Based on the provided documents, **RepairMonitor** by **MachineMonitor** follows a structured and comprehensive process for managing the repair and overhaul of high-voltage wound rotor induction motors (WRIM). This process ensures that repairs are conducted efficiently, meet technical standards, and are thoroughly documented. Below is a summary of the key steps involved in the repair management process as outlined in the files:

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### **1. Transport and Packing**

- **Objective**: Safely transport the machine to the repair facility while protecting it from damage.

- **Key Actions**:

- Use anti-vibration measures (e.g., rubber under feet).

- Secure the machine with chains at lifting lugs and install shaft locking devices.

- Cover the machine with a tarpaulin during transport.

- Pack the machine for long-term storage unless otherwise specified.

- **Compliance**: The contractor must meet specific transport requirements, with evidence of compliance documented.

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### **2. Dismantle, Cleaning, Initial Inspection, and Report**

- **Objective**: Disassemble the machine, clean it, perform initial inspections, and generate a detailed report.

- **Key Actions**:

- Record the machine’s condition upon receipt, including insulation resistance.

- Dismantle the machine and clean all components using approved methods.

- Conduct initial electrical and mechanical surveys (e.g., insulation resistance, resistance measurements, visual inspections).

- Submit an **Opening Report** within two working days, including:

- Results of inspections and tests.

- An Inspection Test Plan (ITP) and Gantt chart for the repair timeline.

- Recommendations for extra work, if needed.

- **Compliance**: The contractor must provide objective quality evidence (OQE) for each task, and any extra work requires a detailed quote.

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### **3. Approval to Proceed**

- **Objective**: Obtain formal approval from the client (Principal) before proceeding with repairs.

- **Key Actions**:

- The contractor submits the Opening Report for review.

- The Principal provides written approval to proceed based on the report’s findings and recommendations.

- **Compliance**: No repair work begins without written authorization from the Principal.

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### **4. Investigations (if required)**

- **Objective**: Investigate any failures or specific conditions identified during the initial inspection.

- **Key Actions**:

- Conduct a detailed investigation, including photographs, descriptions, and likely causes of failure.

- Submit a fully documented failure report to the Principal.

- **Compliance**: The contractor must provide a comprehensive report, and the Principal may involve a third party for independent investigation.

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### **5. Electrical and Mechanical Surveys**

- **Objective**: Perform in-depth electrical and mechanical tests to assess the machine’s condition.

- **Key Actions**:

- **Electrical Survey**:

- Stator winding tests (e.g., IR/PI, DDF, partial discharge, resistance measurements).

- Rotor winding tests (e.g., IR/PI, resistance, impedance).

- Ancillary equipment tests (e.g., brushgear, heaters, temperature detectors).

- **Mechanical Survey**:

- Shaft cleaning and checking (e.g., journal size, run-out, keyway condition).

- Bearing and clearance checks, including insulation resistance for insulated bearings.

- Inspection of ancillary equipment (e.g., fans, couplings, heat exchangers).

- **Compliance**: All tests must meet specified standards (e.g., AS1359, IEEE standards), with results documented in the Opening Report.

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### **6. Repair/Overhaul of Windings (if required)**

- **Objective**: Repair or overhaul the stator and rotor windings based on survey findings.

- **Key Actions**:

- Clean and bake the windings using approved methods (e.g., solvent wash, cryogenic blast).

- Conduct wedge surveys and repairs if necessary, with risk assessments for extensive work.

- Apply remedial repairs to stress grading and corona protection.

- Ensure all materials used are compatible and meet safety standards.

- **Compliance**: The contractor must follow approved procedures and provide material safety data sheets (MSDS) for all materials used.

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### **7. Assembly**

- **Objective**: Reassemble the machine to operational condition.

- **Key Actions**:

- Reassemble all components, ensuring correct torque settings for fasteners.

- Install brushgear, ensuring proper alignment and tension (e.g., 1200g pressure for tensators).

- Replace or refurbish nameplates and terminal boxes as needed.

- Apply anti-seize compound to threaded fasteners.

- **Compliance**: The contractor must record all torque settings and ensure brushgear meets OEM specifications.

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### **8. Final Testing**

- **Objective**: Verify the machine’s performance and compliance with standards.

- **Key Actions**:

- Conduct insulation resistance (IR) and polarization index (PI) tests before other tests.

- Perform open circuit rotor voltage balance and locked rotor tests.

- Run a functional no-load test for at least 2 hours, monitoring bearing temperatures.

- Measure vibration levels and shaft-to-ground voltage.

- Confirm the magnetic center and brush alignment on slip rings.

- **Compliance**: All test results must meet specified criteria, with detailed records provided.

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### **9. Painting**

- **Objective**: Apply protective and aesthetic coatings to the machine.

- **Key Actions**:

- Prepare surfaces manually and apply paint (e.g., "Signal Red") as specified.

- Protect nameplates and other sensitive areas from overspray.

- **Compliance**: The contractor must follow the specified painting procedure and provide evidence of compliance.

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### **10. Reporting**

- **Objective**: Compile a comprehensive closing report documenting the entire repair process.

- **Key Actions**:

- Include details from the Opening Report, all test reports (electrical, mechanical, balance, no-load), and material safety data sheets.

- Provide a statement of compliance with applicable standards.

- Submit the closing report to the Principal.

- **Compliance**: The closing report must be complete and submitted as part of the final deliverable.

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### **Additional Key Elements**

- **Hold/Witness Points**: The process includes specific points where the Principal may inspect or witness activities (e.g., during final testing or painting) to ensure quality control.

- **Standards and Codes**: All work must comply with relevant standards (e.g., AS1359, IEEE, ISO), and the contractor must provide a compliance checklist.

- **Documentation**: Objective Quality Evidence (OQE) and images are required for each step to verify compliance.

- **Third-Party Involvement**: The Principal may involve third-party contractors for specific tasks (e.g., failure investigations), and all third parties must be approved in writing.

### **Summary**

The repair management process for high-voltage WRIMs through **RepairMonitor** by **MachineMonitor** involves a meticulous, step-by-step approach that ensures the machine is repaired to the highest standards. From initial transport and inspection to final testing and reporting, each phase is carefully documented and subject to strict compliance checks. The process emphasizes quality control, adherence to technical standards, and transparent communication with the client (Principal) at every stage. This structured approach minimizes risks, ensures operational reliability, and provides a clear audit trail for future reference.