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MANUFACTURING AND INSPECTION PLAN PFI – 2001i

ABNT / IEC 63 TO 355 AND Edition 1ª-07/2004


FRAMES NEMA 143 TO 587 Sheet 01/05
Review 2-04/2006

Origin: Quality Planning Section

Purpose: This Manufacturing and Inspection Plan has the p urpose to inform the customer about the manufacturing flow chart and
the procedures in the inspe ction of electric motors.

Note: The non-controlled copies of this plan are subject to changes without previous notice.
SEVERAL INSULATED COOPER STEEL
ALUMINIUM PIG IRON STEELBAR
PARTS CABLES ROD PLATES

SEVERAL SQUIRREL CAGE


COPPER WIRE STATOR ROTOR FAN COVER ROTOR CASTINGS SHAFT

DRAW ING STAMPING STAMPING STAMPING MELTING MELTING MOLDING MACHINING


C
Ó
PI
A
N
ÃO
THERMAL PRESSING
ENAMELING PHOSPHATTIZATION DIE CASTING DIE CASTING MELTING
TREATMENT SQUIRREL CAGE
PAINTING
ROTOR
C
O
N
CASTING
CLEANING
TR
O
LA
D
CLAMPING
A

CASTING MACHININGOF MACHINING


PRESSING
CLEANING CASTS PARtS COMPLETE ROTOR
SQUIRREL
CAGE
ROTOR

PRESSING
WOUND
WINDING STATOR
FRAMES 364
UP TO 587

MACHINING
IMPREGNATION

ASSEMBLING

SIMBOLOGY
MOTORTEST

- Quality Inspection - Raw Material

MOTOR - Manufacturing Process


ASSEMBLING
- Product
- Quality Control Component

- Transport
- Process
- Product Storage Identification
SHIPMENT

Verification: Gustavo Gamberalli Approval: Paulo Henrique Nicolau


MANUFACTURING AND INSPECTION PLAN PFI – 2001i
ABNT / IEC 63 TO 355 AND Edition 1ª-07/2004
Sheet 02/05
FRAMES NEMA 143 TO 587 Review 2-04/2006
Quality Records Participation
Applicable Inspected Inspec- Γ customer
Flow Chart
Documents Characteristics tion With Records Γ third parts
Fre- W/O
quency NR RA Mod. File Lot/Item OV RV CR
INCOMING MATERIAL INSPECTION
1. Several Components
Bolts CQR-066
Fan CQR-074 Visual / Dimensional
Key CQR-062
Wavy Washer CQR-143
Noise / Visual /
Bearing CQR-037
Dimensional
Elastic Pin CQR-045
Hexagon Nut CQR-040
C
Visual / Dimensional
Washer CQR-056 Ó
Circlip CQR-057 PI
Eye Bolt CQR-163
A
2. Insulating Material /
N
Cables
ÃO
Solid Content
Varnish CQR-031 Spec. Weight
C
Viscosity O
Visual / Dimensional
CQR-041
N
Cable Electric voltage
TR
CQR-105 Thermal Shock O
Visual / Dimensional LA
High voltage
Polyester CQR-042
Aging D
Thermal Resistance A
Visual / Dimensional S X
Insulating tube CQR-043 Disruptive voltage
Thermal aging
Visual / Dimensional
3. Copper Rod CQR-065
Chemical composition

4. Enameled Wire CQR-047 Visual / Dimensional

Visual / Dimensional
CQR-051 Electric Losses
CQR-007 Chemical
Composition

5. Steel Plates Visual / Dimensional


Mechnical
CQR-135 Characteristics
Chemical
Composition

CQR-080 Visual / Dimensional

Visual
Chemical
6. Aluminum 99,7% CQR-028
Composition
Electric Conductivity
Chemical
7. Pig Iron CQR-008
Composition
Visual / Dimensional
Chemical
8. Steel Bar CQR-046
Composition
Mechanical Charact.
MANUFACTURING AND INSPECTION PLAN PFI – 2001i
ABNT / IEC 63 TO 355 AND Edition 1ª-07/2004
FRAMES NEMA 143 TO 587 Sheet 03/05
Review 2-04/2006
Quality Records Participation
Applicable Inspected
Inspec- Γ customer
Flow Chart
Documents Characteristics
tion Fre- With Records Γ third parts
quency
W/O
NR RA Mod. File Lot/Item OV RV CR
INSPECTION IN THE PRODUCTION PROCESS
9. Copper Wire
9.1. Drawing TGP-64 Dimensional
X
Dimensional
9.2. Enameling TGP-121
Physical Charact
10. Stator
Visual / Dimensional X
10.1. Stamping
TGP-10 Concentricity
TGP-60
Oven conditional
10.2. Thermal treatment X
Electric. Losses C
10.3. Clamping TGP-13 Visual / Dimensional X
Ó
PI
Visual / Finishing
10.4. Winding TGP-109
Ohmic Resistance
A
TGP-11 Hipot N
TGP-69 ÃO X
TGP-73 Insulation class /
10.5. Impregnation visual
C
TGP-115 O
TGP-8
10.6. Stator Pressing Visual / Dimensional
TGP-33
N
TGP-59
TR
X
11. Fan Cover * O
(63 up to 132 f rames) LA
11.1. Stamping Visual / Dimensional D
TGP-6 Bath condition
11.2. Phosphatizat ion
A
Coat / adherence
Painting
Viscosity
X
12. Several parts
(Aluminum)
12.1 Melting Conductibility
Temperature
TGP-211
12.2 Die casting Visual / Dimensional
Temperature
12.3 Cleaning parts Visual / Dimensional X

12.4. Machining TGP-5 Visual / Dimensional


13. Squirrel Cage Rotor
Conductibility
13.1. Melting X
Temperature
TGP-35
13.2. Die Visual / Dimensional
X
casting(Aluminum) Temperature

* The inspection form and frequency, the acceptance or rejecti on criteria can be found in the applicable documents.
MANUFACTURING AND INSPECTION PLAN PFI – 2001i
ABNT / IEC 63 TO 355 AND Edition 1ª-07/2004
FRAMES NEMA 143 TO 587 Sheet 04/05 Review 2-04/2006

Quality Records Participation


Applicable Inspected
Inspec- Γ customer
Flow Chart
Documents Characteristics
tion Fre- With Records Γ third parts
quency W/O
NR RA Mod. File Lot/Item OV RV CR

INSPECTION OF THE PRODUCTION PROCESS

14. Castings (Foundry)


TGP-98
TGP-40
14.1. Molding TGP-39 Visual X
TGP-23
TGP-154
TGP-80
TGP-68 Chemical
14.2. Melting TGP-37 Composition X
TGP-78 Tensile Strength

14.3. Cleaning of TGP-29


TGP-184 Visual / Finishing
Castings
TGP-81
C
14.4. Machi ning
Ó
*
PI
Frames
TGP-62 A
Endshield TGP-117
Visual / Dimens.
TGP-116
N
Terminal TGP-5
ÃO
box X
Several C
15. Shaft
O
N
15.1 Machining TR
15.2. Squirrel cage rotor TGP-119 Visual / Dimens.
pressing TGP-67
O
TGP-118 LA
15.3. Machining of Visual / Dimens.
complete rotor Radial Beating D
FINAL PRODUCT INSPECTION
A
TGP-115 Component
16. Assembling TGP-8 Checking
X
TGP-33 Visual / Dimens.
TGP-59

Thermal Protection X
Current (no load) X

TIM-251 High voltage test X


TIM-240 100%
17. Final Test ( In Line) Direction of rotation X
TIM-250
Bearing noise X

Magnetic noise X

Rubbing X
TGP-115
TGP-8 Packing
18. Motor packing Marking X
TGP-33
TGP-59 Motor record

* The inspection form and frequency, the acceptance or reject ion criteria can be found in the applicable documents.
PFI – 2001i
MANUFACTURING AND INSPECTION PLAN
ABNT / IEC 63 TO 355 AND Edition 1ª-07/2004
FRAMES NEMA 143 TO 587 Sheet05/05
Review 4-04/2006
Quality Records Participation
Inspec- Γ customer
Flow Chart
Applicable Inspected
tion Fre- With Records Γ third parts
Documents Characteristics
quency W/O Filing
NR RA Mod. Lot/Item OV RV CR
Place
SPECIAL FEATURES
NBR5432

IEC 60072-1 *
19. Dimensional Test Visual / Dimens. *

NEMA MG1
(part 4)
Ohmic Resistance
No-load test
NBR5383 Locked rotor test
20. Routine Test * *
NBR7094 High voltage
C
Ó
Insulation resistance
NEMA MG1 PI
Ohmic Resistance
IEEE STD 112 No-load test
A
Locked rotor
N
IEC 60034-1 Temperature rise ÃO
21. Type Test IEC 60034-2 Load test * *
Max. Torque test *
CSA C390 High voltage
C
Insulation Resistance
O
N
NBR-7565 TR
IEC-60034-9 Noise pressure
22. Noise Level Test * *
Level test in dBA
O
NEMA MG1
LA
(part 9) D
NBR 11390 A
IEC-60034-14 Vibration speed
23. Vibration Test * *
mm/s in RMS
NEMA MG1
(part 7)
Coat
24. Painting Plan NBR 11003 * *
Adherence
* Performed if requested.

TERMINOLOGY

TGP – Process Procedures (WEG) W/O – Without

OV - Obligatory visit PFI -Manufacturing and Inspection plan

RV - Reserves the right of visit NR - Non traceable

CR - Without witness / to send copies of the reports RA – Traceable

PIW - WEG Inspection Plan CQR - Instructions for incoming inspection

S – Sampling

N – Not Performed (only if required)