SIEMENS Gearless Drive Assembly Schedule

Apex Silver Mines Co.
/ USA Date: 2005-07-28

ASC San Cristobal Page: 1 of 14
I&S IP MIN / P-10005970
Assembly Schedule Gearless Drive
1 SOLEPLATES 2
2 STATOR 3
3 ROTOR SEGMENTS 5
4 SLIPRING / TOOTH SEGMENTS FOR THE TACHO-GENERATOR 7
5 ALIGNING THE STATOR 9
6 WINDING SHIELDS 10
7 MONITORING DEVICES 11
8 HEAT EXCHANGER, FANS, ANTI-CONDENSATION HEATERS 12
9 ELECTRICAL CONNECTIONS 12
10 Final inspection 14

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Apex Silver Mines Co. / USA Date: 2005-07-28
I&S IP MIN / P-10005970
1 SOLEPLATES
1.1 Clean all parts of the machine in accordance with Siemens Factory
Instructions Module D 625 Operating Instructions.
D625
After completion of work signed by:
Siemens Rep. Name/Date Client Rep. Name/Date
1.2 Inspect the foundations and lay the alignment plates in accordance with MS
100-220.
MS100-220

I&S IP MIN / P-10005970
1.3 Lay and align the soleplates in accordance with Siemens Factory Instructions
Module 723 Operating Instructions.
M723
1.4 The soleplates are not to be grouted until the stator has been installed and
finally aligned.
2 STATOR
2.1 For rotating of each stator quart two cranes are required. Each crane with a
safe handling load of one stator quart.
2.2 Unpack and clean the stator segments
2.3 Lift and slide the two lower quarters onto the soleplates on the foundations in
the required position for assembly. Bolt up the lower joint temporarily.
2.4 Rotate the upper quarts from the transport position to the assembly position.
This requires the use of two cranes.
Note: When an upper quarter is being turned the segment will, due to the
position of the centre of gravity tend to swing over by itself. It is essential to use
suitable restraining chains (10 t) in order to keep the segment under control.

I&S IP MIN / P-10005970
2.5 Place the two upper quarters in position and bolt up the three joints
temporarily.
2.6 Make suitable shims for stator core joints according to the measuring
protocols of fabrication and insert them. See Siemens Factory Instructions
Module 745 Operating Instructions.
M745
2.7 Tighten all joint bolts to the pressure values indicated in the drawing by using
the special tool supplied by Siemens.
2.8 Insertion of the separate delivered winding coils, connections to the ring
circuit conductors and brazing of the windings.
Note: This work requires scaffolding to provide access to all the joints.
A resistance, high-voltage and insulation test must be carried out on the coils and
complete stator housing.
For these works the I&T's and documents are existing separately.

I&S IP MIN / P-10005970
3 ROTOR SEGMENTS
3.1 Measure the mill flange together with the mill builder's representative to
ensure dimensional accuracy.
3.2 Unpack and clean the pole segments.
3.3 Fit the segments to the mill flange and bolt them up temporarily with the two
centre bolts. See Siemens Factory Instructions Module 755 Operating
Instructions.
M755
Note: This job requires the jacking-oil system for the mill bearings to be in
operation since the mill has to be rotated a number of times.
For rough alignment when fitting the segments to the mill flange, insert two spacers
between the body of the mill and the rotor plate. Ascertain the size of the spacers
from the text in the dimension drawing.
3.4 Concentricity and diameter checks after installation of all pole segments.
For the concentricity check, mount two dial gauges at the drive and non-drive ends
of the pole core assembly. Switch on the jacking-oil system for the mill bearings
and rotate the mill slowly and continuously while recording the gauge readings

I&S IP MIN / P-10005970
To ascertain the diameter of the rotor, shift the stator over the rotor poles and
measure the air gap. Record the measurements and remove the stator again
afterwards.
3.5 Align the pole segments to match the concentricity of the rotor and the
diameter (i.e. the air gap).
When the required values of concentricity and diameter have been achieved,
insert the two external fitting bolts together with the eccentric bushes and fit the
anti-twist pins.
Then tighten all the bolts with the special tool to the pressure values specified in
the drawing.
3.6 Provide the electrical connections by fitting the bolted copper lugs between
the individual pole segments.

I&S IP MIN / P-10005970
4 SLIPRING / TOOTH SEGMENTS FOR THE TACHO-GENERATOR
4.1 Unpack and clean the slipring segments and measure the insulation
resistance.
4.2 Fit the slipring segments to the pole segments and tighten the fixing bolts
temporarily.
4.3 Bolt up the joints and make the electrical connections.
4.4 Concentricity check of the positive and negative sliprings by dial gauge.
Repeat the alignment procedure until the required values have been achieved and
then finally tighten the fixing bolts.
Note: It is essential for the fixing bolts to be tightened with a torque wrench.

I&S IP MIN / P-10005970
4.5 Smooth off the slipring butt joints with a belt grinder and perform a final
concentricity check. Record the measurements.
4.6 Fit the tooth segments and align them as indicated in the drawing with the
special device supplied by Siemens. Measure the axial runout and record the
measurements.

I&S IP MIN / P-10005970
5 ALIGNING THE STATOR
5.1 Shift the stator over the rotor and align them roughly.
5.2 Measure the air gap and the magnetic centre and align the stator accordingly.
See Siemens Factory Instructions Module 893 Operating Instructions.
M893
Note: The jacking-oil system should be switched on when taking the air gap
measurements.
5.3 Tighten the fixing bolts with the special device to the pressure values
specified in the drawing.

I&S IP MIN / P-10005970
6 WINDING SHIELDS
6.1 Fit the drive-end and non-drive end winding shields and any other shields as
indicated in the drawing.
6.2 Fit the V-seals, the brushes and the lubrication piping.

I&S IP MIN / P-10005970
7 MONITORING DEVICES
7.1 Fit the mounting plates for the tacho-generator and the mounting plates for
the proximity sensors in the drive-end winding shield.
7.2 Fit all Pt 100 thermometers, flow sensors, proximity sensors, optical sensors
and install their control circuits.
7.3 Install the current transducers at the neutral point.

I&S IP MIN / P-10005970
8 HEAT EXCHANGER, FANS, ANTI-CONDENSATION HEATERS
8.1 Install the heat exchangers, fans and anti-condensation heaters
9 ELECTRICAL CONNECTIONS
9.1 Install all the internal wiring and connect up as shown in the circuit diagram.

I&S IP MIN / P-10005970
9.2 Install and connect the power leads from the ring circuit conductor to the
terminal boxes.
9.3 Mount the brush-holder supports on the drive-end winding shield, adjust the
brush-holders and fit the brushes.
9.4 Connect the external power leads and exciter leads.
Note: Carry out all electrical connections in accordance with AR 161-220.
AR161-220

I&S IP MIN / P-10005970
10 FINAL INSPECTION
10.1 Clean the interior of the motor with a vacuum cleaner.
10.2 Carry out a final inspection in accordance with AR 191-220.
AR191-220


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Apex Silver Mines Co.

/ USA Date: 2005-07-28

Assembly Schedule Gearless Drive

4 SLIPRING / TOOTH SEGMENTS FOR THE TACHO-GENERATOR 7

5 ALIGNING THE STATOR 9

8 HEAT EXCHANGER, FANS, ANTI-CONDENSATION HEATERS 12

Assembly Schedule Gearless Drive

Assembly Schedule Gearless Drive

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

Assembly Schedule Gearless Drive

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

2.2 Unpack and clean the stator segments

Assembly Schedule Gearless Drive

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

Assembly Schedule Gearless Drive

3.2 Unpack and clean the pole segments.

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

Assembly Schedule Gearless Drive

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

Assembly Schedule Gearless Drive

4 SLIPRING / TOOTH SEGMENTS FOR THE TACHO-GENERATOR

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

4.3 Bolt up the joints and make the electrical connections.

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

Assembly Schedule Gearless Drive

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

Assembly Schedule Gearless Drive

5 ALIGNING THE STATOR

See Siemens Factory Instructions Module 893 Operating Instructions.

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

Assembly Schedule Gearless Drive

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

Assembly Schedule Gearless Drive

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

After completion of work signed by:

Siemens Rep. Name/Date Client Rep. Name/Date

7.3 Install the current transducers at the neutral point.