Information
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Audit Title
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Audit No.
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Report Revision No
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Conducted on
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Audit Team
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Personnel
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Audit Objectives (may include determining the extent of conformity of the system, evaluation of the capability of the process, evaluation of the effectiveness of the management system in meetings specified goals, identification of areas for potential improvement, etc)
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Audit Scope (Extent and boundaries of the audit)
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Audit Criteria (Set of policies, procedures or requirements used as a reference against which audit evidence is compared)
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Audit Process / Plan (Description of the activities and arrangements for the audit).
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Location
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Client / Site
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Report Prepared by
EASA Accreditation Audit Checklist Notes
Scope
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The EASA Accreditation Program applies only to three-phase, squirrel-cage motors that are repaired in accredited service centers. As such, the scope of the program includes mechanical repairs as well as electrical rewinding.
Notes
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The auditor shall record the audit outcome for each item on the Accreditation Checklist by marking the corresponding check box as follows:
S - Satisfactory
U - Unsatisfactory*
N - Not observed**
N/A - Not applicable***
* Description of any unacceptable condition(s) shall be provided.
** Applicable mandatory criteria not observed in a prior audit must be observed at the next scheduled audit; the auditor’s comments shall also include the reason(s) that the criteria could not be observed.
*** Criteria that do not apply to a specific service center
The auditor shall review the service center’s calibration program and the calibration status of associated equipment. See Annex A for list of equipment that must be calibrated.
For each criteria the service center shall record all applicable tests and measurements made with calibrated equipment.
Audit criteria categories:
All criteria on the EASA Accreditation Audit Checklist are mandatory. To complete an audit, the service center must submit to an audit and receive a Satisfactory (S), Not Observed (N) or Not Applicable (N/A) score on each checklist item. Any checklist criterion marked “Unsatisfactory” will require Corrective Action (CA) that the auditor will specify and review.
Opening and Closing Meetings
Opening Meeting (Pre-audit Briefing)
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Date and Time of Opening Meeting
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Location
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Attendees
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Brief Included
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Additional Comments
Closing Meeting
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Date and Time of Closing Meeting
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Location
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Attendees
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Brief Included
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Additional Comments
Notes
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EASA Accreditation Audit Checklist (Version 2.0)
Scope:
The EASA Accreditation Program applies only to three-phase, squirrel-cage motors that are repaired in accredited service centers. As such, the scope of the program includes mechanical repairs as well as electrical rewinding. -
The auditor will record the audit outcome for each item on the Accreditation Checklist by marking the corresponding check box as follows:
S - Satisfactory
U - Unsatisfactory*
N - Not observed**
N/A - Not applicable***
* Description of any unacceptable condition(s) will be provided.
** Applicable mandatory criteria not observed in a prior audit must be observed at the next scheduled audit;
the auditor’s comments must also include the reason(s) that the criteria could not be observed.
*** Criteria that do not apply to a specific service center
General Information
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Type of building:
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Type of activities carried out:
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Approximate area (Sq metres):
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No of floors:
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No of personnel in area:
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Name(s) of Supervisor(s) or area in charge:
Service Centre - General
A. House Keeping
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Work areas and equipment are clean and orderly, by auditor observation.
B. Training
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Internal training of technicians is documented.
C. Internal Audits
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Annual internal audits are performed and documented.
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Annual internal audit reports are submitted to external auditor for review.
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If applicable, corrective actions for internal audits findings are taken and documented.
1. Identification and condition assessment
Criteria
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Original nameplate data of repaired motors is documented; or document if nameplate is not present or illegible.
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Shop order number is permanently marked on motors received for repair.
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Records of each shop order are established and retained for at least 3 years after repair.
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The primary cause of failure is determined, if possible, and documented in the repair record.
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Job records document findings during incoming inspections, such as physical condition, mechanical damage, and evidence of overheating; and customer's reason for repair.
2. Terminal leads, connectors and boxes
Criteria
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Terminal leads of completed repairs are labelled.
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Terminal lugs, if so equipped, are properly crimped.
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Size and type of replacement lead wire are documented.
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Terminal box integrity (e.g., not damaged) is checked.
Equipment
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Confirm calibration and functionality of associated equipment.
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Terminal crimpers function checked at least quarterly for wear and proper crimp by service centre.
3. Cooling System
Criteria
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Fan and fan cover integrity (e.g. not damaged) are checked.
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Check is performed for evidence of damaged or missing cooling system parts.
4. Shafts
Criteria
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Shaft integrity (e.g., not damaged or worn) is checked.
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Mounting position of the shaft in relation to the leads (e.g. F1 or F2) is noted.
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Initial and, if applicable, after repair shaft dimensions and run out are documented.
Equipment
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Confirm calibration and functionality of associated equipment.
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Outside micrometres.
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Dialed indicators verified by service centre.
5. Bearings (ball, roller; sleave)
Criteria
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Visually inspect bearings for evidence of fretting, fluting, scoring or other damage.
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As-received, and if repaired, post-repair bearing fit dimensions are documented.
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If repaired, rolling bearing fits are built to applicable AR100 table size.
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Replacement bearings are equivalent to the original or are better suited to the application; and original and replacement bearing numbers are documented.
Equipment
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Confirm calibration and functionality of associated equipment.
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Inside micrometers (including bore gauges).
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Outside micrometers.
6. Lubrication
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Lubricant used is compatible with the customer's lubricant; and lubricant used by service centre is documented.
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In the absence of the motor manufacturer's lubrication instructions; the grease reservoir is filled to approximately 1/3 capacity.
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If motor is oil-lubricated, there is a means to indicate proper oil level.
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If motor is oil lubricated, check is performed for evidence of lubricant leakage.
7. Frame and bearing houseings
Criteria
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Frame and bearing housing integrity (e.g., not damaged) are checked.
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Check is performed for evidence of damaged or missing frame or bearing houseing parts.
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Parts are match-marked in accordance with service center policy.
Equipment
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Confirm calibration and functionality of associated equipment.
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Inside micrometers (including bore gauges).
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Outside micrometers.
8. Squirrel cage rotors
Criteria
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Check is performed for rotor damage.
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Rotor core is checked for tightness on shaft or spider.
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If repaired, original electrical and mechanical characteristics are maintained. Repair method used is documented.
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Rotor is growler and/or single-phase tested. Test results are documented.
Equipment
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Confirm calibration and functionality of associated equipment.
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Growler (functionality).
9. Balancing
Criteria
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Dynamic balancing of the rotating element is to the level specified by the customer; or in the absence of a requested level, dynamic balance is to ISO quality grade G2.5 or better for machines rated 2500 rpm or slower, and to the level of grade G1.0 or better for machines rated above 2500 rpm. Original and final balance values are documented. Exception: Rotors of shaker (vibrator) motors do not need to be balanced
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Balance weights are located so as not to interfere with other components.
Equipment
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Confirm calibration and functionality of associated equipment.
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Balancing machine (calibration by service center or outsource firm).
10. Accessories
Criteria
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Space heaters are tested for rated current or power at rated voltage and subjected to a ground insulation test.
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Bearing and winding sensors or protectors are identical with or equivalent to the original devices in electrical and thermal characteristics.
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Check is performed for evidence of damaged or defective accessory components.
Equipment
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Confirm calibration and functionality of associated equipment.
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Ammeter and voltmeter or
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Megohmmeter or
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Ohmmeter
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Wattmeter
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High-potential tester
11. Winding removal and core integrity
Criteria
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Core testing is performed before burnout or other equivalent process, and after winding removal, and the results are documented. Evaluation assessment of core<br>acceptability (watts per lb or kg and temperature rise) is documented.
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Burnout oven has part temperature limited to 700°F (370°C) or less, analog or digital recorder; and water mist system is functional.
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If core test losses increase more than 20% between the before and after winding removal tests, the core is repaired or replaced.
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Parts are oriented and supported in oven so as to avoid distortion.
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Check is performed that core slots are clean and free of sharp edges or particles.
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Core teeth are not splayed (i.e., flared at ends of slots).
Equipment
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Confirm calibration and functionality of associated equipment.
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Temperature meter.
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Water mist system (functionality).
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Analog/digital recorder.
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Core tester (wattmeter, ammeter and voltmeter integral with tester).
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or loop test with seperate/standalone:
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Wattmeter
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Ammeter
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Voltmeter
12. Rewind data (specification)
Criteria
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Details of old winding are documented (e.g., EASA Polyphase Winding Data Card).
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Winding data is verified for accuracy.
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Winding changes made to maintain or improve efficiency of a rewound motor are documented.
13. Stator windings, insulation systems, conductors and coils
Criteria
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Voltage rating and insulation class of winding system are equal to or greater than the original, unless redesigned by agreement with, or at the instruction of, the customer.
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Coil extension lengths are not to exceed original.
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Winding wire cross-sectional area per amp is equal to or greater than original.
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Random coils are wedged with full-length top sticks, and phase insulation is used.
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Form coils are wedged and fit securely in slots; and wedges are tight in wedge grooves.
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Magnetic wedges are replaced with equivalent magnetic wedges.
Equipment
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Confirm calibration and functionality of associated equipment.
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Outside micrometer.
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Coil winding machine turns counter (accuracy verified by service center).
14. Winding impregnation
Criteria
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Windings of rewound motors are preheated, varnish/resin treated and cured in accordance with varnish/resin manufacturer’s instructions.
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Bake oven temperature control set in accordance with varnish/resin manufacturer’s instructions.
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Varnish is maintenance tested in accordance with manufacturer’s instructions. Test results and any maintenance actions are documented.
Equipment
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Confirm calibration and functionality of associated equipment.
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Temperature meter.
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Vaccum pressure imprgegnation (VPI) process (if applicable):
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Vacuum gauge.
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Pressure gauge.
15. Winding insulation and coil tests
Criteria
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Stator winding insulation resistance is measured, and results are documented.
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Stator winding resistance is measured, and results are documented.
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Stator winding surge comparison test is performed, and results are documented.
Equipment
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Confirm calibration and functionality of associated equipment.
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Megohmmeter.
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Ohmmeter or milli-ohmmeter (as applicable).
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Surge tester.
16. High-potential tests
Criteria
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High-potential test new and reconditioned windings and document results.
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High-potential test accessories of new and reconditioned windings and document results.
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Windings and accessories of windings not reconditioned are insulation resistance tested, and results are documented.
Equipment
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Confirm calibration and functionality of associated equipment.
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High-potential tester.
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Megohmmeter.
17. Bearing insulation
Criteria
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If applicable, bearing insulation is insulation resistance tested, and results are documented.
Equipment
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Confirm calibration and functionality of associated equipment.
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Megohmmeter.
18. No-load tests
Criteria
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No-load running test using test panel is performed at rated voltage.
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Speed is measured and compared with nameplate speed.
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No-load currents and voltages are measured and documented.
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Vibration levels are measured and documented.
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Evaluation assessment of acceptability is documented (e.g., “OK to ship”).
Equipment
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Confirm calibration and functionality of associated equipment.
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Test panel (functionality; instruments calibrated if applicable)
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Voltmeter
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Digital tachometer (functionality)
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Ammeter
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Vibration meter
19. Finish and handling
Criteria
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Motor is externally clean and painted (if applicable).
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Shaft extensions are treated to prevent corrosion.
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Motor is packed/packaged suitably for the form of transportation to be used.
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Oil-lubricated motors are shipped without oil, and the need for lubricant is clearly identified.
20. Calibration
Criteria
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Proof of current (at least annual) calibration to applicable national standard is available for all applicable instruments.
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Proof of current (at least every 3 years) certification for standards and gauge blocks (if applicable) used for micrometer calibration is available.
Equipment
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All applicable instruments on Equipment List (Note: All applicable are included above).
Please sign and email the report to the QHSE Administrator
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Select date
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Add signature
Annex A (normative)
Equipment
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• Unless noted otherwise, all equipment listed must be on site and functional.
• Except for gauge blocks, all instruments must be calibrated at least annually to applicable national standards. After initial accreditation is achieved, the service center must retain calibration records for a 3-year period, or until the next external audit is performed.
• Verification: Confirming, through the use of objective evidence, that specified requirements have been fulfilled.
Electrical
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Milli-ohmmeter
Ohmmeter
Voltmeter (AC)
Ammeter (AC)
Wattmeter (AC )
Megohmmeter
High-potential tester
Surge tester
Core tester [1]
Loop test [1]
Growler (functional)
Test panel (to motor rated voltage; individual instruments calibrated)
Mechanical
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Inside micrometers
Outside micrometers
Dial indicators (verification by service center)
Digital tachometer (verification by service center)
Terminal crimpers (verification by service center)
Vibration meter
Balancing machine [2]
Gauge blocks (if applicable) [3]
Physical
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Temperature meters
Burnout oven part temperature control
Burnout oven analog or digital recorder
Burnout oven water mist system (verification by service center)
Bake oven temperature control
Winding machine with turns counter (verification by service center)
VPI system vacuum gauge [4]
VPI system pressure gauge [4]
Notes
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[1] Must have either one or both of these items
[2] Outsourcing permissible
[3] Periodic verification by gauge block manufacturer or other qualified external source.
[4] Only applies if service center has VPI system (VPI process outsourcing permissible)
