World Class Power Solutions

Excellent Technology, Efficiency and Quality

Electrical Machine Service

Overhaul, Conditioning,
On-Site Service and Diagnostics
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Your partner for Your partner for
Electrical Machine Service the requirements of tomorrow

BENNING factory II
Robert-Bosch-Straße 20, 46397 Bocholt, Germany

Maintenance, Reproductions and Diagnostics We offer:

Since more than 7 decades machine repairs represents an
• Qualified employees
essential part of the companies’ activities.
Today the company offers a large range of high quality service • Advanced manufacturing processes
applications and some manufacturing of electrical motors
h s e r v i c e :
additional to the standard repair service.
• Diagnostic reports
24 3 888
Customers are located in Germany and in neighbour coun- • Performance analysis
(0 ) 2 8 7 1 / 9
phone: +49
An overhauled synchronous motor tries.
• Short delivery time
with a capacity of 8400 kW
in our maintenance shop In two plants more than 700 employees develope • Short delivery periods due to high amount
and produce a recognized product range. of spares and materials on stock

BENNING is the leading manufacturer of power

supply. Overhaul of a 2000 kW DC motor
with armature rewinding
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Diagnostics by using Decades of experience
up-to-date equipment and reliability

Thermographic image

Partial discharge test of an electrical machine

in good condition (graphics above)

CNC stamping of laminations Core stacking

Partial discharge test of an electrical machine Electrical performance analysis, for example HV-testing,
in critical condition impulse testing, PD-test, loss tangent acc. EN, IEC, VDE.

Condition monitoring for cost effective maintenance Manufacturing of laminations

Manufacturing of laminated rotors and stators produced by
Extract of tests and services: stamping or laser cutting technology.
• Insulation resistance test
• Insulation test
• Partial discharge (PD)
• Baker test
• Tan-delta test
• Polarization index (Pi test)
• Frequency analysis
• Vibration test
• Noise testing
• Laser alignment
• Thermographic image

BENNING service vehicle

Laser cutting technology

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Standard scope Craftsman’s tradition
of overhaul and state of the art technology
Our standard scope of overhaul includes Organizational sequence of maintenance
the following services: and repair tasks
• Record of performance data You supply the machine specifications, such as manufactur- If you place your order, we draw up an inspection report after
• Control of overall machine condition er, type, capacity, voltage, rotational speed, model, type of dismantling and testing the windings and mechanical parts.
• Checks of all machine parts and auxiliaries bearing, etc., as well as the potential damage.
(such as external fans, speed detectors, brakes, sensors, etc.) We prepare an offer comprising the respective scope of
• Dismantling of machine repair work.
• Visual checks and dimensional measurement of all
machine parts, such as bearings seats, fits, centering fits,
bearing shells, shaft ends, keyways, etc.
• Run out check
• Bearing check

DC rotor after re-winding (1,600 kW, 8 t, 600 rpm)

Assembling and preparation of machines Control of electrical parts

• Cleaning of all machine parts and windings by special • Check of windings and winding support elements
cleaning treatment incl. drying procedure by vacuum-oven • Check of press fit of cores and slot wedges
treatment • Check of banding insulation, terminal boxes, terminal
• Control of cleaning results and electrical measurements bolts, insulators and winding leads
after cleaning • Check of rotor cage in order for cracks in rotor bars and Additional scope of work
• Impregnation of existing windings short-circuit-rings In case other originally unknown damages on the machine
• Dynamic balancing of rotors • Check and overhaul of brush-arrangements are found during this inspection, which we think should be
• Check of sleeve bearings (white metal, bearing clearance, • Overhaul slip-ring surfaces by turning procedure repaired, we draw up an additional offer. The decision
appearance of bearing surface after bedding in) incl. auxil- • Check of pole fastening of salient pole rotors regarding the execution of this additional repair work is made
iaries such as oilrings, sealings etc. • Adjust salient pole fixing after consulting you.
• Change of antifriction bearings • Adjust commutator fixing
• Change and replacement of all screws • Check connection between windings and commutator
• Test-run incl. bearing check and vibration check • Overhaul commutator by turning procedure
• Electrical test acc. to latest standards EN, IEC, VDE • Adjust commutator by segment cutting procedure
• Repainting the machine • Sawing out mica and adjust shape of edges of segments
• Thermographic image

New winding
of a HV stator
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Craftsman’s tradition High quality reproduction and retro fitting of
and state of the art technology AC and DC machines, special drives and transformers
Experienced winding experts
BENNING manufactures HV-windings up to 11 kV nominal volt-
age using latest technologies.
Coil inserting, electrical connections, providing winding overhang Original machine and reproduction:
supports is carried out by experienced staff in our winding shop. DC motor, 780 kW, 500/100/1500 rpm
Wound stators run through a process of vacuum impregnation
and drying process using high quality materials.

BENNING guarantees
Competent order execution by experienced staff.
Preparation of design and testing documentation.

Modification of existing machines, such as:

• Changes of nominal power

• Increase of efficiency
• Noise reduction
• Modification of bearing arrangement

DC rotor,
1400 kW 1500 rpm
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Technical know-how is our strength Cleaning is a core competence for overhaul activities
Grinding of commutator, spot welding Cleaning with dry ice or solid carbon dioxide snow
Environment-friendly and cost effective
Dry ice cleaning ensures an environment-friendly and cost
effective method of cleaning for surface treatment.

While other blast cleaning methods are based on using sand,

glass, water, steam or solvents have an impact on environ-
ment, dry ice cleaning is uncritical in this respect.

Further on the dry ice equipment can be used for on-site

services as well.

The above detail of the foto shows the comparison

of a dry-ice cleaned part before and after cleaning.

BENNING overhaul services comply with highest Long term experience for cleaning of:
requirements • Electrical motors
The commutator´s copper segment is scanned by a laser The grinding tool is operating with a speed of 9000 rpm. • Generators
device. • Turbines and other driven equipment in many applications
and customer sites
Spot welding
Winding bars and round-wire windings can be welded to the
commutator risers ensuring a high quality.
This ensures a high amount of operational safety of the
machine especially when operating in higher thermal classes
(e.g. traction applications).

Spot welding at a Dry ice cleaning of a generator rotor on job site

commutator
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Explosion protected machines (ex) Mechanical machining
Mobile test bench Flexibility and high precision
By developing a mobile test bench (for AC and DC Safety and testing
motors) BENNING offers a solution for no-load- Up-to-date maintenance requires diagnostic measures from
motor testing beginning to delivery.
• Test bench will be delivered as “ready for use” All machines have to pass a final test run in our own test
• Recording of test values facility.
• Easy operation by touch panel
• 3˜ or DC version available
• Incl. CE connector
• Made for motor service center or enduser´s service shops

SCCP

Know-how in the field of special machines

Overhaul and repair activities of explosion protected machines
requires to fulfil several standards and legal requirements.
BENNING is certified to carry out services for explosion pro-
tected machines (ex-machines incl. machines for use in zone
0, 1, 2, 20, 21, 22)

Test bench for functional-checks

and performance data testing

Motors for mining

application Zone 0
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Mechanical machining Manufacturing and re-design
Flexibility and high precision of machine parts

CNC Turning machine

Examples of machine parts

Mechanical machining for Duplicates of machine parts: manufactured by BENNING
professional manufacturing of components Several machine parts and components made of copper,
High precession CNC turning machines are directly linked to Due to additional machining devices, drilling and grinding steel, aluminium etc. can be manufactured as new parts,
an AUTOCAD (3D) system. operations (such as grinding of keyways) can be machined even if there are no more drawings available from
The system has a capability to machine shafts up lengths of by using the same clamping. the original machine manufacturer.
4500 mm.
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Let our service

convince you
Service package
Time is money. And this fact especially applies to unnecessary Supervised by competent specialized site managers, the BENNING
shut down periods and the resulting consequences. maintenance-crew carries out installation and overhauling tasks
Therefore BENNING has, in accordance with the customer’s on job sites in Germany and abroad.
wishes, optimized the execution of repair work in the plants, as
well as by the service team on job sites. The BENNING service vehicles are equipped with state of
the art measuring and installation tools for all types of outside
maintenance tasks.

These maintenance tasks comprise:

• Execution of diagnostic, inspection and repair tasks on site

10123459.20 GB 07/2016 paus Design & Medien, Bocholt Subject to alterations. Printed on chlorine free paper.
• Dismantling and assembling of machines

• Execution of balancing work, vibration measurements and

bearing performance checks

• Supplementary installation of additional equipment

(Thermometers and temperature sensors, tacho-genera-
tors, stand still heaters, etc.)

• Commissioning

BENNING Elektrotechnik und Elektronik GmbH & Co. KG

Robert-Bosch-Str. 20 • 46397 Bocholt
Tel.: +49 (0) 28 71 / 93-269 • Fax: +49 (0) 28 71 / 93-6425
E-Mail: bem@benning.de • www.benning.de
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