ thinner. Do not use sandpaper or scraper.
Before mounting the motor, see that the motor feet are
properly cleaned.
As a standard practice, the transmission elements to be
fitted to the motor should be dynamically balanced.
Please note that the rotors of the motors are dynamically
balanced with half key inserted in the shaft extension of
the motor. Transmission elements must be fitted and
removed only by means of suitable tool. Refer fig.2.
Install the motor in such a manner that the cooling air
has free access and can escape unobstructed. Discharged
air or hot air from neighboring equipment, must not be
sucked in again. Clean the entire path of air over the
motor (between ribs and air inlet in fan cowl) at regular
intervals to remove any foreign deposits, preferably by
means of compressed air.
Motors are provided with plugged drain-holes, located
at lowermost point on both the endshields for drainage
of condensate water. Please ensure that these holes are
the lowest point of the motor. If necessary rotate the
end shield.
For foot mounted motors to be fixed on the wall a support
should be provided for the mounting feet from below.
In the case of motors with shaft end facing upwards
or downwards, measures must be taken (by the user)
to ensure that no water or dust can penetrate into the
upper bearing. (Refer 2.2)
Initial lubrication of the bearings is carried out in works.
For motors with regreasing facilities, bearings must be
regreased when the motor is running.
For motors without regreasing facilities, bearing or grease
replacement must be carried out in accordance with
clauses 2.6.1, 3.2.3, 3.3 and 3.4.
If the belt drive is used, install the machine in such a
manner that it can be shifted on its base (e.g. on slide
rails) to obtain correct belt tension. Excessive belt tension
may result in damage to the bearing and /or shaft. For
permissible radial loads on shaft extension and
recommended pulley sizes refer the Siemens catalog or
contact our office.
CAUTION
Excessive belt tension may result in damage to the
shaft bearings; for permissible values, see catalog
or enquire.
Due attention should be given to the measures necessary
to prevent accidental touching of rotating parts
(couplings, pulleys, etc.)
Quiet running
Stable foundations or mounting conditions, exact
alignment of the motors and a well-balanced
transmission element are essential for quiet vibration-
free running. If necessary, shims should be inserted
under the motor feet to prevent strain.
2.4 Electrical connection
Examine the rating plate data and ensure that it matches
with the power circuit to which the motor is to be
connected. Check to see that system voltage and
frequency agree with the data given on the rating plate.
Select the size of supply cables as required for the
particular current rating. Connect the supply cables in
accordance with the connection diagram shown inside
the terminal box cover.
Connection and arrangement of the terminal links must
agree with the diagram provided in the terminal box.
Refer Fig. 3 to Fig. 6 for various Terminal box
arrangements.
Please refer to the table below for tightening torques for
terminal bolts and nuts (except for terminal strips).
Thread-ø Nm M4 M5 M6 M8 M10 M12 M16
Tightening Min 0.8 1.8 2.7 5.5 9 14 27
Torque(Nm) Max 1.2 2.5 4 8 13 20 40
3
Ensure that the direction of rotation of the motor is as
required. For induction motors, the direction of rotation
can be reversed by interchanging two supply phase
connections in the terminal box. All motors of type 1LA0
are suitable for bi-directional rotation.
Before closing the terminal box ensure that:
– Interior of the terminal box is clean and free of cable
residue.
– All terminal screws and bolts are firmly tightened.
– Minimum air-clearance (>10mm upto 500V. >14mm
upto 1000V) is maintained.
– Unused cable entries are sealed off with the plugging
elements firmly screwed in.
– All sealing surfaces have adequate contact.
When the motors are provided with anti-condensation
heaters, ensure that the supply to heaters is switched
off before switching on the motor.
Before starting and during operation, make sure that all
the relevant safety and statutory regulations pertaining
to the area of operation are complied with.
2.4.1 Earthing
Connect the earthing conductor to the terminal with the
earth marking in the Terminal box as well as on the Stator
housing.
Clean the area underneath the earthing terminal and
smear it with petroleum jelly before making earthing
connections.
2.5 Checking the insulation resistance
The insulation resistance of the windings must be
measured prior to initial startup of the machine, and after
long periods of storage or standstill (approximately 6
months).
WARNING
While the measurement is being taken and
immediately afterwards, some of the terminals carry
dangerous voltages and must not be touched.
Measurement
The insulation resistance of the windings to ground is
measured with 500V DC. The winding temperature
should be 30ºC±15ºC.
Checking
Minimum insulation resistance value (at 40°C) as
specified in IS: 4722 is Rm =kV + 1, where kV is the rated
voltage of the machine. Thus, for 415V rated voltage
the insulation resistance of the winding should not be
less than 1.42 MOhm.
If less the winding must be suitably dried as per IS: 900
4
2.6 Bearing and lubrication
All motors, as a standard feature, are provided with
floating bearing at drive end and fixed bearing at non-
drive end.
Motors upto and including frame size 225 are provided
with prelubricated bearing (without grease nipples) and
motors of frame size 250 and above are provided with
regreasing arrangement (grease nipples). If required and
ordered, motors upto frame sizes 225 can also be
provided with regreasing arrangement.
2.6.1 Prelubricated bearing
For initial lubrication of bearings, Lithium Complex grease
UNIREX-N3 of ExxonMobil is used.
Under normal operating conditions, with horizontally
mounted motors and coolant temperatures up to 45ºC,
the regreasing interval should be:
– After 20,000 operational hours or 3 years (whichever
occurs first) in case of motors with speeds upto 1800
rev/min.
– After 10,000 operational hours or 1 year (whichever
occurs first) in case of motors with speeds above
1800rev/min.
These intervals apply for normal loading conditions, low-
vibration running, approximately neutral ambient air and
assuming high quality rolling bearing grease is used. In
case of doubt, shorter intervals should be allowed for.
2.6.2 Regreaseable bearings
In case of motors with regreasing arrangement (grease
nipples), it is recommended that the greasing instructions
and type of grease used as mentioned on the lubrication
data plate should be followed.(Standard type of grease
used is UNIREX N3 of ExxonMobil).
Mixing greases of different thickeners and basic oils
reduce the quality and should therefore be avoided.
Only in special cases should deviations be made from
the usual greasing data. The regreasing intervals should
be shortened for instance, if the motors are operated at
ambient air temperatures higher than originally allowed
for, or if corrosive vapours occur or extremely heavy
contamination is present.
While regreasing, clean grease nipples and press in the
grease stipulated on the lubrication data plate using
grease gun. At the same time, the shaft should be
rotating in order that the new grease is distributed
uniformly in the bearing. After regreasing, the bearing
temperature will rise by a few degrees and drop to its
normal value when the grease reaches its normal service
viscosity and the excess grease has been forced out of
the bearing.
The old grease from several greasing operations gathers
in the space inside the outer bearing cover/endshields.
Remove the old grease while overhauling the machine.
2.7 Balancing, transmission elements
A suitable device should always be used for fitting and
removing the transmission elements (coupling halves,
pulleys, pinions).
As standard, the rotors are dynamically balanced
with the half key inserted.
When fitting the transmission element, keep the
type of balance in mind! Balance with half key.
WARNING
The usual measures should be taken to guard
transmission elements from touch. If a motor is
started up without transmission element attached,
the key should be secured to prevent it being
thrown out.
2.8 Commissioning
NOTE: Where the torque is very uneven (the drive of a
reciprocating type compressor, for example), the
inevitable result is a non-sinusoidal motor current, whose
harmonics can lead to excessive system perturbation or
excessive electromagnetic interference.
In case of converter-fed motors, high-frequency current
or voltage harmonics in the motor cables can give rise to
electromagnetic interference. This is why the use of
shielded cables is recommended.
Before commissioning, check that:
- The minimum insulation resistances are adhered to.
- The rotor turns freely without rubbing.
- The motor is properly assembled and aligned.
- The transmission elements are correctly adjusted (e.g.
belt tension) and the transmission element is suitable
for the given operating conditions.
- All electrical connections, mounting screws and
connecting elements are properly fitted and
tightened.
- All protective conductors are properly installed.
- Any auxiliaries that may be fitted (brakes,
speedometer, separate fan) are in working order.
- Touch protection guards are installed around moving
and live parts.
- The maximum speed nmax is not exceeded, especially
for motors with variable speed drive.
NOTE: The maximum speed nmax is the highest operating
speed permitted for short periods. It should be kept in
mind that motor noise and vibration are worse at this
speed, and bearing life is reduced. (For details refer
catalogue or contact nearest Siemens office).
CAUTION
After motor installation, the brake, if fitted, should
be checked for proper functioning.
It is not possible to formulate a complete checklist
for all operations and applications. Other checks may
also be necessary!
3. Maintenance
Safety Precautions
WARNING
Before starting any work on the motor or
other equipment, particularly before opening
covers over live or moving parts, the motor
must be properly isolated from the power
supply. Besides the main circuits, any
additional or auxiliary circuits that may be
present must also be isolated.
The “5 Safety rules” to be followed are:
- Isolate the equipment
- Take effective measures to prevent
reconnection
- Verify equipment is dead
- Ensure proper earthing connections
- Cover or fence off adjacent live parts
The precautions listed above should remain
in force until all maintenance work is finished
and the motor has been fully assembled.
NOTE: Where motors are fitted with plugged drain holes,
these should be opened from time to time to allow any
accumulated condense water to be drained away.
Condense water openings should always be at the lowest
point of the motor!
3.1 General
Periodic overhauling of the motor is recommended to
ensure long trouble free service.
Before starting the maintenance work, make sure that
the supply is disconnected. These motors are provided
closely pitched ribs for effective cooling of the motor.
These ribs should be cleaned at regular intervals either
by oil free compressed air, or by scraping, depending on
the level of contamination.
The inside of the motor should be cleaned using dry
compressed air during normal overhauling of the motor.
Special care should be taken while cleaning the windings
to remove loose dust, moisture etc.
5
3.2 Dismantling
3.2.1 Pressing on and pulling off drive elements
Use the tapped hole provided in the end of the shaft
for fitting drive components such as couplings,
gearwheels, belt pulleys etc. and, if possible, heat the
components as necessary. Use a suitable puller tool for
removing the components. Do not strike the
components, e.g. with a hammer or similar tool, when
fitting or removing them and do not exert more than
the maximum value of radial or axial force – according
to the catalog – transmitted to the motor bearings
through the shaft extension.
3.2.2 Fans
Plastic fan
Thermo plastic fans have two cast-on tabs that snap into
the ring groove on the shaft to prevent axial movement.
Before the fan is pulled off the shaft, the two tabs must
be disengaged (lifted up) and held temporarily in that
position, e.g. by inserting packing.
Thermoplastic fans have two openings for the insertion
of the puller arms so that the pulling force can directly
act on the fan hub. On delivery, a film of plastic may
cover these openings and later on they should be
punched.
A suitable device (puller) should be used for pulling the
fan off and pressing it back on. Hammer blows must be
avoided to protect the fan and bearings.
Cast Iron fan
Cast iron fans are axial locked with separate circlip. Cast
iron fans are best removed by engaging the puller arms
on the outer rim of the fan. In case of larger fans, the
puller holes provided on the hub can be used.
3.2.3 Removal of Bearings
For removing bearings use proper pullers. Reusable
bearings, which are non-separable (e.g. Deep groove ball
bearing), should be withdrawn by attaching puller arms
to the inner ring of the bearing. If it is a must to apply
puller arms on the outer ring of the bearing, the bearing
should be rotated during withdrawal to avoid damage
to the bearing.
Removal of bearings or inner rings which are not to be-
used is facilitated by heating them with gas or welding
torch.
in good condition. Place the gaskets carefully to achieve
the correct sealing. Replace the gaskets with the new
ones if the same are damaged.
All fasteners that are used on the exterior of the motor
are provided with a coat of bearing grease to prevent
ingress of water and dust through tapped holes. Ensure
that the same is provided at the time of re-assembly.
Do not interchange location (DE & NDE) of bearing
covers, as the spigot dimensions may be different.
A bearing must be replaced if it is damaged. Damage to
bearing is often difficult to recognize; in doubtful cases,
replace the bearing. Bearings, which have been removed,
should be reused only if they show no trace of damage
and provided they are thoroughly cleaned beforehand.
For cleaning bearings use proper cleaning agent e.g.
White spirit. Wear gloves.
CAUTION
The cleaned bearing must be free of foreign bodies
(fibres from cleaning rags, hair from brushes, etc.)
It is recommended that the new rolling bearings be
installed as follows:
Heat the deep groove ball bearing or the inner race of
the separable bearing. (Roller/Angular contact ball
bearing) in oil or air to a temperature of approximately
80-100°C and slip them into the shaft. Heavy blows may
damage the bearing and must be avoided. When
installing single angular contact ball bearing, make sure
that the broad shoulder of the inner race is with operating
position pointing upwards i.e. in a direction opposite to
that of the axial force.
After fitting, the bearing must be filled with sufficient
quantity of grease.
3.4 Initial fill of grease
Grease is to be filled in the bearing spaces completely,
in-between the gaps of the rolling elements and in one-
third open space, near the bearing, inside the inner
bearing cover.
Pack the bearing cavities flush with grease! The cover
plate or endshield is kept free of grease to prevent over
greasing.

3.3 Re-assembly
The motor must be assembled in a dust free, dry and
clean location.
As the motor conforms to the type of protection IP55, all
machined mating surfaces are provided with a thin even 1 Endshield /
coat of bearing grease. Provide a fresh coat of this grease Outer bearing
cover
at the time of re-assembly.
2 V – Ring
Unmatched surfaces are provided with rubber gaskets. 3 Auxiliary shim
At the time of re-assembly, ensure that the gaskets are
6
In case of regreaseable bearings, also fill the grease ducts
in the endshield and the inner bearing cover.
When assembling the shaft sealing rings, ensure that they
are fitted properly.
Ensure that the V rings are in the proper axial position.
This is ensured with the help of auxiliary shim such that
the bearing cover face / Endshield face and outer edge
of the V-ring are flush.
Any worn sealing elements (such as shaft sealing ring,
etc.) should also be renewed.
Whenever labyrinth seal is used, the gap between the
labyrinth and Outer bearing cover should be filled with
bearing grease.
NOTE:
a) Motors provided with cylindrical roller bearings on
the drive end sides have very high dynamic capacity.
As per bearing manufacturers, the roller bearing
performs satisfactorily only when it is radially loaded
to approximately 1-2% of its dynamic capacity. In view
of this, the roller bearing may not run smooth when
the motor is run uncoupled or with low radial load
(e.g. In direct flexible couplings.)
b) Type of grease for standard machines:
Grease lifetime and lubrication intervals specified are
valid for UNIREX N3 type of grease only.
Special greases are indicated on the lubricating data
plate.
c) Avoid mixing different types of grease!
Applicable Standards
The motors comply with the following standards:
IS: 325: Specification for three phase induction motors
IS: 900: Code of practice for installation and maintenance
of induction motors.
IS: 4691: Degree of protection provided by enclosure for
rotating electrical machinery
IS: 7816: Guide for testing insulation resistance of
rotating machines.
IS: 9628: Specification for Three phase induction motors
with type of protection ‘n’.
IS: 6381: Specification for construction and testing of
apparatus with type of protection ‘e’.
IS: 12065: Permissible limits of noise level for rotating
electrical machines.
IS: 12075: Mechanical vibration of rotating electrical
machines with shaft heights 56mm and higher –
Measurement, Evaluation and Limits of Vibration
severity.
IEC: 60034-1: Rotating electrical machines – Part 1:
Rating and Performance.
IEC: 60034-5: Degree of protection for rotating electrical
machines.
EN: 60204: Safety of machinery – Electrical equipment
of machines.

3.5 Joint sealing

When reassembling machines with degree of protection
IP56 (see rating plate), the joint between the motor frame
and the endshields are sealed with rubber ‘O’ rings. It
should be ensured that these are not damaged.

4 Spare Parts
When ordering spare parts, please indicate the correct
Motor Type, Serial Number (as shown on the rating plate)
and also the correct part description. This will ensure
speedy and correct delivery of spare parts. Please refer
to the exploded view of the motor (Fig.1).

NOTE:
In addition to the above information, it is recommended
that the user refers to IS: 900 – “Code of practice for
installation and maintenance of Induction Motors”.

7
Siemens Ltd.
Automation & Drives - Motors
Thane Belapur Road
Thane 400601
Fax: +91 22 27600076
E-mail: motors.in@siemens.com Order No. 4I-0099-0118134 001
Siemens Ltd. Product development is a continuous process. Consequently Time Prints
MOT- the data indicated in this booklet is subject to change without 030504
prior notice.
 DATA SHEET

DISC SPRINGS

DESCRIPTION SPECIFICATION

GENERAL DATA:

MAKE M/S. GALA PRECISION TECHNOLOGY LTD

APPLICATION REAR WALL FRONT WALL ROOF WALL

SPRING SIZE (MM) 100 X 51 X 6 100 X 51 X 6 71 X 36 X 4

EXTERNAL DIAMETER (MM) 100 100 71

INTERNAL DIAMETER (MM) 51 51 36

THICKNESS (MM) 6 6 4

DESIGN STANDARD DIN 2093 DIN 2093 DIN 2093

SPRING SERIES 2A 2A 2A

SPRING FORCE (NEWTON) 4893 Kgs 4893 Kgs 2090 Kgs

HEIGHT OF AN UNLOADED 7.0 7.0 5.6

SINGLE SPRING

NO. OF SPRINGS IN SINGLE 3 NOS. 3 NOS. 3 NOS.

STACK

NO. OF SPRING STACKS 4 NOS. 4 NOS. 10 NOS.

TOTAL NO. OF SPRINGS 42 NOS. 123 NOS. 78 NOS.

HANGER DOWNWARD TRAVEL 2.05 2.05 4.165

DISTANCE (MM)

MATERIAL SPECIFICATION 50 CR. V4 50 CR. V4 50 CR. V4

SUPPLIER’S ADDRESS:
M/S. GALA PRECISION TECHNOLOGY LTD,
PLOT NO.A-59, ROAD NO. 10,
WAGLE INDUSTRIAL ESTATE,
THANE - 400 604.
 DATA SHEET

SPRING HANGER

DESCRIPTION SPECIFICATION

MAKE M/s. PIPE SUPPORTS INDIA PRIVATE LTD,

TYPE COMET
SPRING VERTICAL HORIZONTAL HOT COLD
NODE MODEL RATE TRAVEL TRAVEL LOAD LOAD VAR. QTY
(Kg/mm) (MM) (MM) (Kgs) (Kgs) (%) (Nos)

FOR FEED PUMP DELIVERY PIPING

120 V1-15-TS2 5.433 3.316 0.86 320 338 6 1

260 V1-15-TS2 5.433 3.311 0.42 320 338 6 1

400 V1-15-TS2 5.433 3.295 0.45 320 338 6 1

540 V1-15-TS2 5.433 3.312 0.83 320 338 6 1

FOR FEED PUMP SUCTION PIPING

270 V1-16-TS2 7.44 4.14 0.066 430 461 7 1

360 V1-16-TS2 7.44 4.14 0.402 430 461 7 1

450 V1-16-TS2 7.44 4.14 0.067 430 461 7 1

540 V1-16-TS2 7.44 4.14 0.324 430 461 7 1

STARTUP VENT PIPING

570 V2-16-TS2 --- 16.330 13.420 452 391 13.4 1

MATERIAL OF CONSTRUCTION

SPRING 50 Cr. V4 / 60 Cr. 4 V2

CASING PIPE ERW (MEDIUM)

PLATES & RODS IS 2062 GR. A / B

TURN BUCKLES FORGED

NAME PLATE ALUMINIUM

PAINT SYNTHETIC ENAMEL

SUPPLIER’S ADDRESS:
M/s. PIPE SUPPORTS INDIA PRIVATE LTD,
DOOR NO. 6, / PLOT NO. 29,
INDUSTRIAL ESTATE,
PERUNGUDI,
CHENNAI - 600 096.
EM-CE-01
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PIPE SUPPORTS INDIA PRIVATELIMITED

Plot No 29 Industrial Estate
Perungudi
Chennai , Tamilnadu
India-600096
Telephone +91 (0) 44-24952668 , 24961003
Fax: +44 (0) 44-24961395
E mail: psindia@vsnl.com
www.pipesupports.com

Erection & Maintenance Manual

Constant Effort Supports

Manual No; EM - CE - 01
Revision; 00

Dated; 02/02/05

Page; 1 of 7

Author; S J Barry

Signed ; M Collingwood

REV DATE DESCRIPTION RAISED APPRD

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Erection & Maintenance Manual

Constant Effort Supports

Index

Section Description Page

1.0 Introduction 3
2.0 Storage 3
3.0 Erection 3
4.0 Maintenance 5
Appendix 1 Typical drawing 7

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Erection & Maintenance Manual

Constant Effort Supports

1.0) INTRODUCTION
This manual gives guidance and recommendations for the erection,
commissioning and subsequent maintenance of ‘COMET’ constant effort
supports.
Constant effort supports deliver a nominally constant supporting effort
to the point of attachment to the supported part; they replicate a very precise
counter-balance mechanism. Because of this it is important that the
suspended mass is reasonably close to the ‘design load and not more than
20% of said load in variance with it.
Constant effort supports exhibit frictional and geometric variances
from the nominal ‘set’ load; that stated as being the design load for the unit
selected. This is usually defined as the ‘deviation’ and is a measure of the
hysteresis of the load-displacement plot. The hysteresis of any particular
support is usually within +/- 5% of the ‘set’s load but may be specified as +/-
2.5% by special agreement.
The significance of hysteresis is that for a given range of load the
support will remain static at it’s set position; in order for the support to
respond to changing conditions the tension generated in the hanger rod or
the compression exerted on the supporting plinth must either increase or
reduce by an amount slightly greater than the frictional resistance within the
support. Therefore the ‘balancing’ of a support is a critical exercise if the
support is to be set at its true mean load.
It is essential that the support is erected in the correct position; error at
the erection stage can cause a re-distribution of the load and make it virtually
impossible to ‘balance’ the supporting system.
When selecting the support at the design stage it is important that any
additional load be added to the nominal design load of the supported part;
large pipe clamps, spreader beams or even long hanger rods can impose
significant increases in dead weight.

2.0) STORAGE;
2.1 Supports should be handled with care and stored in a dry and dust
free environment, preferably off the floor and under cover.

3.0) ERECTION:
3.1 Constant effort supports are mechanisms that rely on freedom of
motion; lack of adequate protection during storage, rough handling and
abuse will significantly reduce the constancy of the support and may
cause seizure of the mechanism.

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3.2 The support should be carefully lifted into its nominated position and
secured using appropriately sized fixing bolts.
3.3 Attachment to the supported pipework is made via the hanger rod and
pipe clamp in the case of suspension type supports and via the plinth in
the case of compression type supports. The pipework should be
accurately adjusted to its correct elevation using either the turnbuckle or
the height adjustment nut.
NB. It is important that the pipe is suspended naturally; sagging or
hogging pipework will impose false loads at the support positions.
3.4 If the pipe work is to be lagged with thermal insulation after the
supports have been erected, the piston plate locking nuts which are
located on both sides of the piston plate on either side of the spring
housing, should not be retracted from their original position i.e. in contact
with the piston plate until lagging is complete.

3.5 If the pipe work is to be subjected to hydrostatic testing, this must take
place with the piston plate locking nuts, which are located on the spring
side of the piston plate on either side of the spring housing, still in their
original position i.e. in contact with the piston plate. Standard spring
supports are designed to withstand an increased load during hydrostatic
testing of up to twice the maximum load for the spring support.

3.6 Once satisfied that the pipework is at its correct elevation the process
of ‘balancing’ the system can commence. If the original assessment of
weight distribution was correct; the pipe has been supplied to the
nominal weight, valves and lagging/ insulation are at their theoretical
weight and all the supports are in their correct position then it is simply a
case of undoing the locking nuts and walking away! However this is
rarely the case.

3.7 The process of balancing the supporting system is very much an

iterative one, adjustment to one support may manifest in a change at
another two or three positions away. It is best to work between fixed
support positions or terminal points and work towards the centre where
the piping is most flexible.

3.8 To determine whether a support is in balance or not it is necessary to

observe the spring compression plate locking nuts found either side of
the spring away from the main mechanism. For balance these nuts
should all be relatively free to be unwound away from the compression
plate leaving the support in a static, self-supporting state. If this is the
case for any particular support we strongly recommend that the nuts
should be wound only 5mm away from the plate at this stage. This is
simply a precaution to avoid the pipe work moving far away from it’s set
position if subsequent supports are not truly balanced.

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3.9 If the support is not in balance then either the forward (spring side)
locking nut or the rear locking nut will offer significant resistance to
turning. Should it be that the forward nut will not rotate then this signifies
that the support is not providing sufficient effort and positive load
adjustment is required. This entails increasing the distance between the
main pivot pin and the pin, which transfers the spring force into the lever
mechanism. This is achieved by rotating the load adjustment nut
clockwise when viewed from above in the case of all types except the VI
group for which the opposite should be applied.

3.10 Subsequent supports should be balanced in the same way however it

is necessary to continually check back to previous supports to ensure
that the effect of changing supports towards the centre of the pipe run
does not alter previously balanced supports. If this is the case then
suitable adjustments should be made to overcome this and return these
supports back to their correct position.

3.11 When all supports are floating, the locking nuts should be backed off
fully to allow the system to operate correctly.

3.12 Where the constant effort support incorporates a limit stop (Reaction
force receiver), the forward (spring side) locking nuts will be positioned at
a distance from the spring compression plate, as shown on the support
detail drawing.

3.13 Prior to operating the plant we recommend that all supports are
checked to ensure -

The locking nuts are fully retracted.

No debris has been allowed to fall into the support, especially in
the spring housing.
The support is free from visual damage, all fixing bolts are secured
and the rotational path of the lever mechanism is clear of
obstructions.
We also suggest that a cold survey is carried out and a record of all
load adjustment settings and travel scale readings is taken.

4.0) MAINTENANCE:
4.1 ‘COMET’ constant effort supports are designed to be maintenance
free, they incorporate dry bearings and brass/ptfe thrust washers.
However common sense should prevail; threaded items require greasing
at intervals to suit the environment, but not longer than 2 years, periodic
inspections are necessary to ensure the supports have not been
damaged or obstructed by such items as temporary scaffolding,
additional equipment or debris that may have fallen into the unit.
Protective coatings should be periodically inspected and if necessary
repaired.

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4.2 Unfortunately due to the wide- ranging environments these devices

are employed in, it is impossible to compile a fully comprehensive
maintenance procedure. It should be remembered that constant effort

supports are mechanisms and the health and longevity of the piping
system depends on the reliable operation of the pipe supports.

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7
 DATA SHEET

SPRING HANGER

DESCRIPTION SPECIFICATION

MAKE M/s. SARATHI

TYPE COMET

SPRING VERTICAL HORIZONTAL HOT COLD

NODE MODEL RATE TRAVEL TRAVEL LOAD LOAD VAR. QTY

(Kg/mm) (MM) (MM) (Kgs) (Kgs) (%) (Nos)

DOWNCOMER

85 VS2-9-B 3 17.048 27.293 342 393 15 1

125 VS2-14-F 17 15.753 37.886 1902 2169 14 1

90 VS3-11-B 3 -27.681 36.716 689 611 11 1

70 VS2-10-F 4 -20.120 20.244 470 385 18 2

100 VS3-9-B 2 -37.590 22.683 407 350 14 1

140 VS3-9-B 2 -38.864 17.420 372 313 16 1

220 VS2-12-F 8 -20.125 21.143 977 817 16 2

250 VS2-11-B 6 -36.361 20.935 842 637 24 1

290 VS2-9-B 2 -37.710 14.444 327 270 17 1

510 VS2-10-F 4 -20.119 20.645 469 384 18 2

540 VS3-9-B 2 -38.289 20.621 408 350 14 1

580 VS3-9-B 2 -39.037 12.653 367 308 16 1

660 VS2-12-F 8 -20.123 21.078 965 806 17 2

690 VS2-11-B 6 -36.844 18.919 895 687 23 1

730 VS3-9-B 2 -37.778 9.661 324 267 18 1

80 VS1-10-B 8.4 -4.705 45.289 650 610 6 1

130 VS2-11-B 5.65 -10.938 49.412 750 688 8 1

240 VS2-10-F 4 -16.491 25.704 452 521 15 1

 DATA SHEET

SPRING HANGER

MATERIAL OF CONSTRUCTION

SPRING 50 Cr. V4 / 60 Cr. 4 V2

CASING PIPE ERW (MEDIUM)

PLATES & RODS IS 2062 GR. A / B

TURN BUCKLES FORGED

NAME PLATE ALUMINIUM

PAINT SYNTHETIC ENAMEL

SUPPLIER’S ADDRESS:
M/S. SESHA ENGINEERING WORKS
PLOT NO.7, H.NO.10-133, STREET NO.12,
HMT NAGAR, NACHARAM,
HYDERABAD - 500 007.
 DATA SHEET

STRAINER

DESCRIPTION SPECIFICATION

GENERAL DATA:

MAKE M/S. ASIAN INDUSTRIAL SYSTEMS

APPLICATION HP DOSING LINE LP DOSING LINE

QUANTITY 2 NOS. 2 NOS.

TAG NO. B1-STR501 & B1-STR502 B1-STR001 & B1-STR002

TYPE ‘Y’ TYPE ‘Y’ TYPE

MEDIUM TRISODIUM PHOSPHATE HYDRAZINE AND WATER

WATER MIXTURE MIXTURE

MAX. WORKING PRESSURE 15 Ksc(g) 15 Ksc(g)

WORKING TEMPERATURE 45°C 45°C

MESH SIZE 40 MESH 40 MESH

HOUSING MATERIAL SS 304 SS 304

MESH MATERIAL SS 304 SS 304

END CONNECTION SCREWED BSP (F) SCREWED BSP (F)

BODY SIZE 25 NB 25 NB

SUPPLIER’S ADDRESS:
M/S. ASIAN INDUSTRIAL SYSTEMS,

B-16, INDUSTRIAL AREA

MOGAPPAIR EAST

CHENNAI - 600 037