Nuclear Maintenance Application Center Guide Guidance For Developing Electric Motor Specialist

2010 TECHNICAL REPORT
Nuclear Maintenance Applications Center:

Guidance for Developing an Electric
Motor Specialist
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Electric Power Research Institute
3420 Hillview Avenue, Palo Alto, California 94304-1338 • PO Box 10412, Palo Alto, California 94303-0813 USA
800.313.3774 • 650.855.2121 • askepri@epri.com • www.epri.com
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Nuclear Maintenance Applications
Center: Guidance for Developing an
Electric Motor Specialist
1021427
Final Report, December 2010
EPRI Project Manager

W. Johnson
ELECTRIC POWER RESEARCH INSTITUTE

3420 Hillview Avenue, Palo Alto, California 94304-1338 • PO Box 10412, Palo Alto, California 94303-0813 • USA
800.313.3774 • 650.855.2121 • askepri@epri.com • www.epri.com
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DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES
THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN
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INSTITUTE, INC. (EPRI). NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE
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PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT.
THE FOLLOWING ORGANIZATION, UNDER CONTRACT TO EPRI, PREPARED THIS REPORT:
Honeycutt Consulting, LLC
NOTE
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e-mail askepri@epri.com.
Electric Power Research Institute, EPRI, and TOGETHER…SHAPING THE FUTURE OF ELECTRICITY
are registered service marks of the Electric Power Research Institute, Inc.
Copyright © 2010 Electric Power Research Institute, Inc. All rights reserved.
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ACKNOWLEDGMENTS
The following organization, under contract to the Electric Power Research Institute (EPRI),
prepared this report:
Honeycutt Consulting, LLC
8205 Bay Berry Dr.
Chattanooga, TN 37421
Principal Investigator
J. Honeycutt
This report describes research sponsored by EPRI.

This report was developed to provide a progressive approach for acquiring the knowledge and
skills needed to become a motor specialist. As the existing work force ages in the nuclear power
industry, motor specialists are retiring. Although many nuclear plants have development plans to
help individuals assuming the role of a motor specialist or component engineer, there are no
complete career programs that present a comprehensive view of all of the areas that a motor
specialist might encounter.
This report identifies topics, lists opportunities, recommends training, and provides a list of
reference documents that will be useful in acquiring the knowledge and skills needed to be
proficient as an electric motor component specialist.
The Information Working Group (IWG) of the EPRI Large Electric Motor Users Group
(LEMUG) determined that a guide was needed to highlight the career path development of an
electric motor specialist. Over the years, many IWG and LEMUG members and vendors have
participated in the preparation of this report; to list them all would be difficult. The IWG
acknowledges the contributions of all those who have taken the time and energy to review and
comment on this report. The following IWG members assisted in the preparation and approval of
the final report:
Henry Johnson Arizona Power Services – Chair
Harry Smith Exelon Corporation
Curtis Biggs Luminant
Joshua Marsh First Energy Corporation
Russ Randolph Duke Energy
Steve Davidovich AREVA
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David Bailey Tennessee Valley Authority
Shane Taylor Tennessee Valley Authority
Antoni Aiken Southern Company
TaIsha Lockette South Carolina Electric & Gas Company
Ray Barth South Carolina Electric & Gas Company
Cuz Lankford Pump & Motor Works, Inc.
Russ Leatham Pacific Gas & Electric Company
Alexander Andre Pump & Motor Works, Inc.
Sergio Andre Pump & Motor Works, Inc.
Fred Wilson Constellation Generation Group
John Wilson Baker Instrument Company
Nicole Jackson Southern Nuclear Company
Jeff Schwartzel Ontario Power Generation, Inc.
Kerry Barrier Tennessee Valley Authority
Wayne Johnson EPRI
This publication is a corporate document that should be cited in the literature in the following
manner:
Nuclear Maintenance Applications Center: Guidance for Developing an Electric Motor

Specialist. EPRI, Palo Alto, CA: 2010. 1021427.
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PRODUCT DESCRIPTION
The people responsible for electric motors in the power industry are known by various titles—
motor specialist, component engineer, motor technician, and electrical technician, to name a few.
Although motor duties and responsibilities are often spread across several departments—such as
maintenance, operations, engineering, and procurement—it is up to the motor specialist to ensure
that motor health and reliability are maintained.
This report presents a tiered approach to developing the necessary skills and knowledge required
to become an electric motor specialist. Included in this report are recommended skill sets,
industry involvement opportunities, training options, mentoring insights, and motor reference
material. This report contains nuclear-specific information; however, it can be used by any
organization or individual for the development of electric motor expertise by excluding areas not
applicable to their industry.
Results and Findings

Electric motors are critical to the continued operation of industrial facilities, especially power
plants. However, there is no consistent process in place to ensure sufficient development of
individuals who are responsible for motors as the facilities age. This report provides a tiered
approach for development of future electric motor specialists by establishing skill sets populated
with the necessary knowledge areas most commonly used to operate and maintain electric
motors.
The Electric Power Research Institute’s (EPRI’s) Large Electric Motor Users Group (LEMUG)
has developed this report to identify motor knowledge that can be obtained through the
following:
• Formal training activities
• Direct observation
• Participation in motor-specific activities
• Industry participation
• Use of skill set matrices
The skill sets presented in the report can be used to accelerate the development of an electric
motor specialist.
Challenges and Objectives

From discussions with the various utilities represented by LEMUG, it became apparent that an
aging work force and attrition were contributing to the loss of many motor specialists within the
industry, and it was difficult to find a plan in place to bring up capable replacements.
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The objective of this report is to point out the many different skills and knowledge areas that are
needed to become an electric motor specialist and provide guidance for a career development
plan.
Applications, Value, and Use

Because the skills are broad and varied, it takes many years to become an electric motor
specialist. An electric motor is approximately 70% mechanical and 30% electrical, requiring that
motor specialists be multidisciplined. This report presents the mechanical and electrical attributes
that must be understood to properly maintain motors and maximize their life expectancy. It is the
responsibility of each user of this report to incorporate the appropriate recommendations to meet
their own training commitments and requirements.
EPRI Perspective
The recommendations within this report are provided in a progressive fashion to allow
contribution while minimizing risk of job impact resulting from inadequate knowledge of or
exposure to equipment. This report is not intended to validate or invalidate qualifications but to
provide a framework for further individual development.
It is expected that each site will review this report and identify the subset of information
necessary to meet site and industry needs.
The resultant product includes four progressive skill sets, with a cross-reference of recommended
training options with alternatives to assist in achieving the motor specialist requirements of each
organization.
Approach
To develop the skill set knowledge areas and the progression of skills in the four skill sets
described herein, guidance was sought from individuals in the utilities who are responsible for
maintaining motors, motor manufacturers, and existing motor specialists. This report, which will
aid utilities in developing what is called a motor specialist, is a collection of their
recommendations.
Keywords
Component engineer
Electric motor
Motor engineer
Motor specialist
Testing
Training
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CONTENTS
1 INTRODUCTION ....................................................................................................................1-1
2 GENERAL DISCUSSION FOR MOTOR SPECIALIST DEVELOPMENT..............................2-1

2.1 Industry Participation ...................................................................................................2-3
2.2 Motor Program Areas of an Effective Motor Program..................................................2-4
3 USE OF THE SKILL SET MATRICES ...................................................................................3-1

Skill Set 1 – Primary Motor Specialist and Back-Up Motor Specialist ...................................3-1
Skill Set 2 – Primary Motor Specialist and Back Up Motor Specialist .................................3-23
Skill Set 3 – Primary Motor Specialist .................................................................................3-40
Skill Set 4 – Primary Motor Specialist .................................................................................3-68
4 SUMMARY .............................................................................................................................4-1
5 INDUSTRY DOCUMENTS .....................................................................................................5-1

5.1 EPRI Documents .........................................................................................................5-1
5.1.1 Assessments.......................................................................................................5-1
5.1.2 Bearings ..............................................................................................................5-1
5.1.3 Cables .................................................................................................................5-1
5.1.4 Electrical - Other .................................................................................................5-1
5.1.5 Environmental Qualification ................................................................................5-2
5.1.6 Equipment Reliability...........................................................................................5-2
5.1.7 Failure Analysis and Troubleshooting .................................................................5-2
5.1.8 Heat Exchangers.................................................................................................5-2
5.1.9 Life Cycle Management ......................................................................................5-3
5.1.10 Lubrication .......................................................................................................5-3
5.1.11 Mechanical – Other..........................................................................................5-3
5.1.12 Nuclear Coatings .............................................................................................5-3
5.1.13 Operations and Maintenance...........................................................................5-3
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5.1.14 Predictive and Preventive Maintenance ..........................................................5-3
5.1.15 Procurement of New Motors ............................................................................5-4
5.1.16 Protective Relays .............................................................................................5-5
5.1.17 Repair and Refurbishment ...............................................................................5-5
5.1.18 Shipping and Storage ......................................................................................5-5
5.1.19 System and Component Health Reports .........................................................5-5
5.2 IEEE Documents .........................................................................................................5-6
5.3 INPO Documents .........................................................................................................5-7
5.4 EASA Documents ........................................................................................................5-7
5.5 National Electrical Manufacturers Association.............................................................5-7
5.6 Code Of Federal Regulations ......................................................................................5-7
5.7 ASTM Documents........................................................................................................5-7
5.8 NFPA Documents ........................................................................................................5-8
5.9 ANSI Documents .........................................................................................................5-8
5.10 ABMA Documents...................................................................................................5-8
5.11 Other Documents ....................................................................................................5-8
A GLOSSARY .......................................................................................................................... A-1
B POTENTIAL TRAINING OPPORTUNITIES AND RECOMMENDED READING ................. B-1

B.1 EPRI Training ............................................................................................................. B-1
B.1.1 Computer Based Training .................................................................................. B-1
B.1.2 Engineering Technical Training Modules ........................................................... B-1
B.1.3 Equipment Qualification ..................................................................................... B-1
B.1.4 Heat Exchangers................................................................................................ B-1
B.1.5 Maintenance Engineering .................................................................................. B-1
B.1.6 Maintenance Programs ...................................................................................... B-2
B.1.7 Non-Destructive Evaluation Program................................................................. B-2
B.1.8 Nuclear Coatings................................................................................................ B-2
B.2 EASA Training ............................................................................................................ B-2
B.3 Vendor Training .......................................................................................................... B-2
B.4 Site Specific Training .................................................................................................. B-2
B.5 Other Training Opportunities....................................................................................... B-3
B.6 Industry Organizations ................................................................................................ B-3
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C TRANSLATED TABLE OF CONTENTS .............................................................................. C-1
繁體中文 (Chinese – Traditional).......................................................................................... C-2
简体中文 (Chinese – Simplified) .......................................................................................... C-12
Français (French) ............................................................................................................... C-24
日本語 (Japanese) ............................................................................................................. C-34
한국어 (Korean).................................................................................................................. C-46

Español (Spanish) .............................................................................................................. C-58
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LIST OF FIGURES
Figure 2-1 Suggested Motor Program Areas .............................................................................2-5
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LIST OF TABLES
Skill Set 1 – Tables 3-1 to 3-14

Table 3-1 Skill Set 1-1 – Site Specific Skills ..............................................................................3-1
Table 3-2 Skill Set 1-2 – Guidance Documents and Contacts...................................................3-7
Table 3-3 Skill Set 1-3 – General Knowledge of Motors ............................................................3-8
Table 3-4 Skill Set 1-4 – Motor Nameplate Information .............................................................3-9
Table 3-5 Skill Set 1-5 – Enclosure Types and Materials ........................................................3-10
Table 3-6 Skill Set 1-6 – Basic Knowledge of Motor Performance Data..................................3-11
Table 3-7 Skill Set -1-7 – Basic Knowledge of Temperature Monitoring Technology and
Design ..............................................................................................................................3-13
Table 3-8 Skill Set 1-8 – Basic Knowledge of Sensory/Monitoring Technology.......................3-14
Table 3-9 Skill Set 1-9 – Basic Knowledge of Stator Winding Heater Technology and
Design ..............................................................................................................................3-15
Table 3-10 Skill Set 1-10 – Basic Knowledge of Bearing Technology and Design ..................3-16
Table 3-11 Skill Set 1-11 – Basic Knowledge of Lubrication Systems, Lubrication Types,
and Quantities ..................................................................................................................3-18
Table 3-12 Skill Set 1-12 – Basic Knowledge of Cooling System Designs ..............................3-20
Table 3-13 Skill Set 1-13 – Basic Knowledge of Winding/Insulation System Types ................3-21
Table 3-14 Skill Set 1-14 – Storage of Motors .........................................................................3-22

Table 3-15 Skill Set 2-1 – Knowledge of System Design and Operation .................................3-23
Table 3-16 Skill Set 2-2 – Knowledge of Motor Drawings (Electrical, Instrumentation, and
Mechanical)......................................................................................................................3-24
Table 3-17 Skill Set 2-3 – Knowledge of Motor Program Guide(s) ..........................................3-26
Table 3-18 Skill Set 2-4 – Knowledge of Long Range Motor Plan ...........................................3-28
Table 3-19 Skill Set 2-5 – Knowledge of Spare Motors ...........................................................3-29
Table 3-20 Skill Set 2-6 – Knowledge of Maintenance Procedures and Surveillance
Instructions.......................................................................................................................3-30
Table 3-21 Skill Set 2-7 – Knowledge of Motor Predictive and Preventive Maintenance
Programs..........................................................................................................................3-31
Table 3-22 Skill Set 2-8 – Knowledge of the Content of the Documents in the Motor
Technical Library..............................................................................................................3-32
Table 3-23 Skill Set 2-9 – Knowledge of Motor Trouble Shooting Guidelines .........................3-33
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Table 3-24 Skill Set 2-10 – Knowledge of Thermography and Ultrasonic Monitoring for
Motors ..............................................................................................................................3-34
Table 3-25 Skill Set 2-11 – Knowledge of Motor Coupling Designs ........................................3-35
Table 3-26 Skill Set 2-12 – Knowledge of Motor Lubrication Programs ..................................3-36
Table 3-27 Skill Set 2-13 – General Knowledge of Motor Shaft Designs ................................3-37
Table 3-28 Skill Set 2-14 – General Knowledge of Different Motor Designs ...........................3-38
Table 3-29 Skill Set 2-15 – General Knowledge of Cooling Coil Designs................................3-39

Table 3-30 Skill Set 3-1 – Commercial Grade Item (CGI) Dedication and Motor Upgrade
Processes ........................................................................................................................3-40
Table 3-31 Skill Set 3-2 – Knowledge of Like for Like Motor Replacement Evaluations..........3-41
Table 3-32 Skill Set 3-3 – Knowledge of Motor Trip Circuits and Protective Relaying.............3-42
Table 3-33 Skill Set 3-4 – Knowledge of Motor Test Equipment .............................................3-43
Table 3-34 Skill Set 3-5 – Specialized Training .......................................................................3-44
Table 3-35 Skill Set 3-6 – Ownership of the Long Range Motor Plan .....................................3-45
Table 3-36 Skill Set 3-7 – Critical Spare Motor Procurement and Preservation ......................3-47
Table 3-37 Skill Set 3-8 – Motor Program Assessments .........................................................3-48
Table 3-38 Skill Set 3-9 – Knowledge of Motor Repair, Refurbishment, and Rewind
Specifications ...................................................................................................................3-49
Table 3-39 Skill Set 3-10 – Knowledge of Motor Performance Trending .................................3-51
Table 3-40 Skill Set 3-11 – Motor Service Shops Processes and Controls .............................3-52
Table 3-41 Skill Set 3-12 – Detailed Knowledge of Different Motor Designs ...........................3-53
Table 3-42 Skill Set 3-13 – Knowledge of Motor Insulation System Design Differences .........3-54
Table 3-43 Skill Set 3-14 – Knowledge of Motor Termination and Insulating Techniques.......3-55
Table 3-44 Skill Set 3-15 – Knowledge of Motor Lead Specifications, Design, Testing...........3-57
Table 3-45 Skill Set 3-16 – Knowledge of Motor Bearing Designs ..........................................3-58
Table 3-46 Skill Set 3-17 – Knowledge of Motor Rotor Design................................................3-62
Table 3-47 Skill Set 3-18 – Knowledge of Motor Shaft Material and Repair Processes ..........3-64
Table 3-48 Skill Set 3-19 – Knowledge of Oil and Air Cooling Coil Designs, Testing
Techniques, and Acceptance Criteria ..............................................................................3-65
Table 3-49 Skill Set 3-20 – Evidence Preservation and Apparent Cause................................3-66

Table 3-50 Skill Set 4-1 – Ownership of Motor Program Guide(s)...........................................3-68
Table 3-51 Skill Set 4-2 – Become Official Liaison Between Management and All Motor
Issues...............................................................................................................................3-70
Table 3-52 Skill Set 4-3 – 10CFR50.59 Trained ......................................................................3-71
Table 3-53 Skill Set 4-4 – Knowledge of Design Change Issues.............................................3-72
Table 3-54 Skill Set 4-5 – Knowledge of Motor Stator Core Testing and Design ....................3-73
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Table 3-55 Skill Set 4-6 – Detailed Knowledge of Motor Insulation Systems ..........................3-75
Table 3-56 Skill Set 4-7 – Knowledge of All INPO, NRC, and NEIL Issues .............................3-79
Table 3-57 Skill Set 4-8 – Detailed Knowledge of Motor Performance Curves........................3-80
Table 3-58 Skill Set 4-9 – Motor Technical and Operability Evaluations .................................3-81
Table 3-59 Skill Set 4-10 – Root Cause Analysis Trained .......................................................3-82
Table 3-60 Skill Set 4-11 – Knowledge of Motor Environmental Qualification (EQ)
Process ............................................................................................................................3-83
Table 3-61 Skill Set 4-12 – Knowledge of Motor Protective Coatings and Service Level 1
Coatings ...........................................................................................................................3-84
Table 3-62 Skill Set 4-13 – Knowledge of Motor Dynamometer Testing .................................3-85
Table 3-63 Skill Set 4-14 – Knowledge of Complete Motor Testing (IEEE 112) ......................3-86
Table 3-64 Skill Set 4-15 – Involvement in Industry Document Development .........................3-87
Table 3-65 Skill Set 4-16 – Assume Chair Positions in Leading Motor Industry Groups .........3-88
Table 3-66 Skill Set 4-17 – Develop and Provide Motor Training ............................................3-89
Table 3-67 Skill Set 4-18 – Become Mentor for Next Generation of Motor Specialist .............3-90
Skill Set Completion Matrix

Table 3-68 Skill Set Completion Matrix (Skill Set 1) ................................................................3-91
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1
INTRODUCTION
This document recommends a set of skills that supports the usage of electric motors. The
guidance is presented such that each site/individual can determine what skills they would want to
develop. The knowledge and skills identified in this document are based on input from the EPRI
LEMUG members. The specific topics and knowledge areas which are presented in this report
reflect the experience gained from subject matter experts, industry support groups, and
equipment suppliers.
The development plan is divided into four skill sets with the expected focus of motor specific
and basic plant knowledge, tasks, and degree of industry involvement. Each skill set includes
potential training options and references to information sources to support the skill set topics.
Time frames are intentionally omitted due to the differences in level of responsibilities at various
sites. Instead, the skill sets are divided into Initial, Intermediate, and Advance. It is
recommended that at least a primary and back-up motor specialist be identified. The back-up
should become knowledgeable of the topics listed in Skill Set 1 (Initial) and Skill Set 2
(Intermediate). It is expected that the primary motor specialist will become proficient in all four
Skill Sets.
As experienced personnel retire and new personnel come into the industry, it is important to plan
for the transfer of knowledge to maintain reliable operation of motors. Suppliers as well as
equipment users find themselves in similar set of circumstances in terms of improving the
knowledge of the individuals assigned to become equipment or component experts. This report
provides a road map for the development of component expertise.
The Institute of Nuclear Power Operations (INPO) recognized the increased number of motor
failures and published several Topical Reports on large pump motors which identified increased
impact on power plant performance and the need for motor users to develop improved motor
programs to reduce impacts on plant performance caused by motor failures. Three Topical
Reports addressing the issues where published: TR4-35, “Analysis of Large Pump Motor
Failures Impacting Power Production”, TR5-50, “Review of Events Impacting Power Production
Involving Large Pump Motors (Supersedes Topical Report TR4-35)”, and TR7-59, “Review of
Events Impacting Large Pump Motors”. These topical reports emphasized increased utility
activity and involvement with their motors including predictive and preventive maintenance,
equipment aging, performance trending, plant personnel training, vendor oversight, and the need
for critical spares. This increased need for industry involvement has lead to the development of
more robust site motor programs and identification of the skills needed to establish and maintain
motor programs.
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Introduction
As a follow-up document, INPO published an Engineering Program Guide (EPG-13) to define

the principles for an effective motor program. Many of the EPRI LEMUG electric motor
documents are referenced in EPG-13 and were used to develop the EPG.
Numerous utilities and vendors supplied input to this document through their participation in
LEMUG Information Working Group meetings. The training, knowledge, and skills
recommended are based upon the varied experiences of the participants.
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2
GENERAL DISCUSSION FOR MOTOR SPECIALIST
DEVELOPMENT
The development of skills required to be proficient at the various aspects related to electric
motors is a lifelong endeavor. The electric motor specialist is not just concerned with the
electrical circuits that make up a motor but a motor specialist must have knowledge of rotating
equipment, bearings, lubrication, assembly/disassembly, balancing, alignment, vibration
analysis, materials, electrical testing, and quite a few more skills that are not in this list.
This guide provides direction to an individual that is new to motors; however, because the skills
are so varied, it is also necessary to have this document as a refresher or reference for the
seasoned person also.
The intent of this guide is to focus the electric motor specialist development by identifying
knowledge areas that should be acquired as the motor specialist career advances. The following
is one perspective of developing a motor specialist:
• Skill Set 1 (Initial knowledge areas – Primary and Back-Up Specialist) provides basic
knowledge that allows a person to become familiar with plant business practices and
regulations, plant layout, and motor designs, applications, and operation.
• Skill Set 2 (Intermediate knowledge areas – Primary and Back-Up Specialist) is crucial to
development of an electric motor specialists. Once these are acquired, the motor specialist
should be capable to:
– Define required motor maintenance tasks
– Adequately evaluate motor tests,
– Make recommendations for continued operation
– Input and assist in the development of the long range motor plan
– Provide motor troubleshooting guidance
– Understand repair, refurbishments, rewind, and purchase specifications
– Understand internal design of motors (electrical and mechanical)
– Be able to identify failure modes and recommend corrective actions
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General Discussion for Motor Specialist Development
• Skill Set 3 (Advanced knowledge areas – Primary Motor Specialist) provides skills necessary
for detailed understanding of the mechanical and electrical design and operation of motors.
The skills listed in this set will enable the motor specialist to establish ownership of the
motor program. Skill set 3 provides guidance on:
– Specialized test equipment
– Long Range motor program
– Trending
– Motor service shop oversight and process control
– Insulation system design
– Bearing design and application
– Shaft and rotor design application
– Lubrication processes
– Apparent cause and evidence preservation
• Skill Set 4 (Advanced knowledge areas – Primary Motor Specialist) provides skills and
knowledge areas for the seasoned motor specialist to provide knowledgeable input and
technical control of the motor program. Although the skills and knowledge areas do not have
to be learned in order, the items listed in this skill set can be better absorbed and understood
by those that have been a motor specialist for several years. Skill set 4 provides guidance on:
– 10CFR50.59
– Design change knowledge
– Stator core design
– Insulation system weaknesses
– Motor leads, cables and connection issues
– Technical contract manager
– Performance curves
– Technical and operability issues
– Root cause analysis
– Environmental Qualification
– Service Level I coatings
– Dynamometer testing
– IEEE 112 testing
– Industry leadership positions
– Provide motor training
– Become mentor
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There are several methods that can be used to enhance the acquiring of skills for the specialist
development. Two key areas that can enhance this development are mentoring and equipment
exposure with hands on opportunities.
Mentoring can greatly accelerate the development of a motor specialist. Mentoring is a

relationship built on trust and one of its primary goals is to make a person new to a field more
confident in their abilities and talents. Mentoring normally involves a member of the same
profession with more experience and connections, helping a new person become more confident
in their chosen field. Although there is some focus on the skills, the main focus in mentoring is a
long-term, ongoing process – it is usually a developed relationship, based on shared experience.
The mentor often passes on not only tangible knowledge, but also philosophy, advice, and
experience from years in the field. The mentor may also provide introductions to people or
organizations that can enhance the knowledge of a motor specialist.
The person that would like to develop skills related to maintaining motors should find as many
opportunities as possible to witness the disassembly, testing, refurbishment, and winding of
motors. Also, since ensuring that their motors operate properly is a primary responsibility,
opportunities to witness the other skills sets such as alignment, balancing, vibration, and
lubrication analysis should be sought out by the individual that would become a motor specialist.
These skills are essential when attempting to determine when and what can be done to a motor
and what level of effort it will require.
As with any development of a specialist, an individual needs to be dedicated predominately to a

particular component. A motor specialist should be the single point of accountability and have
responsibility for the motor program(s). Since the program(s) requires resources and finances,
the motor program owner (motor specialist) will have to justify why certain tests, maintenance
activities, and refurbishment/rewind time intervals have to be followed. The more
knowledgeable the motor specialist is, the easier it is to technically justify the action taken to
make the motor program successful. The effectiveness of the motor program should be reflected
in the reliability of the motors.
It is important that a comprehensive electric motor library (either electronic, hard copy, or both)
be compiled so that the necessary reference information will be readily available. There is a
significant amount of information that has been developed over the past years on electric motor
insulation system design, failure identification, mechanical repairs, testing, refurbishment
specifications, procurement specifications, and environmental qualification. These documents
are listed in the industry document section of this guide.
2.1 Industry Participation
Attending industry training or being involved in industry groups such as EPRI LEMUG, IEEE,
EASA, ANSI, ASTM, NETA, etc. provides an important opportunity for gaining industry
experience. Being involved in industry has many benefits such as:
• Establishing industry contacts that help support motor repair, rewind, parts, critical spares,
etc. Some of these contacts could provide various levels of mentoring as well.
• Benchmarking other sites programs
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• Discussing and gaining knowledge on motor problems from different sites as well as from
other industries and motor OEMs.
• Providing opportunities for inspecting motors during:
– Disassembly
– Testing
– Repair or refurbishment
– Rewinding
– Re-assembly
– Final testing
• Training on certain topics such as online testing, oil analysis, vibration, alignment, etc.
The benefits of industry participation are many for both the motor specialist and the site and are
recommended as a vital part of a motor specialist’s career development. Industry activities are
part of the equipment exposure and hands-on skill development opportunities. Funding is
essential and it is important to lay out an individual development plan with year to year goals
that has identified industry involvement and the associated costs (including training courses).
2.2 Motor Program Areas of an Effective Motor Program
Motor program areas that the motor specialist must be familiar with are shown in Figure 2-1.
Although other groups will be owners of some of the programs, the motor specialist should know
how each program is implemented, be able to interpret the results, and determine overall motor
health. In addition the long range motor refurbishment, rewind, and replacement schedules
should be owned by the motor specialist. This does not mean that the motor specialist will have
final say so on refurbishments and rewinds due to the fact that company resources and finances
are limited; however, the motor specialist should provide the proper technical information to
assist management in the decision process.
2-4
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Figure 2-1
Suggested Motor Program Areas
2-5
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3
USE OF THE SKILL SET MATRICES
The skill sets are intended to be used as a recommended career development guide to assist sites
with developing primary and back-up motor specialists. The matrices contain a comprehensive
list of skills and knowledge areas that should be learned over time. Acquiring these skills and
knowledge will require considerable time and will vary dependent upon the individual and site
goals.
As stated in Section 2, it is the expectation that the primary motor specialists and the back-up
will become knowledgeable of the topics listed in Skill Set 1 (Initial) and Skill Set 2
(Intermediate). It is recommended that the primary motor specialist will become proficient in
Skill Set 3 & 4 (Advanced). The topics in the skill sets do not have to be covered in the order
they are listed. However, some of the topics in skill sets 3 and 4 will be better comprehended by
experienced motor specialists.
It is important that a career path be developed to maintain individuals in the motor discipline for
a considerable amount of time in order for them to become motor specialist. It will be essential
for these persons be developed and provide mentoring to others entering the motor field or there
will be very few motor specialists in the future. Although the recommended level of training, site
involvement, industry participation, and knowledge listed in this document requires a significant
investment; the return on the investment in the development of the motor specialist more than
pays for itself when a motor specialist can avert one major motor failure that would have affected
site production.
The Skill Sets are divided into 6 distinct columns.

1. The Topic column provides a high level topic that may have several knowledge areas
assigned to it. All of these topics are listed in the Skill Set Completion Matrix listed at the
end of Section 3.
2. The Knowledge column expands on the topic in an attempt to identify the most important
knowledge areas that need to be learned by the motor specialist. This column essentially
directs the motor specialist to the most important areas that the motor specialist should be
involved in or have knowledge of.
3. The Development Opportunities column provides recommendations on activities the motor
specialist should be involved in to gain knowledge of the topic listed. Some of these
recommendations will be observing work being performed, some will be hands on, and some
will be working with other groups to better understand their job function and/or processes.
4. The Training Opportunities column lists training recommendations that can be obtained
from industry groups and companies. The general training recommendations are provided for
the associated topic. Specific training courses are listed in Appendix C. It should be noted
3-1
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Use of the Skill Set Matrices
that the training courses listed are not all inclusive and may not always be available. Some
training recommendations will require outside training while other training courses can be
brought to the site. Most of the training recommended will have a cost associated with it but
also brings a benefit to the site by increased knowledge of the motor specialist.
5. The Site and Industry Documents column provides a list of references associated with the
topic in the row in which they are listed. The documents are listed by number only in the
column. The full names of the documents are listed in Section 5. The documents listed can be
obtained by public domain or purchased. As stated earlier, many documents pertaining to
performing maintenance, operating, testing, refurbishment, repairing, rewinding, procuring,
and storage, etc. of motors have been developed within the past 10 years. It is important the
motor specialist know where to find information within these references and it is preferable
that this information is readily accessible. The documents in this column are listed in Section
5. The documents listed in this column are based on the experience and knowledge of the
authors. They are not all inclusive and can be adjusted as needed by the user. Only main
headings are listed in this column. There can be several documents associated with each main
heading and they are individually listed in Section 5.
6. The Comments column was developed by existing motor specialists in an attempt to provide
lessons learned and mentoring to the individuals using this document for their development
into a motor specialist. The comments in each row are associated with the topic and
knowledge areas listed in that row.
As stated earlier, this document is not intended to take the place of onsite component engineer
development programs, but to provide a motor specialist development plan to enhance the skills
and knowledge of the individuals assigned to the motors so that future motor specialist will be
trained in the many different mechanical and electrical attributes of motors to maintain a high
level of motor reliability and maximize motor life expectancy.
A Skill Set Completion Matrix is included in this document at the end of Section 3 to provide a
tool for tracking topic completion for the primary and back-up motor specialist. The completion
matrix is divided into the individual skill sets with a complete list of recommended topics under
each skill set.
3-2
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Skill Set 1 – Primary Motor Specialist and Back-Up Motor Specialist
Table 3-1
Skill Set 1-1 – Site Specific Skills
Topics Knowledge Development Training Site and Industry Comments

Opportunities Opportunities Documents
(See App. B) (See Section 5)
1.1.1 General Motor function and Become familiar with Onsite system Site Specific System Satisfactory completion of
System operation per the plant and motor training training documents site system training.
Knowledge system locations and how
they interact with plant
systems
1.1.2 Site Motor Motor Program Participate with the Onsite training Site program EPRI, INPO, NRC, and the
Program Overview craft, repair shops, documents Insurance Companies are
PDM groups, planning Mentor all pushing for a strong
Supporting group, project 5.1.4, 5.1.5, 5.1.6, motor program with at least
Organizations Existing onsite 5.1.10, 5.1.13,
management, program a 10 year long range plan to
procurement group, 5.1.14, 5.1.18, maintain motor reliability.
Long Range Plan 5.1.19, 5.2, 5.3, 5.4,
and mentor to gain
Critical Spares knowledge of the site 5.5, 5.7, 5.10 A general understanding of
program. the motor program is
Testing required. Increased
knowledge of each of these
Service Shops and areas are presented in the
Vendors used to additional skill sets.
support the program
Project
management of
program
Procurement
processes
3-1
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Table 3-1 (continued)


1.1.3 Electrical Electrical Theory Observe testing and Onsite training Site Specific Safety Testing from the breaker
Theory and safety precautions courses Programs can be dangerous due to
Safety Precautions while during testing the compartment having an
testing from the activities on motors On the job 5.1.4, 5.1.14, 5.2, energized bus potential
breaker training 5.4, 5.5, 5.8
compartment Obtain basic
understanding of arc Attend Motor
Safety around flash dangers Theory training
energized
equipment
Safety of personnel
around equipment
being tested
1.1.4 Site Need to be able to Work with both Onsite training Motor vendor Reading and understanding
Drawings, read both electrical mechanical and courses manuals electrical and mechanical
Technical and mechanical electrical craft and drawings are essential.
Manuals, and drawings ( outline other engineers to On the job Motor electrical and
Vendor and cross sectional become familiar with training mechanical drawings A motor is 30% electrical
Documents drawings) to the cross sectional and 70% mechanical in
Mentor Electric Motor design.
understand motor and electrical reference books
operation and drawings for your
design motors 5.4, 5.5
Need to know
location of drawings
and manuals
3-2
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1.1.5 Operating Need to understand Work with site OE Attend EPIX Site OE program OE can provide valuable
Experience the OE program coordinator to gain training information on motor
(OE) Review and review relative knowledge of the OE 5.3 failures from other sites and
Program motor OE program and receive Mentor industries
daily download of
relative OE
1.1.6 Site Maintenance Work with applicable Onsite training Site procedures This should be provided at
Procedures procedures personnel to gain each site. Working with a
knowledge of site On the job mentor is one of the more
Installation and procedures training effective approaches to OJT
replacement and procedure
procedures Mentor
familiarization.
Operating
procedures
Plant safety
procedures
3-3
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1.1.7 Support Walk Know what to look Participate in Onsite training 5.1.13, 5.1.14, Walk down inspections can
downs for operations, PDM, 5.1.17, 5.1.19, 5.3, identify degraded conditions
maintenance, and Existing onsite 5.4 that can be corrected before
Be able to engineering walk program they cause a major issue or
recognized downs in-service failure. More of
anomalies Attend EPRI
motor courses these conditions can be
Be able to identify found using knowledgeable
deviations from Attend offsite personnel that know the
normal operating motor courses normal operating
parameters parameters of each motor
Make a walk on the walk down route.
down log for each
motor listing its
normal operation
parameters
Mentor
1.1.8 Planned Preventive Observe both EPRI LEMUG 5.1.2, 5.1.4, 5.1.6, The difference between
Maintenance maintenance electrical testing and workshops and 5.1.10, 5.1.13, preventive and predictive
activities mechanical meetings 5.1.14, 5.1.17, 5.2, maintenance needs to be
maintenance activities 5.3, 5.4, 5.5, 5.7, understood. Since no site
Predictive on motors Onsite training 5.10 can support all
maintenance courses recommended
activities Have a general maintenance, the best
understanding of the Offsite courses
Mentor activities and monitoring
site required time need to be identified that will
based and condition maintain motor reliability.
based activities and
testing
Review motor PM
Basis Documents
3-4
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1.1.9 Corrective Have general Observe field repair Onsite training 5.1.2, 5.1.4, 5.1.6, Observing corrective
Maintenance knowledge of the courses 5.1.7, 5.1.9, 5.1.11, maintenance activities will
following Be at the service 5.1.12, 5.1.13, increase motor specialist
maintenance shops during motor On the job 5.1.14, 5.1.17, knowledge of failure modes
activities: disassembly to training 5.1.18, 5.2, 5.4, 5.5, and repair processes.
identify degraded 5.6, 5.9, 5.10
Scheduled conditions and failure EPRI LEMUG This is a talent that gets
corrective evidence workshops and better with increased
maintenance meetings knowledge and experience.
Initiate and evaluate
Emergent corrective corrective action Offsite motor
maintenance documents, and courses
initiate corrective Mentor
Initiation and actions
planning of
maintenance
requests
Photo
documentation
3-5
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1.1.10 Support General knowledge Observe start to finish Onsite training Site procedures There are many challenges
Motor of the following: activities during motor to removing and installing a
Removal and replacements On the job 5.1.4, 5.1.9, 5.1.10, large motor. Knowing these
Installation Know removal and training 5.1.11, 5.1.13, will greatly improve the
installation Ask questions 5.1.14, 5.1.18, 5.2, efficiency of the activity and
challenges Mentor 5.4, 5.5, 5.9
Take photos minimize surprises during
Rigging outage or online activities.
requirements
Know the different
groups and vendor
contacts that may
be needed to
support these
activities.
Post installation
testing
requirements
3-6
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Table 3-2
Skill Set 1-2 – Guidance Documents and Contacts (Specific Documents are Listed in the Reference Section of This Report)
Topics Knowledge Development Training Site and Comments

Opportunities Opportunities Industry
(See App. B) Documents
(See Section 5)
1.2.1 Development of a Establish motor library from Work with site EPRI LEMUG All documents Establishing a motor
motor industry reference section of this document control workshops and contained in reference library is
document library document. In addition, site to locate vendor meetings Section 5 important to be able to
and establish motor drawings (outline and information and find information on
industry contacts cross section) and vendor motor drawings Offsite motor many common and
and Subject Matter manuals for each motor need to courses unique motor issues.
Experts (SMEs) for be located or established within Use the industry Building a library of
document section Vendor training
motors the motor specialist library. courses these documents and
Caution: only use the controlled of this document being familiar with the
copies of onsite documentation to obtain library Mentor content of each is a
for accurate technical reference material necessity for becoming
information Industry a motor specialist.
Develop industry and SME participation can To assist in motor
contact list provide a source issues that are not
for many motor easily answered from
Establish sound working and SME contacts the motor library
relationships with onsite information, industry
personnel and offsite support contacts can be a
(service shops, vendors, etc). viable resource.
Industry participation
will provide
opportunities to
develop this list of
contacts.
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Table 3-3
Skill Set 1-3 – General Knowledge of Motors

(See Section 5)
1.3.1 Motor Become familiar with Work with applicable Site Training 5.1.4, 5.1.5, To truly understand motors, how
Application the following motor groups to gain a better 5.1.6, 5.1.9, they operate, how they wear
and applications and understanding of the EPRI LEMUG 5.1.10, 5.1.12, and age, and their weaknesses
Classification classifications motor classifications workshops and 5.1.13, 5.1.14, and failure modes, you must
listed in the knowledge meetings 5.3, 5.6 understand both the original
Applications: column design attributes of the motor as
Offsite training
Important to Plant courses well as their unique site
Operation classification
Mentor
Operating
Environment
System Function
Classification:
Balance of Plant
Safety Related
Class 1E non-
Environmentally
Qualified (EQ)
Safety Related
Class 1E EQ
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Table 3-4
Skill Set 1-4 – Motor Nameplate Information

(See Section 5)
1.4.1 Motor Become familiar with Read and EPRI LEMUG 5.5, 5.11 NEMA MG-1 and IEC documents
Nameplate the different understand workshops and provide a minimum amount of
Information information that is minimum meetings information on motor nameplates
listed on a standard recommended depending on their voltage and
motor nameplate and nameplate Offsite motor horsepower. When ordering new
how it defines the information listed in courses motors, it is recommended to request
boundaries of NEMA MG-1 On the Job maximum information on the motor
operation. (OJT) nameplate or even require an
Observe and record additional nameplate to ensure that
the motor Training at critical design and performance
nameplates during Service Shops information about that motor is
walkdowns or while preserved and accessible for future
working on them Mentor maintenance and/or performance
activities.
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Table 3-5
Skill Set 1-5 – Enclosure Types and Materials

(See Section 5)
1.5.1 Low Become familiar with the various Observe the EPRI LEMUG 5.1.4, 5.1.14, The different enclosures are
voltage enclosure types that can be different workshops and 5.1.15, 5.4, 5.5, designed to meet certain
and designed into the NEMA frame and enclosures meetings 5.11 ambient and environmental
medium non-NEMA frame motors. during Offsite motor conditions. For example WP1
voltage Open Drip Proof (ODP) walkdowns courses and WP2 motors are designed to
motor and shop be outside motors, however, in a
Totally Enclosed Air Over Mentor
enclosure visits. nuclear site due to water spray
(TEAO)
types Take photos potential, these enclosures may
Totally Enclosed Fan Cooled be required inside the plant.
for your motor
(TEFC)
library Sheet metal motors are usually
Totally Enclosed Water Cooled not considered as rugged as a
Pay attention
(TEWC) cast iron motors
to the air flow
Weather Protected 1 (WP1) paths within Cast Iron is usually the choice for
Weather Protected 2 (WP2) the motor and NEMA frame size industrial
Explosion Proof the stator air motors
flow for the Non-NEMA frame motors
Others
different (usually greater than 500hp) will
Also become familiar with the designs have either a cast iron or
various materials that these
fabricated steel enclosure.
enclosures can be fabricated from:
Cast aluminum motors are good
Cast iron
for certain applications but can
Cast aluminum create vibration issues plus they
Sheet metal (usually only in are hard to mechanically repair.
NEMA frame sizes below Cast iron motors are rugged but
100 hp) can be cracked by impact. They
Fabricated steel cannot be easily repaired by
Combination of cast iron and welding.
fabricated steel Fabricated steel enclosures can
be weld repaired but can be
more expensive to purchase.
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Table 3-6
Skill Set 1-6 – Basic Knowledge of Motor Performance Data

(See App B) Documents
(See Section 5)
1.6.1 Common Basic knowledge of Become familiar with EPRI LEMUG 5.1.14, 5.1.17, Motors can be electrical tested
Motor Tests common electrical and applicable test workshops and 5.2, 5.4, 5.5, from various locations such as
mechanical test, online procedures meetings 5.7, 5.11 from the switchgear or at motor
and offline test of terminal box. Each test location
motors. Need to Observe testing (site Onsite training has different safety
understand test and offsite) requirements and can yield
Offsite motor
methods, precautions, Become courses different test results
preparation knowledgeable with
requirements and risk of Test equipment Mechanical tests are usually
the test equipment performed locally at the motor
testing. manufacturer
Become familiar with training If tests are performed while the
the various locations motor is energized (online
in the plant from which Mentor
electrical tests, vibration) extra
motors can be tested precautions are required for
personal safety. Usually the site
will have the safety issues
identified within the testing
programs
The documents listed in the
reference column provide some
guidance for the testing. More
complete understanding of
these tests and how to interpret
the test results will be learned
during the knowledge areas
listed in Skill Set 2.
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Skill Set 1-6 – Basic Knowledge of Motor Performance Data

(See Section 5)
1.6.2 Motor Online Basic knowledge of how Observe craft, PDM, Vendor training Vendor Online testing monitoring
Performance to obtain data from the or vendors while operating provides real time data of the
Monitoring following monitoring: performing on line On the job manuals motors and their performance
electrical testing training during normal operation. This
(Continuous Vibration Plant can provide an early warning of
Monitoring if Perform hands on Mentor procedures
Bearing temperatures a degrading condition. It is
installed on testing to gain test important that all safety
motors) equipment experience 5.1.14, 5.1.17,
Winding temperatures 5.2, 5.4, 5.5, measures are understood
(this may have to take during online testing if test
Voltage place in a shop or 5.7, 5.11
equipment installation is
training environment) required.
Amps
If online monitoring is
Partial Discharge a plant data system
then ensure it is
Learn which parameters
connected to your
have preset alarm points
computer if possible
Learn the importance of
trending data.
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Table 3-7
Skill Set -1-7 – Basic Knowledge of Temperature Monitoring Technology and Design

(See App B) (See Section 5)
1.7.1 Temperature Become familiar with Review motor EPRI LEMUG Vendor manuals Temperature monitoring is one of
monitoring the different designs to determine workshops and and drawings the best predictive tools that a
elements temperature elements the type of meetings motor specialist can use to
and methods used to temperature 5.1.2, 5.1.4, determine the health of a motor.
monitor winding monitoring elements Offsite motor 5.1.14, 5.1.15, Temperature limits need to be
temperatures and installed on the courses 5.1.17, 5.2, 5.4, established and understood so that
bearing temperatures motors 5.5, 5.11 temperature increases can be
OJT at Service
Shops properly addressed to preserve
Resistance motor life. There are a finite
Temperature Detector Mentor amount of reasons why motor
(RTD) – (10 ohm, 100 temperatures increase. To
ohm etc) understand these will expedite the
Thermocouples – understanding of why a motor is
(type T, K, J, etc) running hotter on its winding and or
bearings. Remember, excessive
Insulated temperature heat causes degradation.. More
detectors heat usually equates to reduced
insulation life or lubricant life
Infrared temperature
test equipment
Skin temperature
Direct winding
resistance readings
(motor has to be
offline and
disconnected from
cables for this
reading)
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Table 3-8
Skill Set 1-8 – Basic Knowledge of Sensory/Monitoring Technology

(See Section 5)
1.8.1 Stator, bearing, Become familiar with the Observe data EPRI LEMUG 5.1.2, 5.1.4, Detection of vibration and
and lubrication different sensory collection activities workshops and 5.1.14, 5.1.15, lubrication issues are some
sensory technologies that are used meetings 5.1.17, 5.2, 5.4, of the best indicators of
monitoring to monitor bearing Become familiar 5.5, 5.7, 5.11 degraded conditions of
technologies vibration, lubrication quality, with the installed Attend vibration motors.
lubrication flow, etc. sensory training
technology Understanding the installed
Accelerometers Attend lubricant or available sensory
analysis training technologies and their
Proximity Probes application to electric
Mentor
Online oil analysis motors is essential
monitoring meters
Oil flow rate meters
Oil pressure gauges
Ultrasonic Monitoring
3-14
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Table 3-9
Skill Set 1-9 – Basic Knowledge of Stator Winding Heater Technology and Design

(See Section 5)
1.9.1 Stator Determine which Determine which Site drawing 5.1.4, 5.1.14, The inside of a motor needs to be at
winding motors are motors have review 5.1.15, 5.1.17, least 9°F above ambient (Ref IEEE 43-
heater equipped with heaters and ensure 5.2, 5.4, 5.5, 5.11 1974 Appendix) to keep out moisture.
technology winding heaters that they are Mentor The winding materials are very
and design operational when susceptible to moisture absorption
Determine the needed. which becomes more of a problem as
heater design the insulating materials age. In
Understand the addition, most motors are constructed
importance of with cast iron and mild steel which will
keeping the stator rust in the presence of moisture.
winding heaters Winding heaters usually are sufficient
operational and the to minimize these issues. Winding
stator temperature heaters are not designed to dry water
above dew point. saturated windings. They are designed
to keep moisture from accumulating on
the windings and the internals of the
motor.
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Table 3-10
Skill Set 1-10 – Basic Knowledge of Bearing Technology and Design

1.10.1 Bearing Become Review motor EPRI LEMUG Vendor Manuals How each bearing type operates is
technology familiar with the bearing cross workshops and and Drawings important. This knowledge comes from
and design following motor section drawings meetings reading and understanding the
(as bearing and Vendor 5.1.2, 5.1.4, mechanical cross sectional drawings of
applicable designs: manuals for Offsite motor 5.1.10, 5.1.14, the bearing assemblies, vendor manuals,
to your Rolling bearing design courses 5.1.15, 5.1.17, 5.2, and hands on experience.
site) Element 5.4, 5.5, 5.10, 5,11
Observe bearing Bearing Become familiar with bearing storage
Bearings manufacturer
refurbishment and and handling
Radial replacement of the training classes
different type The following list of bearing types is not
Thrust Participate in all inclusive:
bearings listed in service shop
the knowledge refurbishment Rolling Element Bearings:
Fluid Film
column. The activities on your
Babbitt
differences motors Open face
Bearings
between these
bearing types need Mentor Single shielded
Radial and
Guide to be learned early
Double shielded
in the motor
Sleeve specialist career. Sealed
Thrust Plate Roller Bearing
Bearings
Tapered roller
Spherical roller
Angular contact
DB, DT, and DF stacking arrangement
for angular contact
Duplex universal design
3-16
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Skill Set 1-10 – Basic Knowledge of Bearing Technology and Design

Stamped cage
Bronze cage
Internal clearance designation (i.e. C3 for
most motor bearings)
Use of wavy washers
Fluid Film Bearings:
Babbitt sleeve bearing
Babbitt tapered land guide bearing
Babbitt segmented guide bearing
Babbitt self equalizing thrust bearing
Babbitt non-equalizing thrust bearing
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Table 3-11
Skill Set 1-11 – Basic Knowledge of Lubrication Systems, Lubrication Types, and Quantities

(See Section 5)
1.11.1 Lubrication Basic knowledge of Review vendor EPRI LEMUG 5.1.2, 5.1.4, Lubrication is essential to the life of any
types and lubrication types and manuals and workshops and 5.1.10, 5.1.14, bearing system. Whether it is grease or oil,
quantities quantities drawings to meetings 5.1.15, 5.1.17, the correct lubricant for the application must
determine the 5.1.18, 5.4. 5.5, be used and the proper quantity must be
Lubrication Lubricant Types recommended EPRI Bearing 5.7, 5.11 maintained. The industry has had several
Systems lubricant & Lubrication issues with improper mixing of lubricants
Grease workshops which has resulted in premature bearing
Mineral Oil Work with the failures. All of these mixing issues were
applicable Offsite motor
courses avoidable with adequate controls over the
Synthetic Oils groups that grease and oil program.
support and Bearing
Basic knowledge of maintain the Precautions:
the importance of Manufacturer’s
sites lubricant training
correct lubricant program Incorrect lubricant can cause premature
quantities courses bearing failures.
Become familiar Oil specialty
Understand and be with the different Incompatible lubricant can cause premature
able to identify the companies lubricant failure which can lead to eventual
motor training
different types of lubrication bearing failure.
lubrication systems: classes
systems Contaminated lubricant can cause
(includes Oil analysis premature bearing failures
Grease lubricated
lubricant level laboratory visit
Oil bath self indicators) Too much lubricant causes overheating and
contained Oil leaks (shortened bearing life).
manufacturer
Oil bath force fed company Too little lubricant causes overheating and
training lubricant starvation (eventual bearing failure)
Oil mist
Mentor There are different failure modes based on
Oil slinger ring the design of the lubrication system. It is
operation important to learn the differences in design.
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Skill Set 1-11 – Basic Knowledge of Lubrication Systems, Lubrication Types, and Quantities

(See Section 5)
In a forced fed lubrication system, small

particles can clog the metering orifice and
cause oil starvation. It is also important
that the proper GPM flow rate is achieved
from the correct metering orifice diameter.
In oil slinger ring self contained oil
systems in horizontal motors, the bearing
is above oil level and is dependent on
proper oil slinger ring operation to ensure
adequate lubricant to the bearing.
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Table 3-12
Skill Set 1-12 – Basic Knowledge of Cooling System Designs

(See
Section 5)
1.12.1 Cooling Become Review air and EPRI LEMUG Vendor A stator can be cooled by:
system familiar with oil cooling workshops and manuals and
External coolers
designs the different system meetings drawings
designs designs of the Natural circulation cooling
(Stator and Offsite motor 5.1.4, 5.1.8,
available motors as
bearing courses 5.1.10, Forced circulation cooling
for stator depicted on
lubrication) 5.1.13,
and bearing the vendor Participate in service Water cooled, Freon cooled
5.1.14,
lubrication drawings shop refurbishment
5.1.15, The stator cooling system for each motor is designed
cooling activities on your
Identify motors 5.1.17, 5.4, to maintain the insulation system within its design
systems motors
with heat 5.5, 5.6, 5.7, limits. A motor should not be operated above its
exchangers Mentor 5.11 insulation system design temperature rating. If the
insulation system temperature rating is exceeded,
insulation material degradation will be accelerated.
Bearings are cooled by the lubricant.
Lubricant can be cooled by:
Immersed internal oil coolers
External oil coolers
Air flow external to the endbell
Natural convection
Oil circulation internal and/or external to the motor
Excessive heat will also degrade the lubricant and
require more frequent oil changes.
Lack of maintenance on the stator and oil cooling
system can result in motor overheating.
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Table 3-13
Skill Set 1-13 – Basic Knowledge of Winding/Insulation System Types

See App B (See Section 5)
1.13.1 Insulation Become familiar Understand the typical Onsite training Vendor manuals The best way to learn about
System with different correlation between stator and drawings insulation systems is to observe
Types insulation system voltage and insulation EPRI Motor insulation system fabrication,
types system type Rewind Seminar 5.1.4, 5.1.5, 5.1.6, installation, and testing at a
5.1.9, 5.1.14, motor manufacturer or a rewind
Random wound <600 volts typically Offsite motor 5.1.15, 5.1.17, 5.2,
courses facility
random wound stators 5.4, 5.5, 5.6, 5.11
Form wound
>600 volts typically form Vendor Training
wound stators Mentor
Observe motors in their
disassembled state to
understand the difference
between these two winding
types
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Table 3-14
Skill Set 1-14 – Storage of Motors

(See Section 5)
1.14.1 Storage Understand the Find all of the EPRI LEMUG Vendor manuals Motors can be damaged if not handled or
of importance of spare motors in stored properly. Damage can occur to
motors storage storage Offsite motor courses 5.1.14, 5.1.18 insulation system, and mechanical components
requirements of Vendor Training which can shorten the life of a motor or cause it
motors and the Ensure the to be inoperable.
consequences if storage and Mentor
not performed handling Motors should be stored in a temperature and
correctly. procedures are humidity controlled environment. The winding
being followed should be kept above dew point by either
installed stator heaters or by temporary heat
sources while in storage to prevent the
insulating materials from absorbing moisture
and corrosion of the non coated internal carbon
steel components.
Limit external vibration which can introduce
false brinelling to the rolling element bearings.
Varmit protection should be provided.
Motors should be stored with adequate good
quality lubricant. Periodic rotation is required to
change the load points on the bearings. Cau-
tion has to be taken when rotation is attempted
on motors with babbitt bearings or bearing
damage can occur during the rotation activity.
If a motor is stored for a significant period of
time, it is recommended to electrically test the
winding and change the lubricant prior to
installation. In some cases on rolling element
bearing motors, bearing change out may be
required.
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Skill Set 2 – Primary Motor Specialist and Back Up Motor Specialist
Table 3-15
Skill Set 2-1 – Knowledge of System Design and Operation

(See Section 5)
2.1.1 System Become familiar with the Work with operations Onsite Site system Achieve a good working
knowledge systems that contain to understand the Systems description knowledge of how your motors
and motor motors well enough to plant systems Training documents affect overall plant operation
performance understand what and performance. This allows
happens to plant Work with system OJT FSAR you to understand which motors
performance when a engineering to obtain are considered critical to plant
a system working Mentor Tech Specs
motor installed in that operations, which ones need
system fails or is not knowledge and to 5.1.4, 5.1.13, more maintenance to maintain
operating properly form a good working 5.1.14, 5.3, 5.4, maximum reliability, and which
relationship 5.5, 5.11 ones need critical spares.
2.1.2 Support Why it is performed Observe operations Site Onsite Surveillance testing provides
Surveillances performing procedures documentation reasonable assurance that the
What information it surveillances and courses motor will perform its intended
provides FSAR function by verifying it is
Review surveillance System training operating within normal
How to obtain data Tech Specs
surveillance results Mentor operating parameters
5.1.6, 5.1.13
What the results tell you
about motor health and
performance
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Table 3-16
Skill Set 2-2 – Knowledge of Motor Drawings (Electrical, Instrumentation, and Mechanical)

(See Section 5)
2.2.1 Vendor and Understand motor Work with vendors Site training on Site documents The electrical drawings will
utility motor winding drawings and and rewind shops to drawings on drawings, provide the winding design of
drawings insulation design gain understanding symbols, and the stator. This will assist in
Work with the
(electrical, drawings of winding and logic: any failure analysis to deter-
different
instrumentation, insulation diagrams mine whether a winding fault
Understand the site engineering Single line
and and drawings. occurred. The location of a
electrical schematic and groups and the
mechanical) Connection fault in a winding relative to
connection drawings as Work with the craft to learn
diagram the motor leads and the
well as logic diagrams electrical design the detail of
neutral will provide information
for the motors and group and the drawings Schematics
on what type of failure the
power supply circuits. electricians to better
On the job Elementary stator winding exper-ienced
understand the
Understand the training diagrams (turn-to-turn on the first phase
electrical drawings
instrumentation draw- coils, weakness in the ground
Be involved in Cross section
ings (junction boxes, Work with the wall at the neutral, etc.)
winding design drawings
terminal blocks, etc) as mechanical
activities at The instrumentation draw-ings
well as be able to deter- engineering group Bearing
service shops will assist in determining
mine the temperature and the machinist to drawings
during rewind temperature monitoring
monitoring instrum- understand the
Shaft/rotor anomalies. Since thermo-
entation, whether they mechanical Mentor
drawings couples provide a milli-volt
are grounded or un- drawings and the
signal for its temperature
grounded design, unique symbols 5.9 reading and a resistance
insulated or un- used on mechanical
temperature detector (RTD)
insulated design, 2 wire drawings
provides a change in resis-
or 3 wire design.
Work with the tance for its temperature
Learn how to read the instrument technic- reading, it is important to know
mechanical cross ians to understand when you are looking at a
section drawings for the different types valid temperature read-ing or
motors. These will of temperature a false one that is skewed by
include bearings, stator, monitoring noise, stray voltage, or high
frames and shafts. elements. resistance joints.
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9842707

Skill Set 2-2 – Knowledge of Motor Drawings (Electrical, Instrumentation, and Mechanical)

(See Section 5)
Be able to understand the Obtain controlled Mechanical drawings are

mechanical symbols such copies of the important since they contain
as RMS surface finish, electrical, information about the
weld types, total indicator instrument, and machined components that
runouts, etc. mechanical have close tolerances,
drawings for each of physical dimensions, fits,
your motors and clearances, material type,
place them in your surface finishes, weld
motor library. information, oil flow paths, air
Ensure only the flow paths, bearing insulation
latest revisions are location and design, etc. You
used. should be able to look at a
mechanical cross section of
any given motor or bearing
assembly and understand
how the motor operates
mechanically. This type of
knowledge is invaluable
when trying to understand
operational anomalies and
will allow you to make proper
recommendations for
continued operation as well
as repair and refurbishment
recommendations.
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Table 3-17
Skill Set 2-3 – Knowledge of Motor Program Guide(s)
Training Site and Industry Comments

Development
Topics Knowledge Opportunities Documents
Opportunities
2.3.1 Motor Become familiar Participate in motor EPRI LEMUG Site procedures Motor program guide(s) is an
Program with the different program workshops and upper tier document(s) for the
Guide(s) elements of your assessments at meetings 5.1.4, 5.1.5, 5.1.6, motor program should contain at
Motor Program other sites 5.1.9, 5.1.14, a minimum the following:
Guide(s) Offsite motor 5.1.15, 5.1.17,
Participate in site course 5.1.18, 5.2, 5.3, Overall description of the motor
assessments 5.4, 5.5, 5.6 program.
INPO training
Network with others A list of the motors included within
that have already Vendor testing the program.
established motor and
program guides refurbishment The different elements that make
recommendations up the motor program.
in the vendor
manuals and Assigned responsibilities of the
instructions different elements of the motor
program.
Mentor
Acceptance criteria for the
required tests.
Frequencies of performance of
testing
Critical spare motor requirements.
The Motor program owners roles
and responsibilities to provide
governance and oversight.
Preventive maintenance program
Routine surveillance program
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Skill Set 2-3 – Knowledge of Motor Program Guide(s)
Training Site and Industry Comments

Development
Topics Knowledge Opportunities Documents
Opportunities
Condition monitoring activities
Dismantled inspections PM,
surveillance, and condition
monitoring intervals
Tracking and tracing guidance
(unique identifiers for each
motor)
Procedure requirements
Base-line data requirements
Condition and predictive based
maintenance requirements
Corrective maintenance
guidance
Quarantine requirements after
failure
Trouble shooting guidance
Trending requirements
Program self-assessment
guidelines
Requirements of motor
refurbishment, rewind, and
procurement specifications
Refurbishment Intervals
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Table 3-18
Skill Set 2-4 – Knowledge of Long Range Motor Plan

2.4.1 Long Range Become familiar with the Obtain the EPRI LEMUG Site integrated A long range plan is
refurbishment history for each of the maintenance history workshops and long range plan important to the sites and
and motors in the motor by working with meetings outside agencies. A long
replacement program guide. This planning and 5.1.1, 5.1.4, 5.1.5, range plan can result in:
plan should include past dates maintenance INPO training 5.1.6, 5.1.9,
for: 5.1.13, 5.1.14, Increased motor reliability
Assist in the Offsite motor 5.1.15, 5.1.17,
Refurbishments development of a courses 5.1.18, 5.3, 5.4, Better INPO ratings
history matrix so Vendor training 5.5, 5.6, 5.10, 5.11 Lower insurance costs
Rewinds easy review of each
Winding retreatments motors history can be Mentor A long range refurbishment
performed and be and replacement plan is
Electrical Tests shown to needed to allow for the long
management as lead times required for
Bearing work necessary maintenance budget,
Bearing replacement outage planning, resource
Attend project allocation, and critical
budgeting meetings spare procurement
Cooler maintenance
and/or refurbishment Attend outage planning.
planning meetings
Alignment
Assist in maintaining the
history data base so it can
be used to defend future
motor refurbishment and
rewind time intervals
Assist in development of
the long range plan for
motors and ensure that it
is part of the sites
integrated long range plan
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Table 3-19
Skill Set 2-5 – Knowledge of Spare Motors

(See
Section 5)
2.5.1 Spare Determine Work with warehouse EPRI LEMUG 5.1.1, 5.1.6, The lack of available spare motors in the power
Motors location of personnel to locate all workshops 5.1.9, industry prevents plants from achieving maximum
the spare spare motors and meetings 5.1.14, reliability. It is difficult to remove an installed
motors 5.1.15, motor, transport it to a repair facility, perform a
Develop a list of critical INPO motor
5.1.18, 5.3, refurbishment and/or rewind, test run, transport it
Identify motors that will have a workshops
5.4, 5.5, 5.6, back to the site, and install it during an outage
installed negative impact on the
Mentor 5.11 time frame. With a critical spare motor onsite, a
motors that plant if they fail. Negative
motor can be removed and a spare motor
do not have impact is either a plant trip,
installed during an outage timeframe. This allows
spares unit de-rating, or reactor
a more thorough and complete refurbishment to
safety issue.
Understand be performed on the removed motor because it
which motors Other areas that may list a will be performed during a non-outage time
are listed as motor as critical are: frame.
critical and
Large economic assets Doing the work during non-outage time allows the
why they
motor specialist to be more involved in the
have this Single point of vulnerability
refurbishments.
classification
Critical component as
Most of the motors in the nuclear utilities are 25
Incorporate defined by AP-913
plus years old. Up until a few years ago bearing
request for
Identify which motors have failures had always been the majority failure
future spare
a critical spare readily mechanism. That trend is changing because of
motors into
available to be installed. the age of the windings. After a winding exceeds
the 10 year
30 years of life, it becomes more susceptible to
plan From those critical motors experiencing a failure due to years of vibration,
that do not have a critical material aging, surge voltages, and
spare motor, present to contamination. As opposed to bearing failures
plant management as part which some can be repaired in-place, winding
of the 10 year plan for the failures almost always require motor removal.
procurement of these Without a critical spare, a failed motor can be
critical spare motors non-recoverable during an outage time frame and
can impact plant generation.
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Table 3-20
Skill Set 2-6 – Knowledge of Maintenance Procedures and Surveillance Instructions

(See Section 5)
2.6.1 Technical Achieve adequate Work with craft Onsite training 5.1.1, 5.1.4, In order to ensure that the
knowledge of knowledge of motor and other 5.1.5, 5.1.6, maintenance procedures have
OJT working
the motor maintenance engineers to gain 5.1.10, 5.1.11, correct and adequate information,
with
maintenance procedures and knowledge in the 5.1.13, 5.1.14, the motor specialist must become
maintenance
procedures and surveillance areas listed 5.1.15, 5.1.17, familiar with the industry developed
and operations
surveillance instructions. The under the 5.1.18, 5.2, 5.4, test and performance criteria. Most of
instructions primary specialist Knowledge Test instrument 5.5, 5.6, 5.7, this information can be found in the
needs to ensure that column manufacturer 5.8. 5.9, 5.10, documents in the motor library
the procedures training 5.11 (EPRI, IEEE, ANSI, ASTM, ABMA,
Work with the
contain proper EASA, NEMA, and CFR). As the
Predictive Offsite specialty
technical information. motor specialist gains experience
Maintenance training:
with what has been developed by
Become familiar with Group for a
Oil analysis technical experts in the industry, he
the technical basis for better
training or she can apply this information to
the acceptance understanding of
the maintenance procedures and
criteria. the vibration Vibration surveillance instructions.
testing and oil training
Become familiar with
analysis The motor specialist needs
the safety precautions Alignment knowledge in the following areas:
in the procedures that Be onsite at the training
control electrical service shops The safety precautions for
tests. when motors are Mentor performing electrical tests
being tested
Electrical Testing and Acceptance
Learn the Criteria
content of the
Vibration Testing and Limits
motor library
which will contain Oil Analysis and Condemning Limits
most of this
Temperature Limits (Stator and
information
Bearings)
Alignment Criteria
Coupling Fit Criteria
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Table 3-21
Skill Set 2-7 – Knowledge of Motor Predictive and Preventive Maintenance Programs

2.7.1 Predictive and Achieve Work with the PDM EPRI LEMUG 5.1.1, 5.1.4, 5.1.6, A motor specialist must have a
Preventive understanding of all groups and workshops and 5.1.8, 5.1.10, thorough understanding of the
Maintenance of the predictive Maintenance during meetings 5.1.14, 5.1.17, predictive and preventive
Programs and preventive the performance of 5.1.18, 5.2, 5.4. technologies and activities that are
maintenance Predictive and Offsite motor 5.5, 5.6, 5.7. 5.8, in the motor program to determine
programs in place Preventive courses 5.9, 5.10, 5.11 the overall health of the motor.
for the motors Maintenance Activities Test equipment
Be able to operate Predictive and Preventive
Assist in the manufacturer programs, if properly
most of the test training
equipment development of time implemented, results evaluated,
intervals to perform Bearing and trended, are the best defense
Understand test these tasks based on manufacturer against in-service failures in
equipment industry guides that training between motor refurbishments.
connection have been developed
challenges Offsite specialty Preventive maintenance activities
Perform hands on training: require knowledge of the parts in
Be able to testing to gain the motors that will age and
recognize test knowledge of the test Oil analysis require change out at certain
anomalies equipment and the training intervals. Usually, motors have a
expected results 10 – 15 year refurbishment
Know when to Vibration interval which will allow
perform these tests training opportunities for these
Know which test to components to be replaced before
Alignment
perform on which they fail in-service.
training
motors
Balancing
Know when to training
change component
out before failure Mentor
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Table 3-22
Skill Set 2-8 – Knowledge of the Content of the Documents in the Motor Technical Library

(See Section 5)
2.8.1 Motor Gain core Read each Be involved in future All documents in See 1.2.1 for motor library
Reference knowledge about document and motor document Section 5 development.
Document motors know where key revisions and
As listed in the Industry document
Library topics are located. development.
Know where to section of this document, a
technical
look to find non- Develop an Many of these significant amount of information has
content
core knowledge electronic version documents are been developed for motors:
(most can be of the library to developed by industry
Testing
found in the allow easy access groups such as EPRI
library resources) of content and LEMUG, IEEE, ASTM, Maintenance
search capability. etc. Repair
Make the
information Participate in selective Refurbishment
readily available industry meetings that
to support motor develop motor Rewinding
issues documents. Component replacement
Mentor Vibration
Lubricant
Alignment
Installation
Procurement
Shipping
Storage
A motor specialist should have
certain core knowledge about
motors; however, there will be many
issues that require more than core
knowledge. This is why there is a
need for the motor reference library.
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Table 3-23
Skill Set 2-9 – Knowledge of Motor Trouble Shooting Guidelines (Electrical and Mechanical)

(See Section 5)
2.9.1 Troubleshooting Learn motor trouble Work with craft EPRI LEMUG Vendor info and Troubleshooting practices must be
(Electrical and shooting processes and other workshops and site procedures known and presented to
Mechanical) so that the most personnel to learn meetings management to aid in the
effective the 5.1.2, 5.1.3, 5.1.4, development of the recovery plan
troubleshooting troubleshooting Onsite Training 5.1.6, 5.1.7, and minimize unnecessary
activities are techniques 5.1.10, 5.1.11, activities. Understanding how
Offsite motor 5.1.13, 5.1.14,
performed first for courses motor components age, degrade,
identified failures Learn trouble 5.1.6, 5.1.17, 5.2, and fail will provide significant
shooting OEM Training 5.4, 5.5, 5.7, 5.8 improvement in the motor
processes specialist troubleshooting abilities.
Mentor
Work with your
mentor.
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Table 3-24
Skill Set 2-10 – Knowledge of Thermography and Ultrasonic Monitoring for Motors

(See Section 5)
2.10.1 Thermography Learn the two Work with the EPRI LEMUG Vendor manuals Thermography and Ultrasonic
and Ultrasonic technologies and groups that workshops and monitoring technologies can be
Monitoring what they can and perform these meetings 5.1.14 useful as part of the motor
cannot find when activities predictive maintenance program.
used on motor Attend equipment
testing Learn to use the manufacturer Thermography needs to have
equipment to better training base line operating temperatures
Know the limitations understand its established and tied to ambient
of each technology limitations Get hands on temperature in order to detect
training small temperature increases
Mentor above normal. Significant
temperature increases can be
found with this technology.
Ultrasonic monitoring is used on
motors mainly to determine
bearing issues and/or loose
parts. Recently it is being used to
assist in bearing re-greasing by
listening to the sound of the
rolling element bearing while
adding grease.
Caution needs to be taken when
using this method for re-greasing
shielded bearings as shield
damage could occur before the
new grease reaches the rolling
elements (balls, roller, etc).
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Table 3-25
Skill Set 2-11 – Knowledge of Motor Coupling Designs (Includes Installation)

(See Section 5)
2.11.1 Coupling Understand coupling Work with the EPRI LEMUG Manufacture’s Each coupling design has
design, design, installation, fits, machinist during workshops and coupling strengths and weaknesses.
alignment, maintenance, coupling meetings specifications
and fits alignment and end float maintenance, Misapplication, improper fit to
issues as well as most installation, and Coupling 5.1.11 the shaft, lack of grease,
common failure alignment activities. manufacturer misalignment, end float issues,
training 5.9 wear, loss of hardware, and
mechanisms.
Learn the strengths gasket integrity have all caused
Several different and weaknesses of Mentor failures in the industry.
coupling designs are each coupling design.
used in the power Ensure coupling inspections
industry: and proper coupling fit to motor
shaft are included in the
Geared refurbishment and replacement
specifications. There have been
Flex several industry motor failures
Direct due to coupling wear and
improper coupling fits.
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Table 3-26
Skill Set 2-12 – Knowledge of Motor Lubrication Programs

2.12.1 Lubrication Become familiar Work with the Onsite training Site Lubrication Lubrication will require either
Programs with oil lubrication responsible group(s) Programs replenishment or replacement
programs and that controls the Attend lubrication during the life of a motor
analysis processes. lubrication program training courses that 5.1.5, 5.1.10, bearing. The life of motor
at the site. provide information on 5.1.14, 5.1.18, 5.4 bearings greatly depends on
Understand the lubrication properties, the quality and correct
lubrication Attend training to be tests and analysis, and quantity of the lubrication.
programs and how able to detect understanding the oil
they differ degrading conditions analysis report. Both oil and grease can cause
depending on the in lubrication. premature bearing
type of bearing Mentor degradation and failure if the
used. proper quality and correct
quantity are not present within
the motor bearing housing.
Too much lubricant as well as
too little can cause lubricating
issues such as overheating
and inadequate lubricant
which will lead to premature
bearing failure.
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Table 3-27
Skill Set 2-13 – General Knowledge of Motor Shaft Designs

(See Section 5)
2.13.1 Shaft Know the difference Work with the machinist EPRI LEMUG 5.1.14, 5.1.15, RMS surface finishes are very
design between a solid shaft during motor refurbishment workshops and 5.1.17, 5.4, 5.5, important on shaft especially in
and a hollow shaft to become familiar with shaft meetings 5.9, 5.11 the bearing journal areas. The
motor. design, surface finish surface finish can be
inspection, and runout Offsite motor determined by electronic
Become familiar with techniques and criteria. courses meters or by comparing it to
RMS surface surface finish standard
smoothness since the OEM training
coupons.
shaft usually contains OJT at Power
the bearing journals. Service Shops Total indicator runout is
during motor usually performed on a lathe
Become familiar with using dial indicators taken at
shaft total indicator refurbishment and
rewind 90 degrees until a complete
runout acceptance 360 degrees shaft rotation has
criteria especially for Mentor been completed.
the journals and the
coupling areas
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Table 3-28
Skill Set 2-14 – General Knowledge of Different Motor Designs

(See Section 5)
2.14.1 General Understand the differences Work with the service shops EPRI LEMUG 5.1.4, 5.1.5, Squirrel cage
knowledge between the following motor during motor refurbishment workshops and 5.1.14, 5.1.15, induction motors are
of motor designs: and rewind activities to meetings 5.1.17, 5.1.18, the least complicated,
design better understand the 5.4, 5.5, 5.11 the largest population,
Induction motors - Squirrel differences in motor design Offsite motor and the easiest to
cage design and operation. courses maintain.
Wound rotor design Mentor The synchronous and
Synchronous motors DC motors can have
variations built into
DC motors them due to the
wound rotors and the
Each motor is designed for dc excitation.
a specific application. The
squirrel cage induction
motor, synchronous motor,
and dc motor design are the
most common in power
plants
Gain knowledge of site
applications for the different
types of motors.
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Table 3-29
Skill Set 2-15 – General Knowledge of Cooling Coil Designs
Topics Knowledge Development Opportunities Training Site and Comments

Opportunities Industry
(See Section 5)
2.15.1 Cooling Identify motors Work with the service shops EPRI LEMUG Vendor manuals Motor oil and air coolers are
coil with coolers during motor refurbishment workshops and and drawings often overlooked in motor
designs and rewind activities to meetings maintenance activities. During
Become familiar determine the different types of 5.1.4, 5.1.8, refurbishments the coolers
with the most coolers and cooler connections Offsite motor 5.1.14, 5.1.15, should be inspected, cleaned,
common materials designed into motors. courses 5.1.17, 5.1.18, and either pressure tested or
used in oil and air 5.4, 5.5, 5.11 hydrostatic tested.
coolers Heat exchanger
training All coolers can be visually
Understand the inspected and straight tube
different designs Mentor
coolers can be eddy current
of internal and tested.
external oil coolers
The most common cooler
Understand the material is 90/10 copper nickel.
different designs Other materials that you may
used for stator encounter are pure copper,
cooling admiralty brass, and stainless
steel.
Each cooler design and material
type will degrade at different
rates.
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Skill Set 3 – Primary Motor Specialist
Table 3-30
Skill Set 3-1 – Commercial Grade Item (CGI) Dedication and Motor Upgrade Processes

(See Section 5)
3.1.1 Commercial Learn how materials have Work with EPRI LEMUG Site dedication This is extremely important to
Grade Item to be purchased and tested procurement workshops and programs understand since materials
and in order to use commercially engineering to gain meetings change frequently and must be
Dedication available materials in Class knowledge of the 5.1.15 evaluated and dedicated
Processes 1E Safety Related – Non- dedication process Onsite training before use in repair or rewind.
Environmentally Qualified Vendor and/or
applications. Work with a vendor The complete motor upgrade
or service shop service shop provides a unique opportunity
Obtain the testing that can upgrade training on CGI to obtain commercially
knowledge of how to commercial NEMA NEMA motor available NEMA frame size
upgrade a commercially frame size motors upgrade process motors and use them in Class
available NEMA frame size using the EPRI Mentor 1E Safety Related – Non-EQ
motor so it can be used in CGI Data Base applications at a fraction of the
Class 1E Safety Related – guidance cost.
Non-EQ applications.
EPRI developed the CGI data
Understand the CGI base in the early 1990s due to
Dedication Process and how problems with obsolete
it applies to motor material materials and equipment. The
replacement as well as guidance of the CGI
upgrading commercial grade documents provides the critical
NEMA frame size motors for characteristics of design and
use in Class 1E Safety acceptance and the dedication
Related Non processes. The three CGIs
Environmentally Qualified referenced are for single
(EQ) applications phase, three phase, and DC
motors.
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Table 3-31
Skill Set 3-2 – Knowledge of Like for Like Motor Replacement Evaluations

3.2.1 Like for like Become Work with EPRI LEMUG Site dedication Like for like evaluations require a sound
motor familiar with the procurement on workshops and programs working knowledge of the electrical and
replacement physical, new motor meetings mechanical operation and design of
5.1.15
evaluations electrical, procurements. motors. The more that is known about
Offsite motor
mechanical, the critical characteristics of design and
Work with the courses
and operation, the more accurate the like for
dedication group to
performance Commercial like evaluation will be.
become familiar
critical graded
with attributes An improper evaluation can have minimal
attributes of dedication
required for motor to major plant impact such as:
motors to allow training and
dedication as they
proper like for activities Motor will not fit on base
are similar to those
like evaluations
required for like for Mentor Motor leads too short or junction box in
of replacement
like motor wrong location
motors
replacements.
Motor weight is not the same which could
affect seismic analysis
Bearings are not the same which can
affect bearing life and lubrication
programs
Motor oil cooler or air cooler lines not in
proper location requiring line relocation
Temperature monitoring elements not the
same as original therefore temperature
monitoring will be affected
The above are a few examples of motor
designs that can cause installation and
operating issues.
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Table 3-32
Skill Set 3-3 – Knowledge of Motor Trip Circuits and Protective Relaying

3.3.1 Protective Become familiar with the protection Work with the Onsite training Plant coordination Each of these
relaying and trip logic associated with each of breaker engineer courses on study protective devices
associated the protective devices. to gain breakers and assist in determining
5.1.4, 5.1.16
with the knowledge of relays if the motor tripped
Each protective, trip, or relay device
different how the due to a motor
protects against a certain type of OJT working
types of protective winding problem, a
circuit, motor, or fault condition with the
motors devices work. mechanical overload
breaker and
The most common devices are listed condition, a cable,
Work with the relay groups
below: issue, a breaker
relay calibration
Vendor issue, or an input
Thermal overloads group to gain
documentation power issue. This will
understanding of
End winding thermal switches explaining aid in testing and
how the relays
how the relays whether or not the
Magnetic Trip Circuit work and what
operate motor can be
they are sensing
Low Voltage Breakers returned to service.
Mentor
Be able to
Medium Voltage Motor Circuit Breaker All of these devices
identify the
trip schemes will be shown on the
targets on a relay
electrical schematic
Instantaneous over-current trip relay after actuation
drawings of the
Time over-current trip relay breaker, board, or
controls for the motor.
Ground fault relay Be able to recognize
Phase differential relay them on the drawings
and how they function
Distance relay in the circuit in order
Synchronizing relay for synchronous to fully understood
motors how they work and
what they are
Under and Over voltage relays sensing.
Reverse power relay
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Table 3-33
Skill Set 3-4 – Knowledge of Motor Test Equipment

(See Section 5)
3.4.1 Motor Test Specialized test equipment used to Be involved in EPRI LEMUG 5.1.4, 5.1.14, Each of the test sets listed
Equipment test motors. most of the workshops 5.2, 5.4, 5.5, under the knowledge column
Winding Resistance Test Set testing and meetings 5.11 can be a discrete test set or be
(Bridge™) activities for Onsite training an all in one electronic test set.
Insulation Resistance Test Set low voltage, courses on Both types require training.
(Megger™) dc, and electrical Knowledge of the sites test
medium testing equipment and keeping up with
DC Hi-pot test set
voltage motors Test new test equipment that is
AC Hi-pot test set being developed by vendors is
Develop a equipment
Surge test set working important to ensure the site has
manufacturer
Partial Discharge test set relationship training adequate testing capability.
Power Factor Tip Up test set with the OJT working Testing just to collect data is
Online Performance Testing groups with the test useless. The tests results (and
Other (Impedance, Inductance, responsible for groups or test result expectations) must
Capacitance, etc.) testing so that maintenance be understood by the motor
you can gain specialist during the testing and
Understand what each test set is Vendor
hands on field the results must be trended in
measuring manuals on
experience order to identify any negative
Be able to interpret and trend the the test
trends.
data to identify a negative trend or equipment
The ability to know when the
an anomaly early Mentor
tests results are valid or not
Be able to operate each test set by during testing allows a second
hands on experience or third test to be performed
Know when the results of each test with a separate test set in order
set are valid or false to validate the test results. With
Know when to perform a second the tagging requirements
test to validate good and/or bad test necessary for most testing, it is
results important to perform all of the
Keep up with new equipment as it is testing at one time or increased
developed to make the testing maintenance, operations, and
easier or more accurate outage time will be required.
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Table 3-34
Skill Set 3-5 – Specialized Training

3.5.1 Specialized Gain knowledge in the following Work with EPRI LEMUG Additional industry Most motor
training areas: responsible workshops and documents specialists will know a
groups to gain meetings lot about one or two
Oil Analysis 5.1.4, 5.1.11,
knowledge of each of the technologies or
Vibration analysis of the specialized Onsite courses 5.1.14, 5.4, 5.5, activities listed in the
activities listed in 5.7, 5.11 topic column,
Accelerometers Test equipment
the topic column manufacturer however, an
Proximity probes
training understanding of all
Orbit analysis Obtain a copy of of these areas will
Shift Strain Gages under Vibration all of reports from Working with the make operational and
Analysis these activities groups repair/refurbishment/r
Strain gauges that pertain to your responsible for ewind decisions more
motors. These can these activities accurate.
Balancing be electronic or
Single plane balancing hard copy. Mentor The more you know
Multi-plane balancing about these
Work with the specialized areas and
Weight attachment techniques responsible what they tell you
Alignment groups to about the motor
understand the performance, the
Double dial indicator anomalies more accurate your
Laser alignment associated with prediction of the
Cold alignment any of these motor health will be.
Hot alignment activities and the
most probable
Understand the testing techniques
resolution
and the test results for each test listed
above.
Gain enough knowledge to be able to
talk one on one with the craft,
technical, or engineering groups
responsible for performing these tests
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Table 3-35
Skill Set 3-6 – Ownership of the Long Range Motor Plan

(See Section 5)
3.6.1 Long Range Establish the history Obtain the maintenance EPRI LEMUG Site integrated Adequate history for each
refurbishment for each of the history by working with workshops and long range plan motor provides crucial
and motors. This should planning and meetings information that can be used
replacement include past dates for: maintenance 5.1.1, 5.1.4, to evaluate failures as well as
plan INPO training 5.1.5, 5.1.6, justify future maintenance and
Refurbishments Develop a history matrix 5.1.9, 5.1.13, refurbishment activities
so easy review of each Offsite motor 5.1.14, 5.1.15,
Rewinds courses (including rewinds).
motors history can be 5.1.17, 5.1.18,
Winding performed and be shown Vendor training 5.3, 5.4, 5.5, 5.6, It is the motor specialist’s
Retreatments to management as 5.10, 5.11 responsibility to capture and
necessary Mentor keep up the history
Electrical Tests documentation as well as the
Use the maintenance present activities being
Bearing work history matrix to plan the performed on the motors. The
10 year plan. EPRI and history records will enable the
Bearing INPO recommendations correct maintenance to be
replacement listed in the industry performed at the correct time
documents will aid in interval to maintain a high
Cooler maintenance
developing the time level of reliability.
Alignment intervals
Some activities are based on
Maintain the history Attend project budgeting condition and some on time
data base so it can be meetings intervals. Time intervals are
used to defend future recommended for
Attend outage planning
motor refurbishment refurbishments.
meetings
and rewind time
intervals Work with contract Time, inspection, and
management to obtain condition based evaluations
Become involved in are recommended for rewinds.
motor trained resources
budgeting the motor The exception to this may be
activities into the sites end of qualified life on EQ
fiscal year budget motors if qualified life
extension cannot be justified.
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Skill Set 3-6 – Ownership of the Long Range Motor Plan

(See Section 5)
Work with outage Work with planning to

management to ensure work packages
ensure the activities contain sufficient and
are scheduled and adequate information to
done within the accomplish the planned
outage scope motor activities
Work with project
management and
contracts to ensure
that you have
sufficient motor
trained individuals
onsite when your
activities are to be
worked
3-46
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Table 3-36
Skill Set 3-7 – Critical Spare Motor Procurement and Preservation

3.7.1 Critical Develop a plan to procure Work with the EPRI LEMUG 5.1.1, 5.1.6, 5.1.9, 5.1.14, Many motor activities cannot
Spare critical spares that do not different groups workshops and 5.1.15, 5.1.18, 5.3, 5.6, be performed during an
Motors exist. This will be a multi- responsible for meetings 5.11 outage time frame (such as
task type of activity budgeting and rewinding). Without a critical
because it involves: procuring motors. Onsite training spare for motors that can
Mentor impact power production or
Plant engineering Assume the are required for reactor
responsibility of operation, many necessary
Project management the point contact maintenance tasks are being
Plant budget control for all technical waived. This will eventually
management issues associated affect motor reliability.
with new motor
Contracts procurements. INPO reports TR5-50 and
TR 7-59, and EPG-13 all
Plant management buy-in Be involved in the recommend that critical
vendor meetings spare motors be available to
Outage management and provide allow necessary
vendor oversight maintenance to be
Scheduling
during motor performed and to minimize
Procurement engineering manufacturing. the risk of extended plant
shut down due to the loss of
Warehouse personnel
a critical spare motor that
Ensure each spare motor is does not have an available
being preserved by having spare.
an adequate storage PM
program
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Table 3-37
Skill Set 3-8 – Motor Program Assessments

(See Section 5)
3.8.1 Motor Become trained in Be a participant OJT 5.1.1, 5.3 The assessment should focus on
assessment assessing motor in motor program implementation of the activities listed in the
at other programs that assessments at Work with other motor program guide document.
nuclear sites parallels EPRI and other nuclear groups that
INPO expectations sites perform As with any program, it takes time for full
assessments to program implementation. The assessments
gain should take this into consideration and
experience develop a time line to fully implement areas
that are identified as not implemented or
partially implemented
Since INPO evaluates the sites motor
program, it is recommended that the
program elements that they consider good
practices be in-place as soon as practical.
3.8.2 Self Develop a working Be a participant Obtain and Site assessment Assessments can go well if preparation is
assessments knowledge of on other self understand programs done prior to the assessment. This will
on the motor assessment assessments to requirements of require data gathering, preparing an
program techniques gain experience the site 5.1.1, 5.3 assessment book, ensuring that
procedures that weaknesses are identified and a corrective
Develop a Become a lead govern actions plan has been written to correct
thorough during self assessments them.
understanding of assessment of
what a good motor the motor Obtain INPO The assessment also will have a more
program should program guidance favorable outcome if the individual(s) being
look like documents on interviewed are familiar with, if not the owner
assessments of the motor program. The assessment
Develop an should focus on identifying the necessary
assessment time Mentor elements of a sound motor program,
interval for self identifying gaps, and ensuring corrective
assessments actions are in place to correct the gaps.
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Table 3-38
Skill Set 3-9 – Knowledge of Motor Repair, Refurbishment, and Rewind Specifications

(See Section 5)
3.9.1 Knowledge Own the motor Develop the EPRI LEMUG 5.1.4, 5.1.5, It is important that standardized
of Site and refurbishment and rewind repair, workshops and 5.1.8, 5.1.12, repair, refurbishment, and rewind
Shop tests specifications refurbishment, meetings 5.1.13, 5.1.14, specification be written and
and repair and rewind 5.1.17, 5.4, 5.5, controlled by the motor specialist.
procedures Be the go-to person for all specifications for Offsite motor 5.9, 5.10, 5.11 This ensures consistency of quality
exceptions taken to the each type of courses of the refurbishment and rewind
specifications by building installed motor activities. EPRI has developed
your reputation with site OEM and shop
sponsored several motor repair, refurbishment,
management, OEM, and Follow a motor and rewind specifications that can
service shop management from start to refurbishment
and rewind be used for guidance. These
and craft finish through a documents are not intended to be
refurbishment training
Know the correct repair, used verbatim, but to be used as a
and rewind Mentor source document to aid the site in
refurbishment, and rewind
techniques and processes Perform preparation of site specific repair,
appropriate refurbishment, and rewind
Provide vendor oversight vendor oversight specifications. The motor specialist
during motor must be intimately familiar with all of
Review and approve off- the information contained in these
site motor refurbishment refurbishment
and/or rewind specifications to ensure motor
and rewind data packages repairs, refurbishments, and
activities
rewinds performed by OEMs and
Assist with on the spot
service shops are in compliance.
changes and dispositions
approvals Oversight during motor repair,
refurbishment, and rewind during
Assist in assuring repair,
critical activities will minimize many
refurbishment, rewind,
issues such as:
and installation meet
industry specifications Not following specifications
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Skill Set 3-9 – Knowledge of Motor Repair, Refurbishment, and Rewind Specifications

(See Section 5)
Foreign material exclusion (FME)

programs not being followed
Proper testing techniques not being
used
Insulation system design does not
meet specification
Workmanship issues
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Table 3-39
Skill Set 3-10 – Knowledge of Motor Performance Trending

(See Section 5)
3.10.1 Performance Obtain the Work with the different EPRI LEMUG 5.1.4, 5.1.6, Taking data without trending and
Trending manufacturers groups that perform workshops and 5.1.9, 5.1.10, evaluation has limited benefits.
performance curves motor performance meetings 5.1.14, 5.1.19, Motor performance will usually
for each of the sites testing 5.2, 5.4, 5.5, 5.7 degrade over a long period of
medium voltage OJT using time and therefore one set of data
motors Have all of the available vendor will not necessarily flag a
performance data curves and test degrading condition. However, if
Learn which routed through the set manuals this data is looked at over time,
performance motor specialist to the negative trends or degrading
parameters of a ensure negative Attend training
on the conditions can be more easily
motor can be trends can be determined.
trended and can detected and performance test
provide early evaluated sets being used Performance modeling enhances
detection of motor Offsite motor the ability to detect negative
performance Learn to use the trends and can be used to defend
performance test sets courses
degradation motor operation during plant
Mentor transients or changes in plant
Be able to identify operating conditions.
negative trends from
the trend data
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Table 3-40
Skill Set 3-11 – Motor Service Shops Processes and Controls

(See Section 5)
3.11.1 Service Gain Observe vendors EPRI LEMUG 5.1.5, 5.1.7, The oversight by a motor specialist
Shops knowledge in during motor workshops meetings 5.1.8, 5.1.12, while a motor is at the shop during
Processes the following refurbishment 5.1.13, 5.1.17, critical activities will minimize in-
and areas: activities. Work with the Service 5.2, 5.3, 5.4, 5.5, service performance issues and is
Controls Shops during motor 5.6, 5.9, 5.10, recommended by both EPRI and
Repair and Oversight activities refurbishments and 5.11 INPO. In order to perform adequate
refurbishment should include but rewinds – learn the oversight, the motor specialist must
specifications not limited to: procedural control know as much if not more than the
processes shop about the testing, repair, and
OEM and Initial as found
plant conditions OJT rewind processes being used on the
drawings plants motor.
Winding inspections Mentor
FME
procedures Recommended
refurbishment
Purchase activities
specifications
Insulation system
On-site design if a rewind is
vendor required
oversight
Rewind activities
Off-site
vendor VPI process
oversight Final testing
Learn the
specifications to
ensure the activities
are being performed
in accordance with
the specifications
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Table 3-41
Skill Set 3-12 – Detailed Knowledge of Different Motor Designs

(See Section 5)
3.12.1 Motor Develop the knowledge to know the differences OJT EPRI LEMUG 5.1.4, 5.1.5, Induction motors
Design between the various types of motors used in the workshops and 5.1.14, 5.1.15, are the least
Differ- utilities. Each motor is designed for a specific Service shop meetings 5.1.17, 5.1.18, complicated, the
ences application. Each of these different motors has visits during 5.2, 5.4, 5.5, largest population,
different internal components, some that have to motor Offsite motor 5.11 and the easiest to
be tested. The various insulation systems within disassemblies courses maintain.
some of these motors (i.e. synchronous and DC) to see the Synchronous and
different Mentor
have to be tested with lower voltage than the dc motors can
stator winding or insulation damage will occur. designs have
Also auxiliary components such as complications built
commutators, slip rings, brushless excitation into them due to
systems, etc. require special inspection and the wound rotors
testing. Become familiar with these differences. and the excitation
system.
Squirrel Cage Induction Motors
Synchronous Motors When working on
synchronous
Brush and slip ring excitation motors, excitation
Brushless Exciter system design and
operation are just
Salient Pole as important as
Amortisseur windings the motor
windings. The
DC Motors
motor specialist
Commutator should become
Shunt design familiar with these
in order to better
Series design understand
Compound design starting, running
issues and trouble
Emergency motors with field energized shooting.
continuously
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Table 3-42
Skill Set 3-13 – Knowledge of Motor Insulation System Design Differences (Commercial, Safety Related Non-EQ, Safety Related EQ)

3.13.1 Motor Know the Work with the EPRI LEMUG 5.1.4, 5.1.5, All insulation systems should be designed for
Insulation differences onsite EQ workshops 5.1.15, 5.1.17, 5.4, maximum life and reliability. However, the
System between the engineer to and meetings 5.5, 5.6, 5.11 more robust you design a commercial
Designs insulation systems gain knowledge insulation system, the more it will cost. The
used in the three of EQ Onsite training safety related non-EQ and EQ systems are
types of motors: requirements OJT more expensive due to QA and QC
involvement as well as the required material
Commercial Observe EQ Mentor certification.
insulation
Safety Related system To ensure robust and long life safety related
Non-EQ fabrication and non-EQ insulation systems, involvement
Safety Related EQ design at during the insulation system design and
services shops approval process is necessary. Oversight will
Become familiar also be required during coil fabrication and
with what material winding to ensure the design is being
substitutions are followed.
acceptable for
each type of motor Safety related EQ insulation systems are
classification more unique and cannot deviate from the
qualified system design or materials without
Know the engineering evaluations and modifications to
uniqueness of the EQ reports. This becomes very difficult if
safety related EQ the design changes or materials are not
motors insulation equivalent to the original system design.
systems and the
special design and Both safety-related non-EQ and EQ
repair processes insulation systems also require seismic
that are required qualification documentation. This is straight
forward on random wound motors; however,
form wound systems weigh more and are
more complex because of the wedging,
blocking, and tying required to secure the
form wound coils and winding connections.
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Table 3-43
Skill Set 3-14 – Knowledge of Motor Termination and Insulating Techniques

3.14.1 Motor lead Become familiar with Work with the EPRI LEMUG Site termination Many motors have had motor lead
connection the following methods groups workshops and processes to cable insulation issues which
termination for motor lead to responsible for meetings have resulted in motor trips and
and insulation cable insulation terminating the 5.1.4, 5.1.14, 5.4, winding failures. Low voltage motor
techniques techniques: motor leads to Onsite training 5.6 lead connection insulation is more
the power Vendor training forgiving than the medium voltage
Taping requirements supply cables. connections. Medium voltage
Low voltage Mentor connection insulation must be
Obtain vendor designed to handle the voltage
insulation processes information on stresses from the cable and at the
Medium voltage the different lugs.
insulation processes types of
insulation and Connections between the cables
Heat shrink insulation know their and motor leads must be correctly
applications limitations designed and insulated. Incorrect
stress insulation on the shielded
Cold shrink insulation cable can lead to failures at the
applications motor main power junction box.
Quick insulators
(removable and
reusable)
Stress Cones
EQ requirements
Oxidation inhibitor
grease
Bolting and Torque
requirements
Dissimilar metal
issues
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Skill Set 3-14 – Knowledge of Motor Termination and Insulating Techniques

3.14.2 Lead Gain knowledge of Obtain vendor EPRI LEMUG Site lugging and Lug matching is required as well as
termination lugging requirements information on workshops and crimping documents correct lug sizing. It should be
processes and termination the different lugs meetings noted that since motor lead wire is
processes available 5.4, 5.1.17 considered a multi-stranded
Onsite training conductor, it is a different size than
Gain knowledge of Obtain cable conductors. For example, a
the differences information on Vendor training
#2 AWG sized lug for a cable will
between motor lead the correct Mentor be too large on the inside diameter
lugs and cable lugs crimping dye to of the barrel for a #2 motor lead
use with the wire. The industry has had
Understand the need lugs
for a flared barrel on problems with using the wrong lug
a motor lead lug size on motor leads which has
resulted in motors tripping because
of lug looseness.
Lugs designed for motor leads are
normally flared at the end of the
barrel to minimize cutting the small
conductor strands of the motor
leads during the crimping process.
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Table 3-44
Skill Set 3-15 – Knowledge of Motor Lead Specifications, Design, Testing

(See Section 5)
3.15.1 Motor lead Have an Work with the EPRI LEMUG 5.1.14, 5.1.15, Motor leads are used for the main
specifications, understanding of different groups workshops and 5.1.17, 5.4, 5.5, power leads to an insulation system.
design, testing the following for responsible for meetings 5.11 Some motor rewind shops and motor
motor leads: motor testing manufacturers also use motor leads for
and cable Cable training coil group connections and jumpers on
EQ requirements testing courses the winding itself. Motor leads are the
Medium/low Offsite motor weak link in properly designed insulation
Work with EQ systems due to aging issues associated
voltage program owners coureses
applications with the lead insulating materials. They
Be involved OJT will swell, crack, and become brittle with
Silicone insulation during motor time. This is why it is recommended not
Mentor to use motor leads for winding
EPDM insulation lead to cable
termination and connections and jumpers to minimize
insulation the amount of motor leads used in a
Glass braided over
activities winding design and to allow motor lead
EPDM or silicone
repair if a lead degrades or fails.
insulation
Be involved
during lugging Motor testing is different than
Motor lead types
activities independent cable testing due to the
Motor lead differences between motor lead
stranding insulation and cable insulation.
However, most motors are tested with
Motor lead the cables connected to the motor leads
degradation and due to the difficulty in de-terminating
aging issues them.
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Table 3-45
Skill Set 3-16 – Knowledge of Motor Bearing Designs

Documents
3.16.1 Bearing Know the different Work with the EPRI LEMUG 5.1.2, 5.1.14, Bearings have been the main
technology, designs, where and groups responsible workshops and 5.1.15, 5.1.17, cause of failure in motors. They
design, and when they are used, for inspecting, meetings 5.1.18, 5.4, 5.5, are the most active component in a
application weaknesses and testing, 5.10, 5.11 motor and rely on proper selection,
strengths of each refurbishing, and Attend bearing handling, installation, lubrication,
design, handling and installing bearings. training courses and maintenance activities in order
installation techniques, Offsite motor to maintain their reliability and
proper fits and Spend time at a maximize their life expectancy.
service shop during courses
clearances, testing and
repair process (if bearing Bearing Rolling element bearings, even
applicable) refurbishment and manufacturer with proper care, have a finite life.
replacement training This is called the L10 or B10 life.
The bearings listed activities Therefore, every motor with a
below are the most rolling element bearing design will
common used in power require bearing replacement in the
plant motor designs: future. This must be performed at
the correct time using procedural
Rolling Element control and trained personnel.
Bearings Predictive monitoring can
determine if a bearing is degraded
Ball and Roller
and needs to be changed,
Deep Groove however, some catastrophic
bearing failures will still occur.
Angular Contact Never reuse a rolling element
bearing once it has been removed
Duplex tandem
from a motor shaft. Always replace
arrangement
with a new one.
Duplex face to face
arrangement
3-58
9842707


(See Section 5)
Duplex back to back Some believe that Babbitt bearings

arrangement will last as long as the motor is in
service. With proper maintenance
Straight roller and lubrication, they will last many
Spherical roller years with some lasting 40 years
plus. However, as listed in the
Tapered roller knowledge column, many failure
modes exist with Babbitt bearings
Fluid Film (Babbitt) and can shorten their life. The only
bearings time these bearings can be visually
inspected is during partial or full
Radial
refurbishments. Inspections,
Split sleeve testing, set-up, and installation
need to be performed with
Segmented procedural control using bearing
trained personnel. Babbitt bearings
Tapered land can be reconditioned during
Non-equalizing thrust refurbishment as long as critical
bearings clearances are maintained. In
worse case conditions, these
Self equalizing thrust bearings can be re-poured and re-
bearings machined back to original
specifications.
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(See Section 5)
3.16.2 Bearing Know the failure modes 5.1.2, 5.4 Many bearings never achieve their
Failure of each type of bearing. design life expectancy due to
Modes A sample list of failure improper storage, mishandling,
modes is listed below: misapplication, improper
installation processes, improper
Rolling Element
fits, lubrication issues,
Fatigue contamination, misalignment, and
Fretting human error issues.
Smearing Bearing failures are still considered

to have the highest failure rate of
Skidding
all of the components that make up
Scoring a motor. At least 50% of the
Abrasive or abnormal bearing failures are avoidable with
wear a good bearing and motor
maintenance program.
Corrosion
On vertical machines it is important
Lubrication failure
to understand the bearing
True or false brinelling arrangement and the axial endplay
Electrical pitting or set up or premature bearing failure
fluting or catastrophic failure can occur.
The industry has had several
Cracks operating events due to improper
Seizures bearing mounting and/or axial
Fluid Film (Babbitt) endplay set up.
Bearings
Abrasion
Contaminants
Bond Failure
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(See Section 5)
Cavitation erosion
Corrosion
Electrical pitting
Erosion
Fatigue
Fretting
High chromium damage
Non-homogeneity
Overheating
Seizure
Structural damage
Improper seating
Improper press fit
Surface wear
Tin oxide damage
Wiping
Lubricant failure
Loss of lubricant
Overload
Loss of clearance
Smearing
Loss of Babbitt bond
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Table 3-46
Skill Set 3-17 – Knowledge of Motor Rotor Design

(See Section 5)
3.17.1 Rotor Learn the function of the rotor Inspect the rotors EPRI LEMUG 5.1.4, 5.1.14, The design of the rotor bars and
design as it relates to starting and during motor workshops and 5.1.15, 5.1.17, the material that they are made
running torque. The design of disassembly and meetings 5.4, 5.11 from define the starting and
the rotor bars are directly determine the rotor running torque of a motor. This
related to the performance of designs. Onsite training process is standardized for
the motor. Become familiar Offsite motor most NEMA frame size motors.
with the different rotor Work with service
shop personnel to courses The rotor is also the component
designs:
understand the OEM training within a motor that limits the
Different rotor designs are different rotor number of starts before cool
listed below: designs Mentor down. This is very important to
learn early in your career
Induction motors (squirrel because abusive starting leads
cage design) to premature rotor failure from
rotor bar and/or shorting ring
Single cage
cracks and failures.
Double cage
Skewed rotor
Vented rotor
Non-vented rotor
Slotted rotor bars
Stepped rotor bars
Aluminum rotor
Magnesium rotor
Copper Bar rotor
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Skill Set 3-17 – Knowledge of Motor Rotor Design

(See Section 5)
Open slot
Closed slot
Channel shorting ring design
Open slot shorting ring design
Wound rotor
Synchronous motors
Brush and slip ring excitation
Brushless Exciter
Salient Pole
Amortisseur windings
Wound rotor design for
synchronous, ac, and dc
motors
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Table 3-47
Skill Set 3-18 – Knowledge of Motor Shaft Material and Repair Processes

(See Section 5)
3.18.1 Shaft Shafts can be made Work with onsite EPRI LEMUG 5.1.17, 5.4 The best way to understand
material from several different metallurgist and welding workshops and shaft materials is to work with
and repair materials. Learn the engineers to understand meetings your company’s metallurgist or
processes repair processes for the differences in the welding engineer to determine
the most common shaft materials. Offsite motor the best materials. Also learn
shaft materials which courses how to identify the existing
are carbon steel and Work with the laboratory OEM material so that a
used for material OEM training
stainless steel. duplicate shaft can be
analysis to determine OJT at power fabricated out of the same
Be able to identify the what material your shafts service shops material and proper repair
difference between a are made from when during motor processes can be used.
pressed on spider and repairs or shaft refurbishment and
a welded spider on the fabrication are required. rewind There are many variations of
shaft these steels and one shaft will
Mentor not work in all applications (i.e.
Become familiar with side loaded shafts require a
RMS surface stronger material than direct
smoothness since the drive shafts).
shaft usually contains
the bearing journals. RMS surface finishes are very
important on shaft especially in
the bearing journal areas. The
surface finish can be
determined by electronic
meters or by comparing it to
surface finish standard
coupons.
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Table 3-48
Skill Set 3-19 – Knowledge of Oil and Air Cooling Coil Designs, Testing Techniques, and Acceptance Criteria

3.19.1 Cooling coil Determine which Work with the heat EPRI LEMUG 5.1.4, 5.1.8, 5.1.15, Cooling coils can last the life of a
designs, motors have exchanger engineer to workshops and 5.1.17, 5.4, 5.11 motor if proper water chemistry
testing cooling coil obtain the knowledge of meetings is maintained with proper flow
techniques, designs how to inspect, test, and rate. Cooling coils are often
and maintain the motors oil Onsite training overlooked during refurbishment.
acceptance Determine the and air cooling coils to Ensure that cooling coil
cooling coil Offsite motor
criteria maximize their life courses inspections and testing are part
material for each expectancy of the motor program. This will
coil Mentor assist in determining the correct
Determine the time to replace the cooling coils
test pressure for and if an upgrade in material is
each cooling coil required or a change in the flow
rate is required.
Understand the
different testing
techniques (i.e.
pressure test,
hydrostatic, eddy
current, etc.)
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Table 3-49
Skill Set 3-20 – Evidence Preservation and Apparent Cause

(See Section 5)
3.20.1 Evidence Learn the basics Be involved in motor EPRI LEMUG Site procedures Once a failed motor is disturbed
Preservation about preserving a failures to gain workshops and by disassembly without a
failed component for knowledge of the meetings 5.1.2, 5.1.4, trained failure analysis
further analysis which different failure modes 5.1.7, 5.4 individual present, significant
begins with the Failure analysis evidence can be lost and may
equipment inspection Observe how the training not be recoverable.
and disassembly failed motor is
quarantined and Offsite motor Understanding why a motor has
process. courses
disassembled in order failed may prevent similar
Learn the need to to determine a better Vender Training motors from having a common
take detailed photos understanding of the mode failure. Knowing why a
during disassembly to mode of failure Service Shop motor failed can also provide
identify potential activities when the opportunities to enhance a
failure causes. motor is being feature of the motor
disassembled (mechanical design or insulation
after failure system design) during the repair
process to keep from having a
Plant Failure future repeat failure.
Analysis and Root
Cause Analysis
training
Mentor
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Skill Set 3-20 – Evidence Preservation and Apparent Cause

(See Section 5)
3.20.2 Apparent Obtain skills of Observe trained EPRI LEMUG Site procedures Apparent Cause is what is
Cause determining the individuals during workshops and usually determined in a failure
Participation apparent cause failure investigations meetings 5.1.2, 5.1.4, analysis report. To obtain a
though team to learn how to 5.1.7, 5.4 true root cause, a more
participation on determine the Failure analysis extensive process is used. In a
every motor failure if apparent cause training lot of cases the apparent
possible. Offsite motor cause is the same as the root
courses cause.
Understand the
importance of Vender Training
retrieving operational
and maintenance Service Shop
history of the motor activities when the
prior to failure to motor is being
better understand disassembled
the potential cause after failure
of failure.
Plant Failure
Understand the Analysis and Root
failure mechanisms Cause Analysis
for the individual training
components of the
motor. Mentor
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Skill Set 4 – Primary Motor Specialist
Table 3-50
Skill Set 4-1 – Ownership of Motor Program Guide(s)

4.1.1 Ownership Obtain detailed knowledge Participate in EPRI LEMUG Site program A motor program guide is the
of the Motor of the following program motor program workshops and documents governing document that is used
Program guides: assessments at meetings All documents in to control the overall motor
Guide(s) Low voltage motors other sites Offsite motor Section 5 program. It is important that the
Participate in self courses motor specialist take ownership of
DC motors this document and ensure that it
assessments INPO training
Motor operated valve has appropriate content.
motors Network with Vendor training
others that have A motor program guide should
Medium voltage motors already Mentor contain the following activities
If a motor program guide established a as well as guidance on these
has been developed, motor program activities:
become the owner of the guide Preventive maintenance program
program Routine surveillance program
If the motor program guide Condition monitoring activities
has not been developed,
then take ownership to Internal and external inspections
develop it (with required inspections
identified and acceptance criteria)
Know all of the areas
within the program and PM, surveillance, and condition
develop a time line for full monitoring intervals
implementation if not fully Tracking guidance (unique
implemented. identifiers for each motor)
Modify the program as Procedure requirements
necessary to match
Base-line data requirements
practical resources and
budget, however, do not Condition and predictive based
sacrifice motor reliability maintenance requirements
and/or plant performance
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Skill Set 4-1 – Ownership of Motor Program Guide(s)

Ensure the motor It will also contain organizational
program addresses responsibilities (listed below) for the
the program areas motor program :
listed in the INPO
Motor Specialist
EPG-13 Motor
Program and any Corporate Motor Specialist (if
site governing applicable)
program Maintenance
documents.
Operations
Scheduling
Personnel Qualifications
Other areas that should be included
are:
Corrective maintenance guidance
Quarantine requirements after failure
Trouble shooting guidance
Trending requirements
Critical spare motor requirements
Program self-assessment guidelines
Requirements of motor refurbishment,
rewind, and procurement specifications
Refurbishment Intervals
Motor testing requirements including
intervals
Motor testing acceptance criteria
Motors listed that are included in the
program
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Table 3-51
Skill Set 4-2 – Become Official Liaison Between Management and All Motor Issues

(See Section 5)
4.2.1 Become main Develop the Be involved in all motor EPRI LEMUG All documents in Taking ownership of the motor
contact and reputation as the issues workshops and Section 5 program will eventually develop
liaison between motor program meetings a reputation for having the
management owner and the Assist in problem solving, responsibility and authority for
and all motor point contact for operability evaluations, Offsite motor the sites motors. Building this
issues all motor issues testing, oversight, long courses reputation takes a very long time
range plans, outage usually coupled with making
activities, and most all Industry
involvement correct decisions on the motor
other motor activities to program and the motors that
build your motor program Standards and maximizes reliability.
ownership reputation guideline Management will eventually
development become dependent on the motor
involvement specialist to take care of all of
the aspects of the motor
Onsite program. The more that is
involvement in learned about the motors, the
all motor issues better your reputation will
become as motor program
Mentor
owner.
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Table 3-52
Skill Set 4-3 – 10CFR50.59 Trained

(See Section 5)
4.3.1 Become Develop the skills Work with a trained Site training 5.6 Not everyone needs to be
10CFR50.59 necessary to 10CFR50.59 10CFR50.59 trained. However, to be
trained perform individual Mentor 10CFR50.59 trained enhances your
10CFR50.59 skills on understanding the safety
evaluations significance of the motors and the
plant
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Table 3-53
Skill Set 4-4 – Knowledge of Design Change Issues

(See Section 5)
4.4.1 Design Understand what Work with design EPRI LEMUG Site Procedures There are some differing opinions of
Change constitutes a design engineering design workshops and what is and is not a design change in
Issues change and what does to understand the training 5.1.5, 5.1.17, motors. As a rule of thumb, physical
with not when repairing, rules of design 5.3, 5.4 changes that affect dimensions, weight,
motors refurbishing, and changes OJT at the site or hardware locations that are shown
rewinding motors Mentor on vendor and controlled drawings are
considered design changes.
Insulation system enhancements such
as higher thermal rating, higher
dielectric strength, and better blocking,
tying, and connection techniques are
usually not considered design changes.
Performance changes due to increased
copper content or a significant change
in the copper conductor size can go
either way depending on site design
change rules
The more knowledge a motor specialist
has about the motor design and
operation, the more defendable
enhancements are without design
changes. Also unauthorized changes
that are considered design changes
can be better addressed.
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Table 3-54
Skill Set 4-5 – Knowledge of Motor Stator Core Testing and Design

4.5.1 Stator Understand how a core is Work with motor EPRI LEMUG 5.1.4, 5.1.15, As motor approach end of life,
core tested for hot spots and service shops workshops and 5.1.17, 5.4, 5.5, the stator cores are starting to
testing watts/lb loss during core meetings 5.11 show signs of degraded
and repair and lamination insulation. When this
Know how to determine the Attend Motor
design restacking insulation degrades to a point
proper excitation of a stator rewind seminar
processes that it stops working, then
core under test and/or training
increased hysteresis and eddy
course
Be able to identify the different currents can cause core
components of a stator core: Attend Motor overheating which will show up
Laminations refurbishment as core hot spots. These hot
and repair spots can be hot enough to
Vent slots training course damage the insulation on the
Finger plates stator coils if the hot spot is next
Tour a lamination
Thru bolts to the coils.
fabrication shop
Know the differences between This condition can sometimes be
OJT at the
a vented and non vented found by visual inspections
service shops
stator core design during refurbishment activities.
when motors are
The best method is to perform a
Understand the need for stator being refurbished
core loss test and use a
core tightness and how to test Mentor thermography camera. The core
for it loss test has to be performed
with the rotor removed and
Know what stack settling is
requires specialized equipment.
and how it occurs
The core loss test is usually
Understand the differences performed in a service shop
and limitations of the environment.
laminations starting with the
There are two types of core loss
steel, then the coating (core
test:
plate material) and finally the
fabrication process: A loop test to saturate the core
and a thermography camera to
Recoating of laminations (pros
detect hot spots
and cons)
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Skill Set 4-5 – Knowledge of Motor Stator Core Testing and Design

C3 Core plate material A core loss test that provides a

readout of overall average loss in
C5 Core plate material
watts/lbs loss.
Fully process steel
Both of these tests are
Oriented steel recommended to provide an
accurate assessment of a core
Non-oriented steel
A core that is marginal by the
Punching fabrication
test results should be evaluated
Laser cutting before rewinding or premature
winding failures can occur. A
Know the differences between core is typically considered
a stator frame with a drop in marginal when the overall
core insert and the stator core average losses are above
made directly in the frame. 4 watts/lb
Learn what types of core Most non NEMA frame size
damage can be repaired and cores and medium voltage motor
repair methods cores built today are made with
Know how to interpret core fully processed non-oriented C5
test results and how the tests coreplate laminations.
are performed
Learn restacking techniques to
minimize lamination shorting
and hot spots
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Table 3-55
Skill Set 4-6 – Detailed Knowledge of Motor Insulation Systems

(See Section 5)
4.6.1 Detailed The following is a list of Work with coil EPRI LEMUG 5.1.4, 5.1.5, The insulation system is the heart of
Knowledge the knowledge basics that designers to workshops and 5.1.15, 5.1.17, the motor. It is also the most easily
of should be learned about understand the meetings 5.4, 5.5, 5.6, damaged and degrades with age,
Insulation insulation system design: coil design Coil fabrication and 5.11 heat, radiation, vibration, and
System Insulating Processes criteria and rewind courses environment. Insulation systems
Designs techniques that can be designed today are
Strand Insulation Offsite motor considerably more robust that the
Work with coil courses
Dedicated Turn Insulation fabrication systems installed in the 1970s
Ground Wall Insulation shops and OEM training which is what is installed in most of
rewind shops to Mentor the nuclear site motors.
Different types of
insulating tapes learn the coil EPRI has developed (with the help
fabrication of motor specialists, insulation
Other tapes used for processes and system designers, OEMs, and
corona rewind service shops) insulation system
Volts/Turn rating techniques designs in the refurbishment and
rewind specifications that will
Volts/Mil rating
provide a 40 year plus insulation
Winding connection system (if maintained properly).
techniques These insulation systems are also
Brazed listed in the EPRI new motor
procurement specifications.
Crimped and brazed
Butt
Overlapped
Series joint
Coil jumper
Parallel connections
Motor leads
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Mechanical Strength A motor specialist will have to
Blocking and tying ensure a robust insulation
components system design is installed during
a rewind or new motor
Surge rings procurement. This requires that
Versapac™ understanding how to design a
Slot wedges bullet proof type system, know
how to avoid weaknesses in
Filler strips alternate designs, and being able
to technically negotiate your
design with OEMs and service
Resin Treatment
shops. If the motor specialist
Trickle resin system does not control the insulation
Dip and Bake system design a weaker
insulation system may be offered
B-Stage
by OEMs or service shops.
Hard coil design
Some insulation systems may
Global vacuum pressure have special requirements for
impregnation system power supplies that can produce
continuous voltage spikes (i.e.
inverters, variable frequency
NEMA winding drives, etc). The motor specialist
temperature must have knowledge of the
classification requirements of these insulation
(Class B, F, or H) systems or insulation life may be
limited.
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4.6.2 Insulation Be able to identify the Work with coil EPRI LEMUG 5.1.4, 5.1.5, 5.4, Insulation systems can last 40
system most common failure designers to workshops and 5.5, 5.11 plus years if properly designed
weaknesses modes of random and understand the meetings and maintained. An insulation
and failure form wound insulation coil design Coil fabrication system’s life can be cut short by
modes systems criteria and and rewind many different failure modes as
Know the stresses that techniques courses well as outside influences. Since
can degrade or fail Work with coil an insulation system is made up
Offsite motor of organic materials (except the
insulation systems fabrication courses
shops and copper conductors) aging
Be able to use the failure OEM training degradation becomes an issue.
mode knowledge to assist rewind shops to
in determining the cause learn the coil Mentor An insulation system begins to
of the failure or fabrication become more susceptible to
degradation processes and failure from the stressors after 30
rewind years of life. Therefore, the older
Be able to recognize techniques the insulation system, the more
precursors to each failure inspections, testing, and care are
mode where possible required to achieve its maximum
life potential
Stressors such as those listed
below will accelerate the aging
and potential failure of
insulating materials:
Thermal
Environmental
Electrical
Mechanical
Some of the most common
failure modes are listed below
Turn-to-turn
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Coil-to-coil
Coil to ground
Phase-to-phase
Open Circuit
Connection failure
The following are some of the
failure mechanisms that can lead
to one or more of the failure
modes listed above:
Fretting
Loose wedges
Movement during starting
Partial discharge
Poor design (materials,
volts/turn, volts/mil)
Inadequate blocking and tying
Lead degradation
Contamination
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Table 3-56
Skill Set 4-7 – Knowledge of All INPO, NRC, and NEIL Issues

(See Section 5)
4.7.1 INPO, NRC, Become Obtain the INPO, EPRI LEMUG 5.3, 5.6, 5.11 NRC has many regulatory
and Insurance knowledgeable in NRC, and NEIL workshops and documents that dictate motor design,
requirements INPO, NRC, and program meetings operation, qualification, and design.
NEIL programs documents that These requirements must be known
pertaining to pertain to motors. INPO workshops by the motor specialist.
motors Work with the site
Get on the INPO has worked closely with EPRI
distribution list for individual LEMUG in their development of
INPO, NRC, and responsible for the INPOs Topical Reports and
NEIL emails and NEIL program and Engineering Program Guide for
information compliance motors. The motor specialist needs
to ensure that the sites motor
programs are in line with INPOs
recommendations as INPO uses
their program guides during
assessments of a sites motor
program.
NEIL is the nuclear insurance
company for the nuclear sites. The
cost for NEIL insurance is directly
related to the sites equipment
maintenance programs. The motor
specialist must ensure that the motor
programs provide a high level of
reliability.
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Table 3-57
Skill Set 4-8 – Detailed Knowledge of Motor Performance Curves

4.8.1 Motor Be able to read and Work with motor EPRI LEMUG 5.1.4, 5.2, 5.4, 5.5, The performance curves of any
Performance understand the manufacturers on workshops and 5.11 given motor provide valuable
Curves different curves that understanding their meetings information about starting,
are generated by the performance curves running, mechanical overload
manufacturer for their Site training conditions, and under and over
motors as listed Required reading voltage conditions. Once you
on motor Offsite motor
below: courses understand the curves, you can
performance curves know if the motor is operating
Speed/torque curves Mentor within its operational limits. The
Speed/current curves curves also assist in trouble
shooting performance anomalies.
Running performance
curves (efficiency –
power factor)
Starting characteristic
curves
Thermal limit curve
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Table 3-58
Skill Set 4-9 – Motor Technical and Operability Evaluations

(See Section 5)
4.9.1 Technical Be able to Work with system EPRI LEMUG FSAR In order to provide the site with a
and technically defend engineering workshops and technically correct evaluation, you must
Operability a motor being meetings Tech Specs know the electrical design, the
Evaluations removed from Work with service mechanical design, and the operational
shop personnel to Offsite motor 5.1.13, 5.6
service or to allow limits for the motor you are evaluating.
continued better understand courses This is why it is important to have copies
operation motor weaknesses of and understand the motors stator,
Site training
Work with mentor frame, shaft, bearing, and cooler
Mentor drawings and have access to motor
vendor manuals and motor industry
documents. It is also important to have a
photo library of the motor if it has been
disassembled to be able to identify
internal components to assist with the
evaluation. The more you understand
how the motor works and how it is
designed the more accurate your
evaluation will be.
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Table 3-59
Skill Set 4-10 – Root Cause Analysis Trained

4.10.1 Root Become fully Participate in root EPRI LEMUG Site Root Cause Root Cause Analysis is a deliberate
Cause trained in Root cause teams during workshops and Program separation of potential causes that could
Analysis Cause Analysis a root cause meetings have created the failure with the potential
investigations. 5.1.7, 5.4 causes that could not have caused the
Site Training failure. It is a detailed process elimination
Become lead for coupled with extensive information
Root Cause Analysis Onsite root cause
training gathering and interviews.
team
Third party root Root Cause Analysis takes a considerable
cause training amount of time and effort with several
individuals participating on the team.
Mentor Many times a Failure Analysis is all that is
needed to understand certain failure
modes of motors; however, site programs
may require a Root Cause Analysis.
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Table 3-60
Skill Set 4-11 – Knowledge of Motor Environmental Qualification (EQ) Process

4.11.1 Environmental Become proficient in Work with site EPRI LEMUG EQ Binders or The motor specialist needs a
Qualification understanding which individual workshops and equivalent thorough understanding of EQ
(EQ) motors have EQ responsible for meetings requirements and to which
status, how they were the EQ program 5.1.5, 5.6 motors they apply because
qualified, the EQ Site training improper maintenance, incorrect
limits, and what Assist in EQ part replacement, inadequate
testing if possible Mentor
repairs can and testing and/or inspections can
cannot be performed Work with trained invalidate the EQ of a motor.
in order to maintain EQ mentor
EQ
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Table 3-61
Skill Set 4-12 – Knowledge of Motor Protective Coatings and Service Level 1 Coatings

4.12.1 Protective Understand the Work with the EPRI LEMUG 5.1.12. 5.1.15, Outside motors, motors in a chemical
Coatings: protective coating individual(s) workshops and 5.1.17, 5.1.18 environment, and motors near salt
requirements of motors responsible for meetings water will degrade significantly faster
such as: the sites coating that motors in other locations.
programs. Offsite motor Unprotected (uncoated) components
Housing coatings courses have a higher potential of premature
Work with failure due to corrosion.
Rotor coatings service shops Coatings
that have the training These coatings are both on the
Bearing oil reservoirs
coatings coating Mentor outside of the motor and on the
processes built internals. One of the areas that have
Special coatings into their caused the industry problems is the
(Service Level 1) programs protective coating of the internal oil
reservoirs.
Understand the
importance of protective Motors that are inside containment
coatings to protect and in special locations of the plant
against the elements, may need Service Level 1 coatings.
chemical damage, oil The different coatings used on
leaks, etc. motors have to be understood so that
incorrect coatings will not be applied
Learn the differences during refurbishment activities. If an
between commercial incorrect coating is applied to a
coatings and Service bearing reservoir and comes loose
Level 1 coatings. during operation it can cause
possible oil contamination, bearing
Service Level 1 coatings
damage or failure, and potential oil
are usually associated
leakage through castings.
with components inside
the containment and
have to survive an
accident condition
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Table 3-62
Skill Set 4-13 – Knowledge of Motor Dynamometer Testing

(See Section 5)
4.13.1 Motor Become proficient Work with the service EPRI LEMUG 5.1.4, 5.1.15, Dynamometer testing is one of the
Dynamometer in dynamometer shops during workshops and 5.1.17, 5.2, 5.4, best ways to verify that a motor will
Testing testing for both dynamometer testing meetings 5.5 perform in accordance nameplate
horizontal and to gain knowledge or information and performance
vertical motors testing techniques and Dynamometer curves.
test results training from
dynamometer Dynamometers are usually limited
manufacturers by horse power ratings and motor
speed.
Observing
dynamometer A dynamometer does not place
testing at down- thrust on a vertical motor,
service shops therefore, certain types of bearings
(tapered roller, spherical roller,
Mentor angular contact rolling element
bearings) may have increased
temperatures during testing due to
ball skid from no down thrust.
Performance curves can be
generated from dynamometer
testing.
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Table 3-63
Skill Set 4-14 – Knowledge of Complete Motor Testing (IEEE 112)

Documents
4.14.1 IEEE 112 Become Required reading EPRI LEMUG 5.2 There are several methods listed in
Complete knowledgeable of the of IEEE 112 workshops and IEEE 112 to perform a complete test.
Test different methods for training The method used will depend on the
performing a Work with service type, horsepower, voltage, and speed of
complete test in shops during Offsite motor a motor and the capabilities of the test
accordance with IEEE performance of courses facility.
112 IEEE 112 testing.
Mentor The dynamometer is the best
performance test for a motor; however,
many test facilities do not have
dynamometers that can fully load large
horse power motors (especially vertical
motors). The large motors will usually
be performance tested in accordance
with IEEE 112 using dual frequency
method if a dynamometer is not
available.
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Table 3-64
Skill Set 4-15 – Involvement in Industry Document Development

(See Section 5)
4.15.1 Industry Become Be involved in EPRI LEMUG 5.1, 5.2, 5.3, 5.4, The motor industry uses
Document knowledgeable industry groups that workshops and 5.5, 5.11 industry standards and
Development enough about motors develop guidance meetings guidelines to design,
to be a contributor to documents and manufacture, test, repair,
industry document standards for motors Offsite motor rewind, ship, and store
development courses motors.
Attend industry Being involved in standards
groups and and guidelines development
committees or revisions will ensure that
responsible for proper technical content and
standards and provide an opportunity to
guides used on incorporate the knowledge
motors learned by the motor
specialist.
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Table 3-65
Skill Set 4-16 – Assume Chair Positions in Leading Motor Industry Groups

(See Section 5)
4.16.1 Industry Gain enough Attend workshops, EPRI LEMUG 5.1, 5.2, 5.3, 5.4, Every motor industry group needs
Group knowledge to be users groups, and workshops and 5.5, 5.11 knowledgeable motor specialist that
Leader considered for a standards group meetings can help provide leadership. This
Position leader position in the meetings and volunteer provides documents and reports
industry groups that for leadership positions Attend industry developed under the direction of a
you are involved in groups and knowledgeable leader to have more
committees creditability and ensure a higher
responsible for level of correct technical content.
standards and
guides used on
motors
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Table 3-66
Skill Set 4-17 – Develop and Provide Motor Training

(See Section 5)
4.17.1 Develop Become Provide onsite EPRI LEMUG Site training There will be opportunities to provide
and knowledgeable training workshops and programs training and give presentations. This
Provide enough to develop meetings not only helps the motor industry by
Training and provide Give presentations Industry transferring knowledge, but also
on Motors training for motors at industry group Industry meetings workshops and allows the motor specialist to develop
at: meetings, and conferences presentations skills in presenting a particular motor
conferences, and subject or issue.
Onsite workshops Vendor
sponsored
Industry Groups training courses
and conferences
Vendor Seminars
Mentor
Sponsored Work
Shops
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Table 3-67
Skill Set 4-18 – Become Mentor for Next Generation of Motor Specialist

(See Section 5)
4.18.1 Mentoring Gain enough For a long term mentoring EPRI LEMUG All documents in As stated in Section 2:
motor relationship with the new workshops and Section 5
knowledge to motor engineers meetings Mentoring can greatly accelerate
mentor the next the development of a motor
generation of Provide technical Onsite training specialist. Mentoring is a
motor specialist information, lessons relationship built on trust and one
learned, reference material, Work side by of its primary goals is to make a
experiences, assistance side with the person new to a field more
when needed, and industry new motor confident in their abilities and
contacts to accelerate the engineer talents. Mentoring normally
development of a motor involves a member of the same
engineer into a motor profession with more experience
specialist and connections, helping a new
person become more confident in
their chosen field. Although there is
some focus on the skills, the main
focus in mentoring is a long-term,
ongoing process. It is usually a
developed relationship, based on
shared experience. The mentor
often passes on not only tangible
knowledge, but also philosophy,
advice, and experience from years
in the field. The mentor may also
provide introductions to people or
organizations that can enhance the
knowledge of a motor specialist.
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Table 3-68
Skill Set Completion Matrix (Skill Set 1)
Topic (Knowledge
Primary Motor Specialist Back-Up Motor Specialist
Base Areas)
Completion Completion
Start Date Start Date
Date Date
Skill Set 1-1 (Site Specific Skills)
General System
1.1.1
Knowledge
1.1.2 Site Motor Program
Electrical Theory and

1.1.3
Safety
Site Drawings,
1.1.4 Technical Manuals, and
Vendor Documents
Site Operating Review

1.1.5
Program
1.1.6 Site Procedures
1.1.7 Support Walk Downs
1.1.8 Planned Maintenance
1.1.9 Corrective Maintenance
Support Motor Removal

1.1.10
and Installations
Skill Set 1-2 (Guidance Documents and Contacts)
Development of Motor
1.2.1
Reference Library
Skill Set 1-3 (General Knowledge of Motors)
Motor Application and

1.3.1
Classification
Skill Set 1-4 (Motor Nameplate Information)
Motor Nameplate
1.4.1
Information
Skill Set 1-5 (Enclosure Types and Materials)
1.5.1 Motor Enclosure Types
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Topic (Knowledge
Base Areas)
Date Date
Skill Set 1-6 (Basic Knowledge of Motor Performance Data)
1.6.1 Common Motor Tests
Motor Online
1.6.2
Performance Monitoring
Skill Set 1-7 (Basic Knowledge of Temperature Monitoring and Design)
1.7.1 Temperature Monitoring
Skill Set 1-8 (Basic Knowledge of Sensory/Monitoring Technology)
Stator, Bearing and

1.8.1 Lubrication Sensory
Monitoring Technologies
Skill Set 1-9 (Basic Knowledge of Stator Winding Heater Technology and Design)
Stator Winding Heater

1.9.1
Technology and Design
Skill Set 1-10 (Basic Knowledge of Bearing Technology and Design)
Bearing Technology and

1.10.1
Design
Skill Set 1-11 (Basic Knowledge of Lubrication Systems, Lubrication Types, and Quantities)
Lubrications Systems,
1.11.1 Lubrication Types, and
Quantities
Skill Set 1-12 (Basic Knowledge of Cooling System Designs)
Stator and Bearing

1.12.1 Lubrication Cooling
System Design
Skill Set 1-13 (Basic Knowledge of Winding/Insulation System Types)
1.13.1 Insulation System Types
Skill Set 1-14 (Storage of Motors)
1.14.1 Storage of Motors
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Table 3-69
Topic (Knowledge
Base Areas)
Date Date
Skill Set 2-1
System Knowledge and

2.1.1
Motor Performance
2.1.2 Support Surveillances
Skill Set 2-2 (Knowledge of Motor Drawings – Electrical, Instrumentation, and Mechanical)
Vendor and Utility Motor

Drawings ( Electrical,
2.2.1
Instrumentation, and
Mechanical)
Skill Set 2-3 (Knowledge of Motor Program Guide(s))
2.3.1 Motor Program Guide(s)
Skill Set 2-4 (Knowledge of Long Range Motor Plan)
Long Range Motor Plan

2..4.1
(10 year plan)
Skill Set 2-5 (Knowledge of Spare Motors)
2.5.1 Spare Motors
Skill Set 2-6 (Knowledge of Maintenance Procedures and Surveillance Instructions)
Technical Knowledge of
Motor Maintenance
2.6.1
Procedures and
Surveillance Instructions
Skill Set 2-7 (Knowledge of Motor Predictive and Preventive Maintenance Programs)
Predictive and
2.7.1 Preventive Maintenance
Programs
Skill Set 2-8 (Knowledge of Content of the Documents in the Motor Technical Library)
Technical Content of
2.8.1
Motor Library
Skill Set 2-9 Knowledge of Motor Trouble Shooting Guidelines (Electrical and Mechanical)
Motor Trouble Shooting

2.9.1 Guidelines (Electrical
and Mechanical)
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Topic (Knowledge
Base Areas)
Date Date
Skill Set 2-10 (Knowledge of Thermography and Ultrasonic Monitoring for Motors)
Thermography and
2.10.1
Acoustical Monitoring
Skill Set 2-11 (Knowledge of Motor Coupling Designs (includes installation)
Motor Coupling Designs,

2.11.1 Maintenance, and
Installation
Skill Set 2-12 (Knowledge of Motor Lubrication Programs)
2.12.1 Lubrication Programs
Skill Set 2-13 (General Knowledge of Motor Shaft Designs)
General Knowledge of
2.13.1
Shaft Designs
Skill Set 2-14 (General Knowledge of Different Motor Designs)
2.14.1 Different Motor Designs
Skill Set 2-15 (General Knowledge of Cooling Coil Designs)
Motor Air and Oil

2.15.1
Cooling Coil Design
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Table 3-70
Topic (Knowledge
Base Areas)
Date Date
Skill Set 3-1 (Commercial Grade Dedication and Motor Upgrade Processes)
Commercial Grade
3.1.1 Dedication (CGI) for
Motor Upgrade
Skill Set 3-2 (Knowledge of Like for Like Motor Replacement Evaluations)
Like for Like Motor

3.2.1 Replacement
Evaluations
Skill Set 3-3 (Knowledge of Trip Circuits and Protective Relaying)
Motor Trip Circuits and

3.3.1
Protective Relaying
Skill Set 3-4 (Knowledge of Motor Test Equipment)
Specialized Test
3.4.1 Equipment Used to Test
Motors
Skill Set 3-5 (Specialist Training)
3.5.1 Specialized Training
Skill Set 3-6 (Ownership of the Long Range Motor Plan)
Ownership over the

3.6.1
Long Range Motor Plan
Skill Set 3-7 (Critical Spare Motor Procurement and Preservation)
3.7.1 Critical Spare Motors
Skill Set 3-8 (Motor Program Assessments)
Motor Program
3.8.1 Assessments at Other
Nuclear Sites
3.8.2 Self Assessments
Skill Set 3-9 (Knowledge of Motor Repair, Refurbishment, and Rewind Specifications)
Site and Shop Motor

Repair, Refurbishment,
3.9.1
and Rewind
Specifications
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Topic (Knowledge Base

Areas)
Completion
Start Date Completion Date Start Date
Date
Skill Set 3-10 (Knowledge of Motor Performance Trending)
Motor Performance
3.10.1
Trending
Skill Set 3-11 (Motor Service Shops Processes and Controls
Motor Service Shops

3.11.1
Processes and Control
Skill Set 3-12 (Detailed Knowledge of Different Motor Designs)
Detailed Knowledge of
3.12.1
Different Motor Designs
Skill Set 3-13 (Knowledge of Motor Insulation System Design Differences)
Motor Insulation System

Designs Differences
3.13.1 (Commercial, Safety
Related Non-EQ, Safety
Related EQ)
Skill Set 3-14 (Knowledge of Motor Termination and Insulating Techniques)
Motor Lead and

3.14.1 Connection Insulation
Techniques
Lead Termination
3.14.2
Processes
Skill Set 3-15 (Knowledge of Motor Lead Specifications, Design, and Testing)
Motor Lead
3.15.1 Specifications, Design,
and Testing
Skill Set 3-16 (Knowledge of Motor Bearing Designs)
Motor Bearing Design,

Technology, and
3.16.1
Application – Rolling
Element and Babbitt
3.16.2 Bearing Failure Modes
Skill Set 3-17 (Knowledge of Motor Rotor Designs)
3.17.1 Motor Rotor Designs
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Topic (Knowledge
Base Areas)
Date Date
Skill Set 3-18 (Knowledge of Motor Shaft Material and Repair Processes)
Motor Shaft Material and

3.18.1
Repair Processes
Skill Set 3-19 (Knowledge of Oil and Air Cooling Coil Designs, Testing, and Acceptance Criteria)
Motor Oil and Air

Cooling Coil Designs,
3.19.1
Testing, and Acceptance
Criteria
Skill Set 3-20 (Evidence Preservation and Apparent Cause)
3.20.1 Evidence Preservation
3.20.2 Apparent Cause
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Table 3-71
Topic (Knowledge
Base Areas)
Date Date
Skill Set 4-1 (Ownership of Motor Program Guide(s)
Owner of Motor Program

4.1.1
Guide(s)
Skill Set 4-2 (Become Official Liaison Between Management and All Motor Issues)
Official Liaison Between

4.2.1 Management and All
Motor Issues
Skill Set 4-3 (10CFR50.59 Trained)
4.3.1 10CFR50.59 Trained
Skill Set 4-4 (Knowledge of Design Change Issues)
Design Change Issues

4.4.1
with Motors
Skill Set 4-5 (Knowledge of Motor Stator Core Testing and Design)
Stator Core Testing and

4.5.1
Design
Skill Set 4-6 (Detailed Knowledge of Motor Insulation Systems)
Detailed Knowledge of
4.6.1 Insulation System
Designs
Insulation System
4.6.2 Weaknesses and Failure
Modes
Skill Set 4-7 (Knowledge of All INPO, NRC, and NEIL Issues)
INPO, NRC, and NEIL

4.7.1
Issues
Skill Set 4-8 (Detailed Knowledge of Motor Performance Curves)
Motor Performance
4.8.1
Curves
Skill Set 4-9 (Motor Technical and Operability Evaluations)
Motor Technical and

4.9.1
Operability Evaluations
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Topic (Knowledge
Base Areas)
Date Date
Skill Set 4-10 (Root Cause Analysis Trained)
Root Cause Analysis

4.10.1
Trained
Skill Set 4-11 (Knowledge of Motor Environmental Qualification Process)
Environmental
4.11.1 Qualification (EQ)
Process
Skill Set 4-12 (Knowledge of Motor Protective Coatings and Service Level 1 Coatings
4.12.1 Protective Coatings
Skill Set 4-13 (Knowledge of Dynamometer Testing)
Motor Dynamometer
4.13.1
Testing
Skill Set 4-14 (Knowledge of Complete Motor Testing (IEEE 112)
4.14.1 IEEE 112 Complete Test
Skill Set 4-15 (Involvement in Industry Document Development)
Involved in Industry
4.15.1
Document Development
Skill Set 4-16 (Assume Chair Positions in Leading Motor Industry Groups)
Industry Group Leader

4.16.1
Positions
Skill Set 4-17 (Develop and Provide Motor Training)
Develop and Provide

4.17.1
Motor Training
Skill Set 4-18 (Become Mentor for Next Generation of Motor Specialist)
4.18.1 Become Mentor
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4
SUMMARY
Motor specialists are necessary in the utilities due to the constant threat of power generation loss
directly related to motor failures. Motor reliability can only be achieved by maintaining the
motors electrical and mechanical health. This requires experienced individuals that understand
motor design, operation, performance, failure modes, and repair techniques. Learning the
knowledge topics of the skill sets contained in this document will aid in developing these
experienced individuals. It can take years to become proficient at the many knowledge topics
listed in the skill sets, however, obtaining proficiency in these knowledge topics will provide the
utilities with motor component specialists that can provide significant improvements to motor
programs, motor reliability, expeditious recovery from failures, and minimize in-service failures.
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5
INDUSTRY DOCUMENTS
There are many more EPRI and Industry documents that contain useful information that can be
applied to motors. The ones listed in Section 5 are documents that have the most pertinent
information for the Topics listed in the skill set in Section 3 of this report.
5.1 EPRI Documents
5.1.1 Assessments
1. TR-107759 – Assessing Maintenance Effectiveness
2. 1007604 – Metrics for Assessing Maintenance Effectiveness
3. 1003682 – Performance Metrics for Condition-Based Maintenance Technology Application
Programs
4. 1001032 – Predictive Maintenance Self-Assessment Guidelines for Nuclear Power Plants
5. 1014798 – Preventive Maintenance Program Implementation Self-Assessment Guidelines for
Nuclear Power Plants
5.1.2 Bearings
1. TR-113059-V1 – Bearing Technology Topics, Volume 1
2. TR-113059-V2 – Bearing Technology Topics, Volume 2
3. GS 7352 – Manual of Bearing Failures and Repair in Power Plant Rotating Equipment
5.1.3 Cables
1. 1018777 – Failure Mechanism Assessment of Medium Voltage Ethylene Propylene Rubber
Cables – Revision 1, May 2009
2. 1001391 – Training Aids for Visual/Tactile Inspection of Electrical Cables for Detection of
Aging, March 2002
5.1.4 Electrical - Other

1. 1003471 – Electrical Connector Application Guidelines
2. EL-5036 – Power Plant Reference Series – Volume 6, Motors
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Industry Documents
5.1.5 Environmental Qualification

1. 1013002 – Random Wound Continuous Duty Motor Stator Rewind Program for
Environmentally Qualified Motors, March 2006
2. 1011946 – Comparative Analysis of Polyrex EM and SRI Greases for Use in EQ Motor
Bearings, October 2005
3. 1003516 – Baseline Materials Data to Support Procedures for Rewinding Environmentally
Qualified Motors: AC Random Wound Stators (Intermittent Duty Applications) and AC Form
Wound Stators (Low Voltage and Medium Voltage (<7kV)), December 2003
4. TR-100516-CD – Nuclear Power Equipment Qualification Reference Manual, August 1997
5. TR-107524 – Condition Monitoring Program for 4kV Environmentally Qualified Motors,
June 1997
6. TR-103585 – Guidelines for the Selection, Procurement, and Acceptance of Nuclear Safety-
Related Mild Environment Motor Insulation for Rewinds, September 1994
7. TR 104872 – Guidelines for the Qualification of Insulation Systems for use in Rewinding
Nuclear Safety-Related Harsh Environment Motors
5.1.6 Equipment Reliability

1. 1020645 – Guideline for System Monitoring by System Engineers, March 2010
2. 1011223 – Aging Identification and Assessment Checklist – Electrical Components,
January 2005
3. 1009743 – Aging Identification and Assessment Checklist – Mechanical Components,
August 2004
4. 1007935 – Critical Component Identification Process – Licensee Examples: Scoping and
Identification of Critical Components in Support of INPO AP913, December 2003
5.1.7 Failure Analysis and Troubleshooting

1. 1000898 – Random Wound Motor Failure Investigation
2. 1000968 – Troubleshooting of Electric Motors
3. 1020368 – Symptom Based Troubleshooting Plan Web Tool V1.0, January 2010
4. 1016907 – Quarantine of Failed Parts to Facilitate Failure Analysis of Nuclear Power Plant
Components
5.1.8 Heat Exchangers

1. 1018980 – Heat Exchanger Maintenance Guide
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Industry Documents
5.1.9 Life Cycle Management

1. 1015076 – Large Motor End of Expected Life and Planning Considerations, December 2007
2. 1007385 – Project Ranking Method for Nuclear Power Plants: Prioritizing Proposed Capital
and O&M Projects, May 2003
5.1.10 Lubrication
1. 1015254 – Lube Notes Compilation 1989–2007
2. 1019518 – Lubrication Guide, Revision 4 (Formally 1003085)
3. 1019517 – Oil Lubrication Guide for Rotating Equipment
4. NP 4916 REV 2 – Lubrication Guide
5. 1013456 – NMAC Reactor Coolant Pump/Reactor Recirculation Pump Lubrication Guide
5.1.11 Mechanical – Other

1. TR-104602 – Maintenance Job Cards
2. 1009706 – Riggers Handbook
3. TR-112449 – Shaft Alignment Guide
5.1.12 Nuclear Coatings

1. 1019157 – Guideline on Nuclear Safety Related Coatings Rev. 2, December 2009
2. 1014884 – Degradation Research for Nuclear Service Level 1 Coatings, September 2007
5.1.13 Operations and Maintenance

1. 1011861 – Considerations for Developing a Critical Parts Program at a Nuclear Power
Plant
2. 1016315 – Foreign Material Exclusion Guidelines
3. 1011896 – Guidelines for Effective Component Engineering
4. 1015307 – Maintenance Engineer Fundamentals Handbook
5. 1003093 – System and Equipment Troubleshooting Guideline
5.1.14 Predictive and Preventive Maintenance

1. NP-7502 – Electric Motor Predictive and Preventive Maintenance Guide
2. 1003095 – Electric Motor Tiered Maintenance Program
3. 1001266 – Partial Discharge Testing of Rotating Machine Stator Windings
4. TR 108773 – Electric Motor Predictive Maintenance
5. 1014908 – Guide for Rotating Electrical Machine Hipot Testing
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Industry Documents
6. 1004003 – Evaluation Tools for Electric Motor Testing: Logic Diagrams

7. 1007270 – Tool for Electric Motor Predictive Maintenance
8. TR-112500 – Guideline for Application of the EPRI Preventive Maintenance Basis
9. 1018758 – PMBD v2.1 (Preventative Maintenance Basis Database)
10. TR 106857 V8 – Preventive Maintenance Basis Volume 8: Low Voltage Electric Motors (PM
Templates)
11. TR 106857 V9 – Preventive Maintenance Basis Volume 9: Medium Voltage Electric Motors
(PM Templates)
12. TR 106857 V10 – Preventive Maintenance Basis Volume 10: High Voltage Electric Motors
(PM Templates)
13. TR 106857 V11 – Preventive Maintenance Basis Volume 11: Direct Current Electric Motors
(PM Templates)
14. 1009585 – Acoustic Monitoring of Bearing Lubrication
15. 1006534 – Infrared Thermography Guide, Rev. 3
16. 1003755 – PdM Technology, Identification, Development, and Implementation for 2003,
Acoustic Bearing Monitoring Testing for Lubrication Effectiveness
17. 1003684 – PDM Technology, Identification, Development, and Implementation – 2004
5.1.15 Procurement of New Motors

1. 1021428 – Nuclear Maintenance Applications Center: Recommended Practice for
Evaluating Interchangeability for National Electric Manufacturing Association Frame Motor
Replacement
2. Interchangeability for National Electric Manufacturers Association Frame Motor
Replacement
3. 1019162 – Critical Spare Parts Program Development, December 2009
4. 1008254 – Guidelines for Optimizing the Engineering Change Process for Nuclear Power
Plants, Revision 2, November 2007
5. 1008256 – Guidelines for the Technical Evaluation of Replacement Items in Nuclear Power
Plants, Revision 1, June 2006
6. 1008034 – JUTG Commercial Grade Item Technical Evaluations on CD-ROM, May 2003
7. 1020625 – Guidance for the Replacement of Large Electric Motors at Nuclear Power Plants,
March 2010
8. TR-102260 – Supplemental Guidance for the Application of EPRI Report NP-5652 on the
Utilization of Commercial Grade Items
9. 1011892 – Guideline for the Specification of Replacement and Spare AC Squirrel-Cage
Induction Motors Having Voltage Ratings of 2,300V to13,200V
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5.1.16 Protective Relays

1. NP-7216 – Protective Relay Maintenance and Application Guide
5.1.17 Repair and Refurbishment

1. 1009700 – Guide for Electric Motor Stator Winding Insulation Design, Testing, and VPI
Resin Treatment
2. 1009699 – Guide for Increasing the Capacity of Induction Motors
3. 1016680 – Guide for the Performance of On-Site and Vendor Shop Inspections of Electric
Motors
4. 1009676 – Model Repair and Reconditioning Specification for DC Motors
5. 1011894 – Guide for Determining Motor Repair Verses Motor Replacement
6. 1008964 – Repair and Reconditioning Specification for AC Squirrel-Cage Motors with
Voltage Ratings of up to 600V
7. 1016679 – Repair and Reconditioning Specification Guidance for AC Squirrel-Cage and
Salient Pole Synchronous Motors with Voltage Ratings of 2.3 to 13.2 kV: Revision 1 of
1000897
8. Quality Electric Motor Repair: A Guidebook for Electric Utilities
9. TR 105729 – Electric Motor Model Repair Specifications
10. 1009676 – Model Repair and Reconditioning Specification for DC Motors
11. TR 105731 – Industrial Motor Repair in the United States
12. EL-5036 – Power Plant Reference Series – Volume 16, Insulation Condition of Large
Rotating Machines
13. EL-5036 – Power Plant Reference Series – Volume 17, Guide for Rewinding and
Reconditioning Medium Voltage Electric Motors
5.1.18 Shipping and Storage

1. 1009698 – Shipping and Storage of Electric Motors
5.1.19 System and Component Health Reports

1. 1009745 – System, Component and Program Health Reporting: Utility Best Practices,
December 2004
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Industry Documents
5.2 IEEE Documents

1. IEEE 43 – IEEE Recommended Practice for Testing Insulation Resistance of Rotating
Machinery
2. IEEE 56 – IEEE Guide for Insulation Maintenance of Large Alternating-Current Rotating
Machinery
3. IEEE 95 – IEEE Recommended Practice for Insulation Testing of Large AC Rotating
Machinery with High Direct Voltage
4. IEEE 112 – IEEE Standard Test Procedure for Polyphase Induction Motors and Generators
5. IEEE 113 – IEEE Guide: Test Procedures for Direct-Current Machines
6. IEEE 115 – Test Procedures for Synchronous Machines, PART 1 – Acceptance and
Performance Testing, PART 2 – Test Procedures and Parameter Determination for Dynamic
Analysis
7. IEEE 118 – IEEE Standard Test Code for Resistance Measurement
8. IEEE 275 – IEEE Recommended Practice for Thermal Evaluation of Insulation Systems for
Alternating - Current Electric Machinery Employing Form-Wound Pre-insulated Stator Coils
for Machines Rated 6900V and Below
9. IEEE 286 – IEEE Recommended Practice for Measurement of Power Factor Tip-Up of
Electric Machinery Stator Coil Insulation
10. IEEE 323 – IEEE Standard for Qualifying Class 1E Equipment for Nuclear Power
Generating Stations
11. IEEE 334 – IEEE Recommended Practice for Seismic Qualification of Class 1E Equipment
for Nuclear Power Generator Stations
12. IEEE 400 – IEEE Guide for Making High-Direct-Voltage Test on Power Cable Systems in
the Field
13. IEEE 429 – IEEE Recommended Practice for Thermal Evaluation of Sealed Insulation
Systems for Alternating-Current Electric Machinery Employing Form-Wound Pre-insulated
Stator Coils for Machines Rated 6900V and Below
14. IEEE 432 – IEEE Guide for Insulation Maintenance for Rotating Electrical Machinery (5hp
to less than 10,000hp)
15. IEEE 522 – IEEE Guide for Testing Turn-to-Turn Insulation on Form-wound Stator Coils for
Alternating-Current Rotating Electric Machines
16. IEEE 841 – IEEE Standard for Petroleum and Chemical Industry—Severe Duty Totally
Enclosed Fan-Cooled (TEFC) Squirrel Cage Induction Motors—Up to and Including 370 kW
(500 hp)
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Industry Documents
5.3 INPO Documents

1. TR 4-35, “Analysis of Large Pump Motor Failures Impacting Power Production - 2004”
2. TR 5-50, “Review of Events Impacting Power Production Involving Large Pump Motors
(Supersedes Topical Report TR 4-35)”
3. TR 7-59, “Review of Events Impacting Power Production Involving Large Pump Motors -
2007”
4. EPG-13, “Engineering Program Guide - Motors – 2008”
5. AP913, “Equipment Reliability Process Description”
6. 05-005 Supplement - Self-Assessment Guide
5.4 EASA Documents

1. Root Cause Failure Analysis
2. Mechanical Repair Fundamentals
3. Principles of Large AC Motors
4. Radial Ball Bearing Chart
5. Cylindrical Roller Bearing Chart
6. Core Iron Study
7. High-Potential Test Using AC/High-Potential Tests Using DC
8. Motor Lead Wire Chart
9. EASA Tech Notes
10. EASA Tech Manual
5.5 National Electrical Manufacturers Association

1. NEMA MG-1
5.6 Code Of Federal Regulations

1. 10CFR50 Appendix B – Quality Assurance Criteria for Nuclear Power Plants and Fuel
Reprocessing Plants
2. 10CFR50.49 – Environmental Qualification of Electric Equipment Important to Safety for
Nuclear Power Plants
3. 10CFR50.59 – Changes, Tests, and Experiments for Nuclear Power Plants
5.7 ASTM Documents

1. ASTM D224-02, “ Standard Practice In-Service Monitoring of Lubricating Oil for Auxiliary
Power Plant Equipment”
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5.8 NFPA Documents

1. NFPA 70E – Standard for Electrical Safety in the Work Place
2. NFPA 79 – Electrical Standard for Industrial Machinery
5.9 ANSI Documents

1. ANSI – AGMA 9002-B04, “Bores and Fits for Flexible Couplings (Inch Series)”
2. ANSI – AGMA 9003-A91, “Flexible Couplings – Keyless Fits”
3. ANSI – Y32.2 – Schematic Symbols
5.10 ABMA Documents
(There are over 25 ABMA standards - the ones most commonly used on motors are listed below)
1. ABMA 1, “Terminology for Anti-Friction Ball and Roller Bearings and Parts”
2. ABMA 4, “Tolerances Definitions and Gaging Practices for Ball and Roller Bearings”
3. ABMA 7, “Shaft and Housing Fits for Metric Radial Ball and Roller Bearings (Except
Tapered Roller Bearings) Conforming to Basic Boundary Plans”
4. ABMA 8.1, “Ball and Roller Bearing - Mounting Accessories, Metric Design”
5. ABMA 8.2, “Ball and Roller Bearing - Mounting Accessories, Inch Design”
6. ABMA 9, “Load Ratings and Fatigue Life for Ball Bearings”
7. AMBA 11, “Load Ratings and Fatigue Life for Roller Bearings”
5.11 Other Documents

1. API-541 – General-purpose Form-wound Squirrel Cage Induction Motors—250 Horsepower
and Larger
2. IEC 60034-1-2004 Rotating Electrical Machines – Part One: Rating and Performance
3. IEC 60034-8-2007 Rotating Electrical Machines – Part Eight: Terminal Markings and
Direction of Rotation
4. IEC 60034-14-2003 Rotating Electrical Machines – Part 14: Mechanical Vibration of Certain
Machines with Shaft Heights 56 mm and Higher—Measurement, Evaluation and Limits of
Vibration Severity
5. IEC 60034-30-2008 Efficiency Classes of Single-Speed, Three-Phase, Cage-Induction
motors (IE-code)
6. ASME Section XI - Rules for In-service Inspection of Nuclear Power Plant Components
7. Insurers – such as NEIL, ANI, etc.
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A
GLOSSARY
ABMA - American Bearing Manufacturers Association
AGMA - (American Gear Manufacturers Association)
Amortisseur (also known as a Damper Winding) – An Amortissuer winding is a winding used to

allow a synchronous motor to start as an induction motor. It uses rotor bars and shorting rings in
conjunction with the field winding on the rotor. It also serves to dampen any speed fluctuations
that may occur due to sudden load changes.
ANSI - American National Standards Institute
API - American Petroleum Institute
ASME - American Society of Mechanical Engineers
ASTM - American Society for Testing and Materials
B10 – See L10

B
Bearing Life – Bearing Life is usually expressed as the number of hours an individual bearing
will operate before the first evidence of metal fatigue develops in the rings or rolling elements. In
past years four different terms have been used when referring to bearing life: L10, B10, L50, and
B50. L10 and B10 mean the same thing and L50 and B50 are just five times as long as L10 and B10.
These values are theoretical.
CFR - Code for Federal Regulations
CGI - Commercial Grade Item
Corrective Maintenance (CM) - is defined as maintenance work which involves the repair or
replacement of components which have failed or broken down. For failure modes which lend
themselves to condition monitoring, corrective maintenance should be the result of a regular
inspection which identifies the failure in time for corrective maintenance to be planned and
scheduled, then performed during a routine plant outage. When corrective maintenance is done,
the equipment should be inspected to identify the reason for the failure and to allow action to be
taken to eliminate or reduce the frequency of future similar failures. These inspections should be
included in the work plan.
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Glossary
EASA - Electrical Apparatus Service Association
EPDM (Ethylene Propylene Diene Monomer) – a type of synthetic rubber that has a wide
industrial use including cable insulation.
EPR (Ethylene Propylene Rubber) – an insulation used for high voltage cables and underground
electrical cables. It has improved thermal characteristics over more traditional cables, such as
cross-linked polyethylene, enabling a smaller cross sectional area for the same load carrying
capacity. The cable is flexible and suited to applications where regular cable movement is
required such as in the mining industry and for temporary installations.
EPRI (Electric Power Research Institute) - conducts research on issues of interest to the electric
power industry in the USA. EPRI is an independent, nonprofit organization funded by the
electric utility industry. Although EPRI is primarily a US organization, it receives international
participation. EPRI's area of interest covers most aspects of electric power generation, delivery
and use.
EQ - Environmental Qualification
FME - Foreign Material Exclusion
FSAR (Final Safety Analysis Report) – The FSAR provides the operating basis for a nuclear
power plant. It bases of agreement between the plant operator and license guarantor that for how
a plant will be operated. The content is called out in US NRC Regulatory Guide 1.70, Rev. 3.
IEEE - Institute of Electrical and Electronic Engineers
INPO - Institute of Nuclear Plant Operations
L10 – The American Bearing Manufacturers Association (ABMA), formerly the AFBMA defines
the Basic Rating Life, L10 as the bearing life associated with a 90% reliability when operating
under conventional conditions, i.e. after a stated amount of time, 90% of a group of identical
bearings will not yet have developed metal fatigue. L10 life is also referred to by manufacturers
as the “minimum expected life”.
LEMUG (Large Electric Motor Users Group) – Industry group started by the Electric Power
Research Institute in 1998 to for the nuclear electric utility industry in order to collect and
exchange information on electric motors.
Low Voltage – Voltage level 600 Vac and below
Medium Voltage – Voltage level between 600 Vac to 15kVac.
NEMA- National Electrical Manufacturers Association
NETA - National Electrical Testing Association
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Glossary
OEM- Original Equipment Manufacturer
Offline – The condition in which a system or component is removed from service and is
considered not capable of performing its intended function.
OJT - On the Job Training
Online - The condition in which a system or component is considered to be in service and is

considered capable of performing its intended function.
Predictive Maintenance (PdM) - is the routine and cost-effective measurement of a number of

parameters indicative of machine and equipment condition, which are trended over time,
correlated and used to make decisions about the type and timing of corrective maintenance
actions within economical parameters of the business. In addition, Predictive Maintenance data
provides historical data to assist in understanding anomalies and to determine the root cause in
the sometimes unfortunate failure event.
Preventive Maintenance (PM) - can be defined as activities performed on a certain schedules

which are intended to maintain reliability and prevent breakdowns or degradation. These
activities can include regular inspections along with solving any discovered problems and
regularly-scheduled part replacements. Preventive Maintenance is a task undertaken with the
goal being to effectively repair an item to prevent failure or to repair an as found condition.
Refurbishment – Refurbishment includes inspections, disassembly, testing, restoration of

components to factory condition, parts replacement as necessary, reassembly, painting (if
required) and final testing including no-load or loaded test run. A refurbishment can be a partial
refurbishment (bearing work only) or a complete refurbishment. A refurbishment does not
include a rewind unless it is required or requested. However, winding cleaning and retreatments
should be included in a complete refurbishment.
Repair – A repair is considered an acceptable fix to a component that will allow it to perform its
intended function within the motor. It does not always restore the component to factory
condition.
Rewind – A rewind consist of a complete removal of the original insulation system, core testing
and repair (if necessary), installation of a new winding (including motor leads) and a resin
treatment process (dip and bake, VPI, etc). Usually a complete refurbishment is performed when
a rewind is necessary.
RMS - Root Mean Square – This is used to define the surface finish of metals. The smaller the
number the smoother the surface finish.
RTD - Resistive Temperature Device - Used to measure either winding and bearing temperatures
SME - Subject Matter Expert
TCM – Technical Contract Manager – This person is responsible contracts assigned to him or
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Glossary
her for use of supplemental personnel or for the procurement of new motors.
TIR - Total Indicator Run-out
Vacuum Pressure Impregnation (VPI) – Process for insulating conductor by which a component
is placed in a chamber (autoclave) and a vacuum is drawn to remove air and moisture and then
the chamber is filled with resin and then the chamber is pressurized to drive the resin into the
insulation material thereby filing any voids that in the insulation and providing an essentially
solid insulation system.
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B
POTENTIAL TRAINING OPPORTUNITIES AND
RECOMMENDED READING
Most vendors that manufacture special test equipment offer training. The vendors that provide
the equipment used onsite should be contacted for training opportunities.
B.1 EPRI Training
B.1.1 Computer Based Training

1. 1015412 – Large AC Motors, August 2007
2. 1010796 – Cable Design and Application
3. 1010797 – Low Voltage System Protection and Coordination
4. 1010799 – Large AC Motors
5. 1010799 – Small AC Induction Motors
6. 1010800 – Medium Voltage System Protection and Coordination
B.1.2 Engineering Technical Training Modules

1. Power Cable Selection and Application (1016698)
2. Large AC Motors (1015412)
B.1.3 Equipment Qualification

1. Equipment Qualification for Nuclear Power Plants Training Course
B.1.4 Heat Exchangers

1. Heat Exchangers (1013591)
2. Fundamentals of Heat Exchanger Maintenance and Troubleshooting
B.1.5 Maintenance Engineering

1. Maintenance Engineering Fundamentals Training (1015307)
2. Large Electric Motor Workshop
3. Lubrication and Bearing Workshop
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Potential Training Opportunities and Recommended Reading
B.1.6 Maintenance Programs

1. Foreign Material Exclusion Site Coordinator Program Training
2. Infrared Technology Level of Awareness
B.1.7 Non-Destructive Evaluation Program

1. Non-destructive Evaluation for Engineers
B.1.8 Nuclear Coatings

1. Comprehensive Coatings Training Course
B.2 EASA Training

1. Principals of A.C. Motors – EASA or equivalent
2. Mechanical Repair Fundamentals of Electric Motors – EASA or equivalent
3. Root Cause Failure Analysis for Motors - EASA or equivalent
B.3 Vendor Training

1. Introduction to Vibration
2. Introduction to Lubrication
3. Rolling Element Bearing Training - (EPRI, EASA. SKF, Kingsbury, or equivalent)
4. Fluid film (Babbitt) Bearing Training - (EPRI, EASA, Kingsbury, or equivalent )
5. Basic Accessories & Instrumentation
6. Hands On Motor Testing Field and Shop Testing - Working with Craft
7. Predictive Technologies
• Thermography
• Vibration
• Oil Analysis
• Partial Discharge
• Temperature Monitoring (Learn Critical Bearing and Stator Thermal Limits)
B.4 Site Specific Training

1. Plant Specific Motor Testing
2. Online Motor Performance Testing – Baker, PDMA, or equivalent
3. Machine/Motor Drawings (OEM) Interpretation - Outline, Accessories, Electrical,
Mechanical, etc.
4. Repair Shop Oversight (OJT)
5. Motor Testing – Shop Testing
6. Quality Programs (10CFR50 Appendix B, ANSI N45.2, ISO 9001, EASA-Q)
7. OE Training
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8. Motor Protection
B.5 Other Training Opportunities

1. Industrial Participation
2. EPRI/LEMUG Working Meetings
3. Fleet/Plant Working Group and Conference Calls
4. Visits to Repair Shop (OJT)
• Assist in repair shop evaluations
• Perform repair procedure review
• Provide site oversight during motor refurbishments and rewinds
5. Participate in Procurement of New Motors
• Develop procurement team
• Prepare procurement specifications
• Perform factory witness inspections
6. DC Motor Operation and Repair
7. Bearing Training
• Bearing refurbishment
• Bearing repair
• Bearing designs
8. Basics of Non Destructive Testing
• Eddy Current
• Die-penetrant
• In Service Inspection (ISI)
• Ultra-Sonic
• Understanding of NDT and troubleshooting
• Metallurgy
9. Alignment Training
10. Coupling Training
11. Accessories and Instrumentation – TC, RTDs, Accelerometers, Transducers, Proximity
Probes, etc
12. Visits to Repair Shop (OJT)
B.6 Industry Organizations

1. NEMA
2. EASA
3. IEEE
4. ASTM
5. ASME
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6. EPRI
7. IEC
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TRANSLATED TABLE OF CONTENTS
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF
WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC.
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BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES) RESULTING FROM YOUR SELECTION OR
USE OF THIS DOCUMENT OR ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR
ITEM DISCLOSED IN THIS DOCUMENT.
THE TRANSLATION OF THIS DOCUMENT FROM THE ENGLISH-LANGUAGE ORIGINAL HAS BEEN
PREPARED WITH LIMITED BUDGETARY RESOURCES BY OR ON BEHALF OF EPRI. IT IS PROVIDED
FOR REFERENCE PURPOSES ONLY AND EPRI DISCLAIMS ALL RESPONSIBILITY FOR ITS
ACCURACY. THE ENGLISH-LANGUAGE ORIGINAL SHOULD BE CONSULTED TO CROSS-CHECK
TERMS AND STATEMENTS IN THE TRANSLATION.
ORGANIZATION(S) THAT PREPARED THIS DOCUMENT
Electric Power Research Institute (EPRI)
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Translated Table of Contents
核維護應用中心：開發電動馬達專家的指南
1021427
2010 年 12 月最終報告
EPRI 專案經理
W. Johnson
美國電力科學研究院（Electric Power Research Institute）• 地址：3420 Hillview Avenue, Palo Alto, California 94304-1338 • PO Box
10412, Palo Alto, California 94303-0813 • USA
電話：+1.800.313.3774 • +1.650.855.2121 • 電子信箱：askepri@epri.com • 網址：www.epri.com
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產品說明
電力行業負責電動馬達的專業人員具有不同的頭銜，比如馬達專家，部件工程師，馬達技
術員和電氣技術員。盡管有關馬達的責任和義務分散到幾個部門，諸如維護，操作，工程
和採購，但通常都是由馬達專家來保証馬達的健康與可靠性。
本報告介紹一個分段方式來開發成為電動馬達專家所必需的技巧和知識。本報告包含推薦
使用的技術組合
，行業介入機會，培訓方式，輔導觀察及有關馬達的參考資料。本報告包含有關核能的特
定資訊；但如果刪除不適合其他行業的內容，該報告也可以由任何其他組織或個人用來開
發電動馬達的專業知識。
結果與發現
電動馬達對行業設施（特別是發電廠）的連續運行至關重要。但是，沒有完善的一致性流
程來充分開發人才以負責隨著設施而日漸老化的馬達。本報告提供一個分段方式來開發未
來電動馬達專家，該方法通過普及經常用於操作和維護電動馬達所必需的知識領域來建立
技術組合。
美國電力研究院（EPRI）大型電動馬達用戶小組（LEMUG）編制此報告以說明可以通過以
下方式獲得這些馬達知識：
 正式培訓活動
 直接觀察
 參與具體的馬達工作
 產業參與
 使用技術組合矩陣
該報告中提出的技術組合可以用來加快開發電動馬達專家。
挑戰與目標
通過與代表LEMUG的各個公用設施部門的討論，很明顯的是老化的員工隊伍與耗損是行業
內失去許多馬達專家的主要原因，而且非常難以找到一個培養替代團隊的方法。
本報告的目標是指出成為電動馬達專家所需的許多不同技能和知識領域並為職業培訓計劃
提供指南。
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應用、價值與用途
由於技能是廣泛而多樣的，所以需要很多年才能成為電動馬達專家。電動馬達的知識大約
70%為機械和30%為電氣，所以要求馬達專家擁有跨學科的知識。該報告提出必需掌握的機
械和電氣專業知識以恰當地維護馬達並使馬達預期壽命最大化。本報告的各個用戶有責任
結合適當的建議以實現自身的培訓承諾并達到其要求。
EPRI的觀點
本報告中的建議是以漸進方式逐漸展開，同時儘量減少因不充分的知識或接觸設備所導致
的工作風險。本報告不是用來驗證或廢止工作資格，而是提供個人進一發展的框架。
希望各單位審核本報告並制定符合單位和行業需要的子集資訊。
最終產物包括四個漸進技術組合並帶有相互參照的可選推薦培訓方式，以幫助各組織達到
馬達專家的要求。
策略
為了開發技術組合的知識領域和本文所述的四個技術組合，指南編制方已向公共設施中負
責維護馬達的個人，馬達產商及現有的馬達專家尋求意見。該報告（將幫助公共設施開發
馬達專家）將集中他們的建議。
關鍵詞
部件工程師
電動馬達
馬達工程師
馬達專家
測試
培訓
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1 簡介.......................................................................... 1-1
2 開發馬達專家的綜合討論 ........................................................ 2-1

2.1 產業參與................................................................. 2-3
2.2 高效馬達計劃的馬達計劃領域 ............................................... 2-4
3 技術組合矩陣的使用 ............................................................ 3-1

技術組合 1 — 首席馬達專家與儲備馬達專家 ....................................... 3-1
技術組合 2 — 首席馬達專家與儲備馬達專家 ...................................... 3-23
技術組合 3 — 首席馬達專家 .................................................... 3-40
技術組合 4 — 首席馬達專家 .................................................... 3-68
4 摘要.......................................................................... 4-1
5 行業文件 ...................................................................... 5-1

5.1 EPRI文件................................................................. 5-1
5.1.1 評估 ................................................................ 5-1
5.1.2 軸承 ................................................................ 5-1
5.1.3 電纜 ................................................................ 5-1
5.1.4 電氣-其它 ........................................................... 5-1
5.1.5 環境鑒定 ............................................................ 5-2
5.1.6 設備可靠性 .......................................................... 5-2
5.1.7 失效分析與故障診斷 .................................................. 5-2
5.1.8 熱交換器 ............................................................ 5-2
5.1.9 壽命週期管理 ........................................................ 5-3
5.1.10 潤滑 ................................................................ 5-3
5.1.11 機械-其它 ........................................................... 5-3
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5.1.12 核涂層 .............................................................. 5-3

5.1.13 操作與維護 .......................................................... 5-3
5.1.14 預測與預防性維護 .................................................... 5-3
5.1.15 新馬達的採購 ........................................................ 5-4
5.1.16 保護性繼電器 ........................................................ 5-5
5.1.17 修理與翻新 .......................................................... 5-5
5.1.18 運輸與存儲 .......................................................... 5-5
5.1.19 系統與部件健康報告 .................................................. 5-5
5.2 IEEE 文件................................................................ 5-6
5.3 INPO文件................................................................. 5-7
5.4 EASA 文件................................................................ 5-7
5.5 國家電氣制造商協會....................................................... 5-7
5.6 美國聯邦法規............................................................. 5-7
5.7 ASTM 文件................................................................ 5-7
5.8 NFPA 文件................................................................ 5-8
5.9 ANSI 文件................................................................ 5-8
5.10 ABMA 文件................................................................ 5-8
5.11 其它文件................................................................. 5-8
A 術語表 ........................................................................ A-1
B 可能的培訓機會及建議讀物 ...................................................... B-1

B.1 EPRI 培訓 ............................................................... B-1
B.1.1 計算機方面的培訓 .................................................... B-1
B.1.2 工程技術培訓組合 .................................................... B-1
B.1.3 設備鑒定 ............................................................ B-1
B.1.4 熱交換器 ............................................................ B-1
B.1.5 維修工程 ............................................................ B-1
B.1.6 維護計劃 ............................................................ B-2
B.1.7 非破壞性評估計劃 .................................................... B-2
B.1.8 核涂層 .............................................................. B-2
B.2 EASA 培訓................................................................ B-2
B.3 產商培訓................................................................. B-2
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B.4 具體現場培訓............................................................. B-2

B.5 其它培訓機會............................................................. B-3
B.6 行業組織................................................................. B-3
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圖表清單
圖2-1建議的馬達計劃領域.......................................................... 2-5
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表格清單
技術組合 1 - 表 3-1 至 3-14

表 3-1 技術組合 1-1 - 具體現場技術............................................... 3-1
表 3-2 技術組合 1-2 - 指南文件及聯系人........................................... 3-7
表 3-3 技術組合 1-3 - 馬達的常識................................................. 3-8
表 3-4 技術組合 1-4 - 馬達銘牌信息............................................... 3-9
表 3-5 技術組合 1-5 - 外殼類型及材料............................................ 3-10
表 3-6 技術組合 1-6 - 馬達性能數據的基本知識.................................... 3-11
表 3-7 技術組合 1-7 - 度監控技術及設計的基本知識.............................. 3-13
表 3-8 技術組合 1-8 - 傳感/監控技術的基本知識................................... 3-14
表 3-9 技術組合 1-9 - 定子繞組加熱器技術及設計的基本知識........................ 3-15
表 3-10 技術組合 1-10 - 軸承技術及設計的基本知識................................ 3-16
表 3-11 技術組合 1-11 - 潤滑系統，潤滑油類型與油量的基本知識.................... 3-18
表 3-12 技術組合 1-12 - 冷卻系統設計的基本知識.................................. 3-20
表 3-13 技術組合 1-13 - 繞組/絕系統類型的基本知識............................. 3-21
表 3-14 技術組合 1-14 - 馬達的貯存.............................................. 3-22
技術組合 2 - 表 3-15 至 3-29

表 3-15 技術組合 2-1 - 系統設計及操作的知識..................................... 3-23
表 3-16 技術組合 2-2 - 馬達圖紙（電氣，儀表及機械）的知識....................... 3-24
表 3-17 技術組合 2-3 - 馬達計劃指南的知識....................................... 3-26
表 3-18技術組合 2-4 - 長遠馬達計劃的知識........................................ 3-28
表 3-19 技術組合 2-5 - 備用馬達的知識........................................... 3-29
表 3-20技術組合 2-6 - 維護驟與監督指導的知識.................................. 3-30
表 3-21技術組合 2-7 - 馬達預測與預防性維護程序的知識............................ 3-31
表 3-22技術組合 2-8 - 馬達技術圖書館中文件內容的知識............................ 3-32
表 3-23 技術組合 2-9 - 馬達故障診斷指南的知識................................... 3-33
表3-24 技術組合 2-10 - 馬達熱攝影術及超聲監控的知識............................. 3-34
表 3-25 技術組合 2-11 - 馬達耦合設計的知識...................................... 3-35
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表 3-26 技術組合 2-12 - 馬達潤滑程序的知識...................................... 3-36

表 3-27 技術組合 2-13 - 馬達傳動軸設計的常識.................................... 3-37
3-28 技術組合 2-14 - 各種馬達設計的常識......................................... 3-38
表 3-29 技術組合 2-15 - 冷卻旋管設計的常識...................................... 3-39
技術組合 3 - 表 3-30 至 3-49

表 3-30 技術組合 3-1 - 商業級組件（CGI）專用及馬達升級程序...................... 3-40
表 3-31 技術組合 3-2 - 相似情況相似對待的馬達更換評估知識....................... 3-41
表 3-32 技術組合 2-3 - 馬達跳閘電路及繼電保護的知識............................. 3-42
表 3-33 技術組合 3-4 - 馬達測試儀器的知識....................................... 3-43
表 3-34 技術組合 3-5 - 專業培訓................................................. 3-44
表 3-35技術組合 3-6 -長遠馬達計劃的所有權....................................... 3-45
表 3-36技術組合 3-7 -關鍵備用馬達的購買與保存................................... 3-47
表 3-37技術組合 3-8 - 馬達計劃的評估............................................ 3-48
表3-38 技術組合 3-9 - 馬達維修，翻新及重繞規範的知識............................ 3-49
表 3-39 技術組合 3-10 - 馬達性能趨勢分析的知識.................................. 3-51
表3-40 技術組合 3-11 - 馬達維修車間過程與控制................................... 3-52
表 3-41 技術組合 3-12 - 各種馬達設計的詳細知識.................................. 3-53
表 3-42 技術組合 3-13 - 馬達絕系統設計差異的知識.............................. 3-54
表 3-43 技術組合 3-14 - 馬達停用與絕技術的知識................................ 3-55

表 3-44 技術組合 3-15 - 馬達引線規格，設計及測試的知識.......................... 3-57
表 3-45 技術組合 3-16 - 馬達軸承設計的知識...................................... 3-58
表 3-46 技術組合 3-17 - 馬達轉子設計的知識...................................... 3-62
表 3-47 技術組合 3-18 - 馬達傳動軸材料及維修過程的知識.......................... 3-64
表 3-48 技術組合 3-19 - 油冷和氣冷旋管的設計，測試技術及驗收標準的知識 .......... 3-65
表 3-49 技術組合 3-20 - 証據保全與表面原因...................................... 3-66
技術組合 4 - 表 3-50 至 3-67

表 3-50 技術組合 4-1 - 馬達計劃指南的所有權..................................... 3-68
表 3-51 技術組合 4-2 - 成為管理部門與所有馬達問題的正式聯絡員................... 3-70
表 3-52 技術組合 4-3 - 10CFR50.59培訓........................................... 3-71
表 3-53 技術組合 4-4 - 變更設計事項的知識....................................... 3-72
表 3-54 技術組合 4-5 - 馬達定子鐵心測試與設計的知識............................. 3-73
表 3-55 技術組合 4-6 - 馬達絕系統的詳細知識................................... 3-75
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表 3-56 技術組合 4-7 - 所有INPO,NRC及NEIL問題的知識............................. 3-79

表 3-57 技術組合 4-8 - 馬達性能曲線的詳細知識................................... 3-80
表3-58 技術組合 4-9 - 馬達技術與操作性評估...................................... 3-81
表 3-59 技術組合4-10 - 根本原因分析培訓......................................... 3-82
表 3-60 技術組合4-11 - 馬達環境鑒定（EQ）程序的知識............................. 3-83
表 3-61 技術組合4-12 - 馬達保護涂層及1級維護涂層的知識.......................... 3-84
表 3-62 技術組合 4-13 - 馬達功率計測試的知識.................................... 3-85
表 3-63 技術組合 4-14 -完整馬達測試（IEEE112）的知識............................ 3-86
表3-64 技術組合 4-15 -參與行業文件開發.......................................... 3-87
表 3-65 技術組合4-16 - 擔任行業主要馬達小組的主席職務........................... 3-88
表3-66 技術組合 4-17 - 開發並提供馬達培訓....................................... 3-89
表3-67 技術組合 4-18 - 成為下一代馬達專家的導師................................. 3-90
技術組合補余矩陣
表 3-68 技術組合補余矩陣(技術組合 1)............................................ 3-91
表 3-69 技術組合補余矩陣(技術組合 2)............................................ 3-93
表 3-70 技術組合補余矩陣(技術組合 3)............................................ 3-95
表 3-71 技術組合補余矩陣(技術組合 4)............................................ 3-98
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核维护应用中心：电动马达专家开发指南
1021427
最终报告，2010年12月
EPRI项目经理W. Johnson
美国电力研究协会3420 Hillview Avenue, Palo Alto, California 94304-1338 ▪ PO Box 10412, Palo Alto, California 94303-0813 ▪ USA
+1.800.313.3774 ▪ +1.650.855.2121 ▪ askepri@epri.com ▪ www.epri.com
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产品说明
电力行业负责电动马达的人员有许多头衔，稍微列举几个：马达专家、零件工程师、马达
技术员和电气技术员。尽管有关马达的职责通常涉及几个部门—
诸如维护、操作、工程和采购部门—
但通常是马达专家来保证马达的完好性与可靠性得到维持。
本报告提出一种分层次的方法来开发成为电动马达专家所必需的技巧和知识。
本报告包含了推荐使用的技术组合、行业介入机会、培训方案、辅导观察及马达参考资料
。
本报告包含有关核能的特定信息；但是任何组织或个人可以将其用于开发电动马达专业知
识，前提是去除与他们所在行业不适用的内容。
结果与发现
电动马达对工业设施（特别是发电厂）的连续运行至关重要。
但是，随着设施的老化，没有适当的一致的流程来充分开发负责马达的人才。
本报告提供一种分层次的方法来开发未来电动马达专家，该方法通过普及电动马达操作与
维护所必需的知识领域来建立技术组合。
美国电力研究协会（EPRI）的大型电动马达用户小组（LEMUG）已编写此报告来识别马
达知识，这些马达知识可以通过以下方式来获得：
 正式培训活动
 直接观察
 参与马达特定专业活动
 行业参与
 使用技术组合矩阵
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该报告中提出的技术组合可以用来加快培养电动马达专家。
挑战与目标
通过与LEMUG代表的各个公共事业部门进行讨论，明显发现工作人员年龄老化与人员自
然削减使得行业内失去许多马达专家，而现在难以找到培养胜任的替代者的合适方案。
本报告的目标是指出成为电动马达专家所需的许多不同技能和知识领域，并为职业发展规
划提供指导。
应用、价值与用途
由于技能广泛而多样，所以需要很多年才能成为电动马达专家。
电动马达覆盖大约70%机械学科和30%电气学科，所以要求马达专家拥有跨学科的知识
。
该报告提出了恰当地维护马达并使马达预期寿命最大化所必需掌握的机械和电气属性特征
。本报告的各个用户应负责结合适当的建议，来满足自己的培训承诺与要求。
EPRI的观点
本报告中的建议是以渐进方式提供帮助，同时减少因不充分了解设备知识或暴露于设备而
影响工作的风险
本报告不是用来使一些资格生效或无效，而只是提供个人进一步发展的框架。
希望每个现场评审本报告并识别出现场和行业必需的信息子集。
最终产物包括四个渐进技术组合，带有互相参照的可交替使用的推荐培训方案，以帮助每
个组织满足马达专家的要求。
策略
为了开发技术组合知识领域和本文描述的四个技术组合的进展，已经向公用事业中负责维
护马达的个人、马达制造商及现有的马达专家寻求了指导。
该报告是公共事业部门建议的集合，将帮助他们培养所谓的马达专家。
关键词
零件工程师
电动马达
马达工程师
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马达专家
测试
培训
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目录
1引言 ..................................................................................................................................... 1-1
2 关于马达专家培养的综合讨论............................................................................................... 2-1
2.1 行业参与 ......................................................................................................................2-3
2.2 有效马达程序的马达程序领域 ......................................................................................2-4
3 技术组合矩阵的使用............................................................................................................. 3-1
技术组合 1—首席马达专家与后备马达专家..........................................................................3-1
技术组合 2—首席马达专家与后备马达专家........................................................................3-23
技术组合 3—首席马达专家.................................................................................................3-40
技术组合 4—首席马达专家.................................................................................................3-68
4 摘要 ..................................................................................................................................... 4-1
5 行业文件 .............................................................................................................................. 5-1
5.1 EPRI文件 .....................................................................................................................5-1
5.1.1 评估 .....................................................................................................................5-1
5.1.2 轴承 .....................................................................................................................5-1
5.1.3 电缆 .....................................................................................................................5-1
5.1.4 电气-其它.............................................................................................................5-1
5.1.5 环境鉴定..............................................................................................................5-2
5.1.6 设备可靠性 ..........................................................................................................5-2
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5.1.7 故障分析与故障处理............................................................................................5-2
5.1.8 热交换器..............................................................................................................5-2
5.1.9 寿命周期管理.......................................................................................................5-3
5.1.10 润滑 .....................................................................................................................5-3
5.1.11 机械-其它.............................................................................................................5-3
5.1.12 核涂层 .................................................................................................................5-3
5.1.13 操作与维护 ..........................................................................................................5-3
5.1.14 预测性与预防性维护............................................................................................5-3
5.1.15 新马达采购 ..........................................................................................................5-4
5.1.16 保护继电器 ..........................................................................................................5-5
5.1.17 修理与翻新 ..........................................................................................................5-5
5.1.18 运输与存储 ..........................................................................................................5-5
5.1.19 系统与零配件完好性报告.....................................................................................5-5
5.2 IEEE 文件 ....................................................................................................................5-6
5.3 INPO文件 .....................................................................................................................5-7
5.4 EASA 文件 ...................................................................................................................5-7
5.5 国家电气制造商协会.....................................................................................................5-7
5.6 美国联邦法规 ...............................................................................................................5-7
5.7 ASTM 文件...................................................................................................................5-7
5.8 NFPA 文件 ...................................................................................................................5-8
5.9 ANSI 文件 ....................................................................................................................5-8
5.10 ABMA 文件 ..................................................................................................................5-8
5.11 其它文件 ......................................................................................................................5-8
A 术语表.................................................................................................................................. A-1
B可能的培训机会及建议的阅读 ............................................................................................... B-1
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B.1 EPRI 培训................................................................................................................... B-1
B.1.1 基于计算机的培训 .............................................................................................. B-1
B.1.2 工程技术培训模块 .............................................................................................. B-1
B.1.3 设备鉴定............................................................................................................. B-1
B.1.4 热交换器............................................................................................................. B-1
B.1.5 维修工程............................................................................................................. B-1
B.1.6 维护程序............................................................................................................. B-2
B.1.7 无损评估程序...................................................................................................... B-2
B.1.8 核涂层 ................................................................................................................ B-2
B.2 EASA 培训 .................................................................................................................. B-2
B.3 供应商培训 .................................................................................................................. B-2
B.4 地点具体培训 .............................................................................................................. B-2
B.5 其它培训机会 .............................................................................................................. B-3
B.6 行业组织 ..................................................................................................................... B-3
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图表目录
图2-1建议的马达程序领域..........................................................................................................2-5
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表格目录
技术组合 1 - 表 3-1 至 3-14
表 3-1 技术组合 1-1 - 特定场所的技术 .......................................................................................3-1
表 3-2 技术组合 1-2 - 指南文件及联系方式 ................................................................................3-7
表 3-3 技术组合 1-3 - 马达常识 ..................................................................................................3-8
表 3-4 技术组合 1-4 - 马达铭牌信息...........................................................................................3-9
表 3-5 技术组合 1-5 - 附件的类型及材料..................................................................................3-10
表 3-6 技术组合 1-6 - 马达性能数据的基本知识 .......................................................................3-11
表 3-7 技术组合 1-7 - 温度监控技术及设计的基本知识 ............................................................3-13
表 3-8 技术组合 1-8 - 传感／监控技术的基本知识 ...................................................................3-14
表 3-9 技术组合 1-9 - 定子绕组加热器技术及设计的基本知识 .................................................3-15
表 3-10 技术组合 1-10 - 轴承技术及设计的基本知识 ...............................................................3-16
表 3-11 技术组合 1-11 - 润滑系统、润滑油类型与数量的基本知识..........................................3-18
表 3-12 技术组合 1-12 - 冷却系统设计的基本知识 ...................................................................3-20
表 3-13 技术组合 1-13 - 绕组／绝缘系统类型的基本知识 ........................................................3-21
表 3-14 技术组合 1-14 - 马达存储 ............................................................................................3-22
技术组合 2 - 表 3-15 至 3-29
表 3-15 技术组合 2-1 - 系统设计及操作知识 ............................................................................3-23
表 3-16 技术组合 2-2 - 马达图纸（电气、仪表及机械）知识 ...................................................3-24
表 3-17 技术组合 2-3 - 马达程序指南知识................................................................................3-26
表 3-18技术组合 2-4 - 远程马达平面图知识 .............................................................................3-28
表 3-19 技术组合 2-5 - 备用马达知识.......................................................................................3-29
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表 3-20技术组合 2-6 - 维护程序与监督指导知识 ......................................................................3-30
表 3-21技术组合 2-7 - 马达预测性与预防性维护程序知识 .......................................................3-31
表 3-22技术组合 2-8 - 马达技术图书馆中的文件内容知识 .......................................................3-32
表 3-23 技术组合 2-9 - 马达故障处理指南知识 ........................................................................3-33
表 3-24 技术组合 2-10 - 马达温度记录及超声监控知识............................................................3-34
表 3-25 技术组合 2-11 - 马达联轴器设计知识 ..........................................................................3-35
表 3-26 技术组合 2-12 - 马达润滑程序知识..............................................................................3-36
表 3-27 技术组合 2-13 - 马达轴设计常识 .................................................................................3-37
表 3-28 技术组合 2-14 - 不同马达设计常识..............................................................................3-38
表 3-29 技术组合 2-15 - 冷却旋管设计常识..............................................................................3-39
技术组合 3 - 表 3-30 至 3-49
表 3-30 技术组合3-1 - 商业级零组件（CGI）专用及马达升级过程 ..........................................3-40
表 3-31 技术组合3-2 - 相似情况相似对待的马达更换评估知识 ................................................3-41
表 3-32 技术组合 2-3 - 马达跳闸电路及保护继电知识..............................................................3-42
表 3-33 技术组合 3-4 - 马达测试设备知识................................................................................3-43
表 3-34技术组合 3-5 - 专业培训 ...............................................................................................3-44
表 3-35技术组合 3-6 - 远程马达平面图所有权 .........................................................................3-45
表 3-36技术组合 3-7 -重要备用马达的购买与保存 ...................................................................3-47
表 3-37 技术组合 3-8 - 马达程序评估.......................................................................................3-48
表 3-38 技术组合 3-8 - 关于马达维修、翻新及重绕规范的知识 ...............................................3-49
表 3-39 技术组合 3-10 - 马达性能趋势分析知识 ......................................................................3-51
表 3-34 技术组合 3-11 - 马达维修车间过程与控制 ...................................................................3-52
表 3-41 技术组合 3-12 - 各种马达设计的详细知识 ...................................................................3-53
表 3-42 技术组合 3-13 - 马达绝缘系统设计分歧的知识............................................................3-54
表 3-43 技术组合 3-14 - 马达停止与绝缘技术的知识 ...............................................................3-55
表 3-44 技术组合 3-15 - 马达引出线规格、设计及测试的知识 .................................................3-57
表 3-45 技术组合 3-16 - 马达轴承设计知识..............................................................................3-58
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表 3-46 技术组合 3-17 - 马达转子设计知识..............................................................................3-62
表 3-47 技术组合 3-18 - 马达轴材料及维修过程的知识............................................................3-64
表 3-48 技术组合 3-19 - 油冷和气冷旋管的设计、测试技术及验收准则的知识........................3-65
表 3-49 技术组合 3-20 - 证据保全与表面原因 ..........................................................................3-66
技术组合 4 - 表 3-50 至 3-67
表 3-50 技术组合 4-1 - 马达程序指南所有权 ............................................................................3-68
表 3-51 技术组合 4-2 - 成为管理部门与所有马达问题的正式联络员 ........................................3-70
表 3-52 技术组合 4-3 -培训的10CFR50.59 .............................................................................3-71
表 3-53 技术组合 4-4 - 设计变更问题的知识 ............................................................................3-72
表 3-54 技术组合 4-5 - 马达定子铁芯测试与设计知识..............................................................3-73
表 3-55 技术组合 4-6 - 马达绝缘系统的详细知识 .....................................................................3-75
表 3-56 技术组合 4-7 - 所有INPO、NRC及NEIL问题的知识....................................................3-79
表 3-57 技术组合 4-8 - 马达性能曲线的详细知识 .....................................................................3-80
表3-58技术组合 4-9 - 马达技术评估与可操作性评估................................................................3-81
表 3-59 技术组合4-10 -培训的根本原因分析 ............................................................................3-82
表 3-60 技术组合4-11 - 马达环境鉴定知识...............................................................................3-83
表 3-61 技术组合4-12 - 有关马达保护涂层及１级服务涂层的知识...........................................3-84
表 3-62 技术组合 4-13 - 马达功率计测试知识 ..........................................................................3-85
表 3-63 技术组合 4-14 - 完全马达测试（IEEE112）知识 ........................................................3-86
表 3-64 技术组合 4-15 - 行业文件开发介入..............................................................................3-87
表 3-65 技术组合4-16 - 在领先的马达行业小组内担任主席职位 ..............................................3-88
表3-66 技术组合 4-17 - 开发并提供马达培训 ...........................................................................3-89
表3-67 技术组合 4-18 - 成为下一代马达专家的指导者............................................................3-90
技术组合完备矩阵
表 3-68 技术组合完备矩阵(技术组合 1)....................................................................................3-91
表 3-69 技术组合完备矩阵(技术组合 2)....................................................................................3-93
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表 3-70 技术组合完备矩阵(技术组合 3)....................................................................................3-95
表 3-71 技术组合完备矩阵(技术组合 4)....................................................................................3-98
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Centre d’applications de
maintenance nucléaire : Guide de
formation d'un spécialiste des moteurs
électriques
1021427
Rapport final, décembre 2010
Directeur de projet EPRI

W. Johnson

3420 Hillview Avenue, Palo Alto, California 94304-1338 ▪ PO Box 10412, Palo Alto, Californie 94303-0813 ▪ États-Unis
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DESCRIPTION DU PRODUIT
Dans l'industrie de la génération d'électricité, les responsables des moteurs électriques portent
des titres variés — spécialiste moteurs, ingénieur de composants, technicien de moteurs et
technicien électricité, pour n'en citer que quelques-uns. Bien que la responsabilité des moteurs et
les fonctions qui s'y rapportent soient partagées entre plusieurs départements - tels que
maintenance, production, ingénierie et approvisionnements - c'est le spécialiste des moteurs qui
doit assurer le bon état et la fiabilité des moteurs.
Ce rapport présente une approche par niveaux du développement des compétences et de la
connaissance nécessaires à la bonne formation d'un spécialiste des moteurs. Ce rapport présente
les ensembles de compétences recommandées, les possibilités de participation de l'industrie, des
options de formation, le point de vue de mentors et des documents de référence. Bien que ce
rapport contienne des informations spécifiques à l'énergie nucléaire, il peut servir à toute
organisation ou tout individu désireux d'améliorer son expertise sur les moteurs, il suffit
simplement d'ignorer ces informations.
Résultats et conclusions
Les moteurs électriques sont des composants essentiels au fonctionnement continu des
établissements industriels, particulièrement à celui des centrales électriques. Malgré cela, il
n'existe aucun processus conséquent procurant une formation suffisante du personnel
responsable des moteurs alors que les centrales vieillissent. Ce rapport fournit une approche par
niveaux de la formation des futurs spécialistes de moteurs électriques et, pour cela, détermine les
ensembles de compétences et les domaines de connaissance habituellement nécessaires à
l'utilisation et à la maintenance des moteurs électriques.
Le Groupe des utilisateurs de gros moteurs électriques (LEMUG) de l'Electric Power Research
Institute (EPRI) a établi ce rapport afin d'identifier les connaissances sur les moteurs qui peuvent
être acquises grâce à :
 Des séances de formation formelles
 L'observation directe
 La participation à des activités spécifiques aux moteurs
 La participation de l’industrie
 L'utilisation de matrices d'ensemble de compétences
Les ensembles de compétences présentés dans ce rapport peuvent permettre d'accélérer la
formation d'un spécialiste des moteurs électriques.
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Défis et objectifs
Les discussions avec le personnel des diverses centrales représentées par le LEMUG ont montré
que le vieillissement des équipes et leur attrition contribuaient, dans l'industrie, à la perte de
nombreux spécialistes des moteurs, et qu'il était difficile de trouver un programme efficace qui
permette de les remplacer par des spécialistes compétents.
L'objectif de ce rapport est, d'une part, de mettre en évidence les compétences, nombreuses et
variées, et les domaines de connaissance nécessaires à la formation d'un spécialiste des moteurs
électriques et, d'autre part, de procurer des directives de conduite des plans de carrière.
Applications, valeur et utilisation

La formation d'un spécialiste des moteurs électriques demande de nombreuses années car les
compétences requises sont vastes et variées. Les connaissances d'un tel spécialiste doivent porter
sur plusieurs disciplines car, dans un moteur électrique, la part de la mécanique est de 70% et
celle de l'électricité de 30%. Ce rapport présente les aspects mécaniques et électriques qui
doivent être maîtrisés afin d'être capable de correctement maintenir les moteurs et de maximiser
leur durée de vie utile. Il appartient à l'utilisateur de ce rapport de sélectionner les
recommandations appropriées aux exigences et objectifs de son propre programme de formation.
Perspective d’EPRI
Les recommandations contenues dans ce rapport sont présentées de manière progressive, de
façon à pouvoir bénéficier de leur contribution tout en minimisant le risque qu'une connaissance
ou une exposition insuffisante présenterait pour les équipements. Ce rapport n'est pas destiné à la
validation on l'invalidation des qualifications, c'est un cadre de travail pour poursuivre la
formation individuelle.
Chaque site va étudier ce rapport et identifier les sous-ensembles d'informations qui lui sont
nécessaires pour satisfaire les besoins du site et de l'industrie.
Le produit qui en résulte comprend quatre ensembles progressifs de compétences, avec
références croisées d'options de formation recommandées, accompagnées de variantes
permettant de satisfaire les exigences des spécialistes de moteurs de chaque organisation.
Approche
On a fait appel au personnel des centrales responsable de la maintenance des moteurs, aux
fabricants de moteurs et aux spécialistes actuellement en fonction pour développer les domaines
de connaissance et la progression des quatre ensembles de compétences décrits dans ce rapport.
Leurs recommandations sont consignées dans ce rapport qui permettra aux centrales de former
ceux que l'on appelle les spécialistes des moteurs.
Mots-clés
Ingénieur composants
Moteurs électriques
Ingénieur moteurs
Spécialistes des moteurs
Essais
Formation
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TABLE DES MATIERES
1 INTRODUCTION ....................................................................................................................1-1
2 GENERALITES SUR LA FORMATION DES SPECIALISTES DES MOTEURS...................2-1

2.1 Participation de l’industrie ............................................................................................2-3
2.2 Domaines d'un programme efficace sur les moteurs...................................................2-4
3 UTILISATION DE MATRICES D'ENSEMBLES DE COMPETENCES ..................................3-1

Ensemble de compétences 1 – Spécialiste principal des moteurs et suppléant du
spécialiste des moteurs.........................................................................................................3-1
Ensemble de compétences 2 – Spécialiste principal des moteurs et suppléant du
spécialiste des moteurs.......................................................................................................3-23
Ensemble de compétences 3 – Spécialiste principal des moteurs .....................................3-40
Ensemble de compétences 4 – Spécialiste principal des moteurs .....................................3-68
4 SOMMAIRE ............................................................................................................................4-1
5 DOCUMENTS DE L'INDUSTRIE ...........................................................................................5-1

5.1 Documents d'EPRI.......................................................................................................5-1
5.1.1 Évaluations..........................................................................................................5-1
5.1.2 Paliers .................................................................................................................5-1
5.1.3 Câbles .................................................................................................................5-1
5.1.4 Autres éléments électriques................................................................................5-1
5.1.5 Qualification environnementale...........................................................................5-2
5.1.6 Fiabilité des équipements ...................................................................................5-2
5.1.7 Analyse des pannes et dépannage.....................................................................5-2
5.1.8 Échangeurs de chaleur .......................................................................................5-2
5.1.9 Gestion du cycle de vie .......................................................................................5-3
5.1.10 Lubrification.........................................................................................................5-3
5.1.11 Autres éléments mécaniques..............................................................................5-3
5.1.12 Revêtements utilisés dans le nucléaire...............................................................5-3
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5.1.13 Opérations et maintenance .................................................................................5-3

5.1.14 Maintenance préventive et prédictive..................................................................5-3
5.1.15 Approvisionnement de nouveaux moteurs..........................................................5-4
5.1.16 Relais de protection ............................................................................................5-5
5.1.17 Réparation et remise à neuf................................................................................5-5
5.1.18 Transport et entreposage....................................................................................5-5
5.1.19 Rapports sur l'état des systèmes et des composants .........................................5-5
5.2 Documents de l'IEEE ...................................................................................................5-6
5.3 Documents de l'INPO ..................................................................................................5-7
5.4 Documents de l'EASA..................................................................................................5-7
5.5 National Electrical Manufacturers Association.............................................................5-7
5.6 Code de la réglementation fédérale.............................................................................5-7
5.7 Documents de l'ASTM .................................................................................................5-7
5.8 Documents de la NFPA ...............................................................................................5-8
5.9 Documents de l'ANSI...................................................................................................5-8
5.10 Documents de l'ABMA .................................................................................................5-8
5.11 Autres documents ........................................................................................................5-8
A GLOSSAIRE ......................................................................................................................... A-1
B POSSIBILITES DE FORMATION ET LECTURES RECOMMANDEES............................... B-1

B.1 Formation d'EPRI ....................................................................................................... B-1
B.1.1 Formation assistée par ordinateur ..................................................................... B-1
B.1.2 Modules de formation technique en ingénierie (ETTM) ..................................... B-1
B.1.3 Qualification des équipements ........................................................................... B-1
B.1.4 Échangeurs de chaleur ...................................................................................... B-1
B.1.5 Génie de la maintenance ................................................................................... B-1
B.1.6 Programmes de maintenance ............................................................................ B-2
B.1.7 Programmes d'évaluation non-destructifs .......................................................... B-2
B.1.8 Revêtements utilisés dans le nucléaire.............................................................. B-2
B.2 Formation EASA ......................................................................................................... B-2
B.3 Formation des vendeurs ............................................................................................. B-2
B.4 Formation spécifique au site ....................................................................................... B-2
B.5 Autres possibilités de formation .................................................................................. B-3
B.6 Organisations de l'industrie......................................................................................... B-3
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LISTE DES FIGURES
Figure 2-1 Domaines suggérés pour les programmes sur les moteurs .....................................2-5
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LISTE DES TABLEAUX
Ensemble de compétences 1 – Tableaux 3-1 à 3-14

Tableau 3-1 Ensemble de compétences 1-1 – Compétences spécifiques au site.....................3-1
Tableau 3-2 Ensemble de compétences 1-2 – Documents guides et contacts .........................3-7
Tableau 3-3 Ensemble de compétences 1-3 – Connaissances générales sur les moteurs ......3-8
Tableau 3-4 Ensemble de compétences 1-4 – Informations portées sur les plaques
signalétiques des moteurs .................................................................................................3-9
Tableau 3-5 Ensemble de compétences 1-5 – Types et matériaux d'enveloppes...................3-10
Tableau 3-6 Ensemble de compétences 1-6 – Connaissances de base sur les
performances des moteurs ..............................................................................................3-11
Tableau 3-7 Ensemble de compétences -1-7 – Connaissances de base sur la
technologie et la conception de la surveillance de l'échauffement...................................3-13
Tableau 3-8 Ensemble de compétences 1-8 – Connaissances de base sur la
technologie des capteurs et de la surveillance ................................................................3-14
technologie et la conception du chauffage des enroulements des stators.......................3-15
technologie et la conception des paliers ..........................................................................3-16
systèmes de lubrification, les différents types et les quantités de lubrification.................3-18
conceptions des systèmes de refroidissement ................................................................3-20
Tableau 3-13 Ensemble de compétences 1-13 – Connaissances de base sur les types
d'enroulements et d'isolants .............................................................................................3-21
Tableau 3-14 Ensemble de compétences 1-14 – Entreposage des moteurs ..........................3-22

Tableau 3-15 Ensemble de compétences 2-1 – Connaissances sur la conception et
l'exploitation des systèmes...............................................................................................3-23
Tableau 3-16 Ensemble de compétences 2-2 – Connaissances sur la conception des
moteurs (éléments électriques, mécaniques et instrumentation) .....................................3-24
Tableau 3-17 Ensemble de compétences 2-3 – Connaissances des guides de
programmes sur les moteurs ...........................................................................................3-26
Tableau 3-18 Ensemble de compétences 2-4 – Connaissances des plans à long terme
sur les moteurs.................................................................................................................3-28
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Tableau 3-19 Ensemble de compétences 2-5 – Connaissances sur les pièces de

rechange des moteurs .....................................................................................................3-29
Tableau 3-20 Ensemble de compétences 2-6 – Connaissances sur les procédures de
maintenance et les instructions de suivi...........................................................................3-30
Tableau 3-21 Ensemble de compétences 2-7 – Connaissances sur les programmes de
maintenance préventive et prédictive des moteurs ..........................................................3-31
Tableau 3-22 Ensemble de compétences 2-8 – Connaissances sur le contenu des
documents de la bibliothèque technique sur les moteurs ................................................3-32
Tableau 3-23 Ensemble de compétences 2-9 – Connaissances des instructions de
dépannage des moteurs ..................................................................................................3-33
Tableau 3-24 Ensemble de compétences 2-10 – Connaissances sur les suivis
thermographique et ultrasonique des moteurs.................................................................3-34
accouplements des moteurs ............................................................................................3-35
Tableau 3-26 Ensemble de compétences 2-12 – Connaissances sur les programmes de
lubrification des moteurs ..................................................................................................3-36
Tableau 3-27 Ensemble de compétences 2-13 – Connaissances générales sur la
conception des arbres de moteurs ...................................................................................3-37
Tableau 3-28 Ensemble de compétences 2-14 – Connaissances générales sur les
différentes conceptions de moteurs .................................................................................3-38
Tableau 3-29 Ensemble de compétences 2-15 – Connaissances générales sur la
conception des serpentins de refroidissement.................................................................3-39

Tableau 3-30 Ensemble de compétences 3-1 – Affectation des éléments de classe
commerciale et processus d'amélioration des moteurs ...................................................3-40
Tableau 3-31 Ensemble de compétences 3-2 – Connaissances sur les évaluations des
remplacements à l'identique des moteurs........................................................................3-41
Tableau 3-32 Ensemble de compétences 3-3 – Connaissances sur les circuits de
déclenchement des moteurs et sur les relais de protection .............................................3-42
Tableau 3-33 Ensemble de compétences 3-4 – Connaissances sur les équipements
d'essais des moteurs........................................................................................................3-43
Tableau 3-34 Ensemble de compétences 3-5 – Formation spécialisée ..................................3-44
Tableau 3-35 Ensemble de compétences 3-6 – Maîtrise du plan à long terme sur les
moteurs ............................................................................................................................3-45
Tableau 3-36 Ensemble de compétences 3-7 – Approvisionnement et préservation des
pièces de rechange essentielles des moteurs .................................................................3-47
Tableau 3-37 Ensemble de compétences 3-8 – Évaluation des programmes sur les
moteurs ............................................................................................................................3-48
Tableau 3-38 Ensemble de compétences 3-9 – Connaissances sur la réparation des
moteurs, leur remise à neuf et les spécifications de rembobinage ..................................3-49
Tableau 3-39 Ensemble de compétences 3-10 – Connaissances sur les tendances de
performance des moteurs ................................................................................................3-51
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Tableau 3-40 Ensemble de compétences 3-11 – Processus et contrôles dans les ateliers
d'entretien des moteurs....................................................................................................3-52
Tableau 3-41 Ensemble de compétences 3-12 – Connaissances détaillées sur les
différentes conceptions de moteurs .................................................................................3-53
Tableau 3-42 Ensemble de compétences 3-13 – Connaissances sur les différences de
conception des isolants dans les moteurs .......................................................................3-54
Tableau 3-43 Ensemble de compétences 3-14 – Connaissances sur les bornes des
moteurs et les techniques d'isolant ..................................................................................3-55
Tableau 3-44 Ensemble de compétences 3-15 – Connaissances sur les spécifications,
la conception et les essais des câbles de moteurs ..........................................................3-57
paliers des moteurs ..........................................................................................................3-58
rotors de moteurs .............................................................................................................3-62
Tableau 3-47 Ensemble de compétences 3-18 – Connaissances sur les matériaux et les
processus de réparation des arbres de moteurs..............................................................3-64
Tableau 3-48 Ensemble de compétences 3-19 – Connaissances sur la conception, les
techniques d'essai et les critères d'acceptation des serpentins de refroidissement à
l'air et à l'huile...................................................................................................................3-65
Tableau 3-49 Ensemble de compétences 3-20 – Préservation des signes et cause
apparente .........................................................................................................................3-66

Tableau 3-17 Ensemble de compétences 4-1 – Maîtrise des guides de programme sur
les moteurs.......................................................................................................................3-68
Tableau 3-51 Ensemble de compétences 4-2 – Assurer la liaison officielle avec le
management sur tous les problèmes des moteurs ..........................................................3-70
Tableau 3-52 Ensemble de compétences 4-3 – Formé conformément à 10CFR50.59...........3-71
Tableau 3-53 Ensemble de compétences 4-4 – Connaissances sur les problèmes de
modification de la conception...........................................................................................3-72
Tableau 3-54 Ensemble de compétences 4-5 – Connaissances sur la conception et les
essais des noyaux de stators de moteurs ........................................................................3-73
Tableau 3-55 Ensemble de compétences 4-6 – Connaissances détaillées des
ensembles isolants des moteurs ......................................................................................3-75
Tableau 3-56 Ensemble de compétences 4-7 – Connaissances sur tous les problèmes
INPO, NRC et NEIL..........................................................................................................3-79
Tableau 3-57 Ensemble de compétences 4-8 – Connaissances détaillées sur les
courbes de performance des moteurs .............................................................................3-80
Tableau 3-58 Ensemble de compétences 4-9 – Évaluations techniques et d'exploitabilité
des moteurs .....................................................................................................................3-81
Tableau 3-59 Ensemble de compétences 4-10 – Formé à l'analyse des causes
profondes .........................................................................................................................3-82
Tableau 3-60 Ensemble de compétences 4-11 – Connaissances sur les processus de
qualification environnementale des moteurs ....................................................................3-83
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Tableau 3-61 Ensemble de compétences 4-12 – Connaissances sur les revêtements de

protection des moteurs et sur les revêtements de niveau de service 1 ...........................3-84
Tableau 3-62 Ensemble de compétences 4-13 – Connaissances sur les essais
dynamométriques des moteurs ........................................................................................3-85
Tableau 3-63 Ensemble de compétences 4-14 – Connaissances sur les essais complets
des moteurs (IEEE 112)...................................................................................................3-86
Tableau 3-64 Ensemble de compétences 4-15 – Établissement d'un document de
participation de l'industrie.................................................................................................3-87
Tableau 3-65 Ensemble de compétences 4-16 – Prendre la présidence de groupes chef
de file dans l'industrie des moteurs ..................................................................................3-88
Tableau 3-66 Ensemble de compétences 4-17 – Établir et dispenser la formation sur les
moteurs ............................................................................................................................3-89
Tableau 3-67 Ensemble de compétences 4-18 – Devenir un des mentors de la
prochaine génération des spécialistes des moteurs ........................................................3-90
Matrice d'achèvement des ensembles de connaissances

Tableau 3-68 Ensemble de compétences sur l'achèvement de la matrice (Ensemble de
compétences 1)................................................................................................................3-91
compétences 2)................................................................................................................3-93
compétences 3)................................................................................................................3-95
compétences 4)................................................................................................................3-98
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原子力保全アプリケーションセンター
：電動機スペシャリスト育成ガイド
1021427
2010年12月最終レポート
EPRIプロジェクトマネージャー
W. Johnson

3420 Hillview Avenue, Palo Alto, California 94304-1338 ▪ PO Box 10412, Palo Alto, California 94303-0813 ▪ USA
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成果品説明
電力業界において電動機の責任者はさまざまな名称で呼ばれている。電動機スペシャリ
スト、機器エンジニア、電動機技術者、電気技術者などである。電動機に対する責務と
責任は、保全、運転、エンジニアリング、調達など、しばしば複数の組織にわたってい
るが、電動機の健全性と信頼性の維持を確保するのは電動機スペシャリストの役割であ
る。
本レポートは、電動機スペシャリストになるために必要な技能と知識を習得するための
階層化されたアプローチを提供する。本レポートに含まれるのは、推奨される技術的能
力、産業界の活動への参加により得られる機会、トレーニングを実施する機会、指導に
関する見識および電動機に関する参考資料である。本レポートには原子力個別の情報が
含まれるが、いずれの組織または個人であっても、その産業に当てはまらない部分を除
けば、本レポートを電動機の専門知識の習得に活用することができる。
結果と発見
電動機は、産業界の施設、特に発電所における継続的な運転に特に重要である。しかし
、施設が経年化していく中で電動機に責任を持つ者を確実に養成する一貫性のあるプロ
セスが存在しない。本レポートは、電動機の運転および保全に最も一般的に使われる必
要な知識分野に係わる技術的能力を特定することで、将来の電動機スペシャリストを養
成するための階層的なアプローチを提供する。
(EPRI)の大型電動機ユーザーズグループ（LEMUG）は、以下によって得られる電動機
の知識を特定するため本レポートを作成した。
 正式なトレーニング活動
 直接的観察
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 電動機に特定した活動への参加
 産業界の活動への参加
 技術的能力に係わる表の使用
本レポートで提示される技術的能力は、電動機スペシャリストの養成を促進するために
活用できる。
課題及び目的
LEMUGにおけるさまざまな電力会社の代表との討議により、産業界において老齢化お
よび人員減少により多くの電動機のスペシャリストが失われていること、および補充す
るための有能な人材の育成計画の存在を確認することが困難であることが明らかになっ
た。
本レポートの目的は、電動機スペシャリストになるために必要なさまざまな技能および
知識分野を明らかにし、人材養成計画のためのガイダンスを提供することである。
適用、価値、及び使用
技能は幅広く多岐にわたっているため、電動機スペシャリストになるには何年もかかる
。電動機は、約70%が機械、30%が電気のパーツで構成されており、電動機スペシャ
リストは複数の専門分野に習熟している必要がある。本レポートでは、電動機の適切な
保全およびその寿命を最大限にするために理解しなければならない機械的および電気的
属性を示す。それぞれのトレーニング実施への公約および要求事項を満たすために、適
切な推奨事項を選択し取込むことは、本レポートの利用者の責任である。
EPRIの展望
本レポートの推奨事項は、機器に対する不十分な知識又は操作経験に起因したタスクへ
の影響のリスクを最小限にしつつ貢献を可能にするために、段階的な形で提供されてい
る。本レポートは、認定のための基準の妥当性を示すことを意図しているものではなく
、個々の人材養成を進めるための枠組みを提供するものである。
各発電所で本レポートをレビューし、発電所および産業界のニーズを満たすための情報
として必要な部分を特定することが期待される。
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成果物には、4つの段階に対応し技術的能力および推奨されるトレーニングオプション
の相互参照情報並びに各組織における電動機スペシャリストの要件を達成するために役
立つ代替手段が含まれる。
アプローチ
技術的能力の知識分野及び本レポートで記述した4段階の技術的能力を規定するため、
本ガイドは、電力会社における電動機の保全責任者、電動機メーカー、および現役の電
動機スペシャリストからの助けを得て作成された。本レポートは、「電動機スペシャリ
スト」と呼ばれる人材を電力会社が育成をすることを支援するためのもので、得られた
推奨事項を集約したものである。
キーワード
機器エンジニア
電動機
電動機エンジニア
電動機スペシャリスト
テスト
トレーニング
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目次
1 はじめに..................................................................................................................................1-1
2 電動機スペシャリスト育成のための一般的議論 ....................................................................2-1
2.1 産業界への参加............................................................................................................2-3
2.2 効果的な電動機プログラムの分野 ...............................................................................2-4
3 技術的能力表の使用................................................................................................................3-1
技術的能力1 –
メインの電動機スペシャリストとバックアップの電動機スペシャリスト ...........................3-1
技術的能力2 –
メインの電動機スペシャリストとバックアップの電動機スペシャリスト .........................3-23
技術的能力3 – メインの電動機スペシャリスト ................................................................3-40
技術的能力4 – メインの電動機スペシャリスト ................................................................3-68
4 要約.........................................................................................................................................4-1
5 産業界の文書 ..........................................................................................................................5-1
5.1 EPRIの文書..................................................................................................................5-1
5.1.1 評価 .....................................................................................................................5-1
5.1.2 軸受 .....................................................................................................................5-1
5.1.3 ケーブル..............................................................................................................5-1
5.1.4 電気 - その他 .......................................................................................................5-1
5.1.5 環境条件..............................................................................................................5-2
5.1.6 機器信頼..............................................................................................................5-2
5.1.7 故障分析およびトラブルシューティング ...........................................................5-2
5.1.8 熱交換器..............................................................................................................5-2
5.1.9 ライフサイクル管理............................................................................................5-3
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5.1.10 潤滑 .....................................................................................................................5-3
5.1.11 機械 – その他.....................................................................................................5-3
5.1.12 原子力関連の塗装 ...............................................................................................5-3
5.1.13 運転および保全 ...................................................................................................5-3
5.1.14 予知保全および予防保全.....................................................................................5-3
5.1.15 新しい電動機の調達............................................................................................5-4
5.1.16 保護リレー ..........................................................................................................5-5
5.1.17 補修および精密点検............................................................................................5-5
5.1.18 搬送および保管 ...................................................................................................5-5
5.1.19 系統および機器の健全性レポート ......................................................................5-5
5.2 IEEEの文書 ..................................................................................................................5-6
5.3 INPOの文書 .................................................................................................................5-7
5.4 EASAの文書 ................................................................................................................5-7
5.5 全米電気機器製造業者協会..........................................................................................5-7
5.6 連邦規則 ......................................................................................................................5-7
5.7 ASTMの文書 ................................................................................................................5-7
5.8 NFPAの文書 ................................................................................................................5-8
5.9 ANSIの文書..................................................................................................................5-8
5.10 ABMAの文書 ................................................................................................................5-8
5.11 その他の文書 ...............................................................................................................5-8
A 用語集.................................................................................................................................... A-1
B トレーニングの潜在的機会および推奨図書 .......................................................................... B-1
B.1 EPRIトレーニング ..................................................................................................... B-1
B.1.1 コンピュータ上のトレーニング......................................................................... B-1
B.1.2 工学技術の訓練モジュール ................................................................................ B-1
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B.1.3 機器認定............................................................................................................. B-1
B.1.4 熱交換器............................................................................................................. B-1
B.1.5 保全エンジニアリング ....................................................................................... B-1
B.1.6 保全プログラム .................................................................................................. B-2
B.1.7 非破壊評価プログラム ....................................................................................... B-2
B.1.8 原子力関連の塗装 .............................................................................................. B-2
B.2 EASAトレーニング..................................................................................................... B-2
B.3 メーカーによるトレーニング ..................................................................................... B-2
B.4 発電所個別のトレーニング......................................................................................... B-2
B.5 その他のトレーニングの機会 ..................................................................................... B-3
B.6 産業界の団体 .............................................................................................................. B-3
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図のリスト
図2-1 推奨される電動機プログラムの分野................................................................................2-5
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表のリスト
技術的能力1 – 表3-1～3-14
表3-1 技術的能力1-1 – 発電所における独得の技能 .................................................................3-1
表3-2 技術的能力1-2 – ガイダンス文書および連絡先..............................................................3-7
表3-3 技術的能力1-3 – 電動機の一般知識................................................................................3-8
表3-4 技術的能力1-4 – 電動機の銘板情報................................................................................3-9
表3-5 技術的能力1-5 – 筐体種別および材料 ..........................................................................3-10
表3-6 技術的能力1-6 – 電動機のパフォーマンスデータの基礎知識 ......................................3-11
表3-7 技術的能力1-7 – 温度監視技術および設計の基礎知識 .................................................3-13
表3-8 技術的能力1-8 – センサー/監視技術の基礎知識...........................................................3-14
表3-9 技術的能力1-9 – 固定子巻線ヒーター技術および設計の基礎知識 ...............................3-15
表3-10 技術的能力1-10 – 軸受技術および設計の基礎知識 ....................................................3-16
表3-11 技術的能力1-11 – 潤滑系統、潤滑種別および潤滑油量の基礎知識 ...........................3-18
表3-12 技術的能力1-12 – 冷却系の設計の基礎知識 ...............................................................3-20
表3-13 技術的能力1-13 – 巻線/絶縁系の種別の基礎知識.......................................................3-21
表3-14 技術的能力1-14 – 電動機の保管.................................................................................3-22
技術的能力2 – 表3-15～3-29
表3-15 技術的能力2-1 – 系統の設計および運転の知識..........................................................3-23
表3-16 技術的能力2-2 – 電動機設計図の知識(電気、計装および機械)..................................3-24
表3-17 技術的能力2-3 – 電動機プログラムガイドの知識 ......................................................3-26
表3-18 技術的能力2-4 – 電動機の長期的計画の知識 .............................................................3-28
表3-19 技術的能力2-5 – 予備電動機の知識............................................................................3-29
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表3-20 技術的能力2-6 – 保全手順およびサーベイランス手順の知識 ....................................3-30
表3-21 技術的能力2-7 – 予知保全および予防保全プログラムの知識 ....................................3-31
表3-22 技術的能力2-8 – 電動機技術ライブラリにある文書内容の知識.................................3-32
表3-23 技術的能力2-9 –
電動機についてのトラブルシューティングガイドラインの知識.....................................3-33
表3-24 技術的能力2-10 – 電動機の赤外線および超音波監視の知識......................................3-34
表3-25 技術的能力2-11 – 電動機のカップリング設計の知識 ................................................3-35
表3-26 技術的能力2-12 – 電動機の潤滑プログラムの知識 ....................................................3-36
表3-27 技術的能力2-13 – 電動機の軸設計の一般知識 ...........................................................3-37
表3-28 技術的能力2-14 – さまざまな電動機の設計の一般知識 .............................................3-38
表3-29 技術的能力2-15 – 冷却コイル設計の一般知識 ...........................................................3-39
技術的能力3 – 表3-30～3-49
表3-30 技術的能力3-1 –
一般産業用等級機器部品（CGI）の安全系での使用承認手続きおよび電動機の
アップグレードプロセス............................................................................................3-40
表3-31 技術的能力3-2 – 同種電動機への取替評価の知識 ......................................................3-41
表3-32 技術的能力3-3 – 電動機のトリップ回路および保護リレーの知識 .............................3-42
表3-33 技術的能力3-4 – 電動機のテスト装置の知識 .............................................................3-43
表3-34 技術的能力3-5 – 専門トレーニング............................................................................3-44
表3-35 技術的能力3-6 – 電動機の長期的な計画のオーナーシップ........................................3-45
表3-36 技術的能力3-7 – 重要な予備電動機の調達および保管 ...............................................3-47
表3-37 技術的能力3-8 – 電動機プログラムの評価 .................................................................3-48
表3-38 技術的能力3-9 – 電動機補修、精密点検および巻線巻替の詳細に関する知識 ...........3-49
表3-39 技術的能力3-10 – 電動機の性能に関する傾向管理の知識 .........................................3-51
表3-40 技術的能力3-11 – 電動機の保全部のプロセスおよび管理 .........................................3-52
表3-41 技術的能力3-12 – さまざまな電動機の設計の詳細知識 .............................................3-53
表3-42 技術的能力3-13 – 電動機絶縁系設計の差異に関する知識 .........................................3-54
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表3-43 技術的能力3-14 – 電動機の端末処理および絶縁技術の知識......................................3-55
表3-44 技術的能力3-15 – 電動機のリード線の仕様、設計、テストに関する知識 ................3-57
表3-45 技術的能力3-16 – 電動機の軸受設計の知識 ...............................................................3-58
表3-46 技術的能力3-17 – 電動機のローター設計の知識........................................................3-62
表3-47 技術的能力3-18 – 電動機の軸の材料および修理プロセスの知識...............................3-64
表3-48 技術的能力3-19 –
油冷および空冷コイルの設計、テスト、技術および許容クライテリアの知識..........3-65
表3-49 技術的能力3-20 – 証拠の保護および明らかな原因の特定 .........................................3-66
技術的能力4 – 表3-50～3-67
表3-50 技術的能力4-1 – 電動機プログラムガイドのオーナーシップ ....................................3-68
表3-51 技術的能力4-2 –
経営層との連絡担当およびすべての電動機の不具合が起きた場合の連絡先..............3-70
表3-52 技術的能力4-3 – 10CFR50.59のトレーニング ...........................................................3-71
表3-53 技術的能力4-4 – 設計変更問題の知識 ........................................................................3-72
表3-54 技術的能力4-5 – 電動機の固定子コアのテストおよび設計の知識 .............................3-73
表3-55 技術的能力4-6 – 電動機の絶縁系の詳細知識 .............................................................3-75
表3-56 技術的能力4-7 – INPO、NRCおよびNEILにおける全ての課題の知識 ......................3-79
表3-57 技術的能力4-8 – 電動機の性能曲線の詳細知識..........................................................3-80
表3-58 技術的能力4-9 – 電動機の技術的およびオペラビリティ評価 ....................................3-81
表3-59 技術的能力4-10 – 根本原因分析トレーニング ...........................................................3-82
表3-60 技術的能力4-11 – 電動機の環境認定（EQ）プロセスの知識 ....................................3-83
表3-61 技術的能力4-12 – 電動機の保護塗装およびサービスレベル1塗装の知識..................3-84
表3-62 技術的能力4-13 – 電動機の動力計を用いたテストの知識 .........................................3-85
表3-63 技術的能力4-14 – 電動機の包括的なテストの知識（IEEE 112）..............................3-86
表3-64 技術的能力4-15 – 産業界文書の作成への参加 ...........................................................3-87
表3-65 技術的能力4-16 –
電動機に関する産業界のグループを率いるための議長職への就任 .................................3-88
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表3-66 技術的能力4-17 – 電動機トレーニングの開発および提供 .........................................3-89
表3-67 技術的能力4-18 – 次世代の電動機スペシャリストの指導者......................................3-90
技術的能力修了管理表
表3-68 技術的能力修了管理表（技術的能力1） ......................................................................3-91
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Nuclear Maintenance Application

Center: 전동기 전문가 양성 지침
1021427
최종 보고서, 2010년 12월
EPRI 프로젝트 매니저

W. Johnson
3420 Hillview Avenue, Palo Alto, California 94304-1338 ▪ PO Box 10412, Palo Alto, California 94303-0813 ▪ USA
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연구결과물 설명
전력 산업계의 전동기 책임자들은 전동기 전문가, 기기엔지니어, 전동기 정비원, 전기

정비원 등의 여러가지 이름으로 불리고 있다. 전동기 관련 직무가 정비, 운영, 엔지니어링,
구매 등 여러 부서에 흩어져 있지만, 전동기의 건전성과 신뢰성의 보증 책임은 전동기
전문가들에 맡겨져 있다.
이 보고서는 전동기 전문가가 되기 위해서 필요한 기능과 지식을 개발하는데 있어

단계적인 접근법을 소개하고 있다. 이 보고서에는 권장되는 기능집합(skill set), 산업계
참여 기회, 교육 옵션, 멘토링 참고자료 등이 포함되어 있다. 이 보고서는 원자력 산업계에
특화된 정보를 담고 있지만, 자신이 속한 산업 분야에 적용이 불가능한 경우를 제외하면
전동기 전문가를 양성하려는 기관이나 개인 누구나 이 보고서를 사용할 수 있다.
결과 및 발견사항
전동기는 산업 시설, 특히 발전소의 안정적인 운전에 매우 중요하다. 하지만 장기간
전동기 책임자를 맡을 수 있는 개인을 충분히 양성하는 일관성있는 프로세스가 없다. 이
보고서는 전동기의 운전 및 정비에 일반적으로 사용되는 필수 지식 영역으로 이루어진
기능집합(skill set)를 정의함으로 향후 전동기 전문가 육성을 위한 단계적인 접근방법을
제공한다.
미국전력연구소(EPRI)의 대형전동기 사용자그룹(LEMUG)은 본 보고서를 작성하면서

아래 활동을 통하여 얻을 수 있는 전동기 관련 지식을 도출하였다.
 정식 교육훈련 활동
 현장 관찰 학습
 전동기 관련 직무 참여
 산업계 참여
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 기능집합(skill set) 매트릭스의 사용
이 보고서에 기술된 기능집합(skill set)은 전동기 전문가 양성을 촉진하는 데에 활용될 수

있다.
도전과 목표
LEMUG에 참여한 다양한 전력회사 대표들간의 토론에 따르면, 근로자의 고령화와
인력감축으로 산업계에 많은 전동기 전문가가 사라지고 있으며 적절한 대체 인력을
찾기도 힘들다고 한다.
이 보고서의 목적은 전동기 전문가가 되기 위해 필요한 여러가지 기능과 지식 영역을
적시하고 개인 경력개발 계획을 세우는 데에 대한 지침을 제공하기 위함이다.
적용, 가치 및 활용
전동기 전문가가 되기 위해 필요한 기능들이 매우 광범위하고 다양하기 때문에 여러 해의
기간이 필요하다. 전동기는 약 70%가 기계, 약 30%가 전기적인 부분으로 되어 있기
때문에 전동기 전문가들은 여러 전문분야의 지식 습득이 필요하다. 이 보고서는 전동기를
적절히 유지 관리하고 전동기 수명을 최대화하기 위해 반드시 이해해야 하는 기계 및
전기적인 속성을 제시한다. 각자의 교육 목표와 요건을 충족시키기 위하여 이 보고서의
적절한 권고사항을 적용하는 것은 각 사용자의 책임이다.
EPRI의 관점
이 보고서 안의 권고사항은 부적절한 설비 지식 또는 설비에 노출되는 것으로 인한 직무
위험을 최소화하면서 기여할 수 있는 단계적인 방식으로 제시되었다. 이 보고서는 기존
자격기준을 검증하기 위한 것이 아니라, 개인능력의 추가 개발을 위한 틀을 제공하려는
것이다.
각 발전소는 본 보고서를 검토하여 현장과 산업계가 필요한 정보들을 도출할 필요가 있다.
최종 결과물에 있는 4가지 단계적인 기능집합은 각 조직의 전동기 전문가 자격요건을

달성하기 위한 대안으로서 권장 교육훈련 옵션간의 상호 참조가 된다.
접근 방법
이 보고서에 기술된 기능집합 지식 영역을 개발하고 4가지 기능집합에 있는 기능들의
발전을 이루기 위한 지침을 현직 전동기 정비 책임자, 전동기 개발책임자 및 현직 전동기
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전문가들로 부터 구하였다. 발전회사가 전동기 전문가라고 불리는 사람들을 양성하는데

도움을 줄 이 보고서는 바로 이들의 권고사항을 모은 것이다.
키워드
기기 엔지니어
전동기
전동기 엔지니어
전동기 전문가
시험
교육훈련
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목차
1 도입.........................................................................................................................................1-1
2 전동기 전문가 양성에 대한 일반적 논점 .................................................................................2-1
2.1 산업계의 참여 ..............................................................................................................2-3
2.2 효과적인 전동기 프로그램의 세부 영역 .......................................................................2-4
3 기능집합(SKILL SET)의 활용 .................................................................................................3-1
기능집합 1 – 전임 전동기 전문가와 보조 전동기 전문가 .....................................................3-1
기능집합 2 – 전임 전동기 전문가와 보조 전동기 전문가 ...................................................3-23
기능집합 3 – 전임 전동기 전문가.......................................................................................3-40
기능집합 4 – 전임 전동기 전문가.......................................................................................3-68
4 요약.........................................................................................................................................4-1
5 산업계 문서 .............................................................................................................................5-1
5.1 EPRI 문서 ....................................................................................................................5-1
5.1.1 평가 .....................................................................................................................5-1
5.1.2 베어링 .................................................................................................................5-1
5.1.3 케이블 .................................................................................................................5-1
5.1.4 기타 전기관련......................................................................................................5-1
5.1.5 내환경검증 ..........................................................................................................5-2
5.1.6 설비신뢰도 ..........................................................................................................5-2
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5.1.7 고장 분석과 문제 해결.........................................................................................5-2
5.1.8 열 교환기.............................................................................................................5-2
5.1.9 수명주기 관리......................................................................................................5-3
5.1.10 윤활 .....................................................................................................................5-3
5.1.11 기타 기계관련......................................................................................................5-3
5.1.12 원자력 코팅 .........................................................................................................5-3
5.1.13 운전 및 정비 ........................................................................................................5-3
5.1.14 예측 및 예방 정비 ................................................................................................5-3
5.1.15 신규 전동기 구매 .................................................................................................5-4
5.1.16 보호 계전기 .........................................................................................................5-5
5.1.17 고장수리 및 재정비 .............................................................................................5-5
5.1.18 이송 및 저장 ........................................................................................................5-5
5.1.19 계통 및 기기 건전성보고서..................................................................................5-5
5.2 IEEE 문서 ....................................................................................................................5-6
5.3 INPO 문서 ....................................................................................................................5-7
5.4 EASA 문서 ...................................................................................................................5-7
5.5 미국전기제조자협회.....................................................................................................5-7
5.6 연방법 코드 ..................................................................................................................5-7
5.7 ASTM 문서...................................................................................................................5-7
5.8 NFPA 문서 ...................................................................................................................5-8
5.9 ANSI 문서 ....................................................................................................................5-8
5.10 ABMA 문서 ..................................................................................................................5-8
5.11 기타 문서 .....................................................................................................................5-8
A 용어 정리 ............................................................................................................................... A-1
B 교육훈련 기회와 추천 도서.................................................................................................... B-1
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B.1 EPRI 훈련................................................................................................................... B-1
B.1.1 컴퓨터 기반 훈련 ................................................................................................ B-1
B.1.2 엔지니어링 기술 훈련 모듈................................................................................. B-1
B.1.3 설비검증............................................................................................................. B-1
B.1.4 열 교환기............................................................................................................ B-1
B.1.5 정비 엔지니어링 ................................................................................................. B-1
B.1.6 정비 프로그램..................................................................................................... B-2
B.1.7 비파괴 검사 프로그램......................................................................................... B-2
B.1.8 원자력 코팅 ........................................................................................................ B-2
B.2 EASA 훈련 .................................................................................................................. B-2
B.3 공급자 훈련 ................................................................................................................. B-2
B.4 현장별 교육훈련.......................................................................................................... B-2
B.5 기타 교육훈련 기회 ..................................................................................................... B-3
B.6 산업계의 기관들.......................................................................................................... B-3
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그림 목록
그림 2-1 추천 전동기 프로그램 영역 ..........................................................................................2-5
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표 목록
기능집합 1 – 표 3-1에서 3-14까지
표 3-1 기능집합 1-1 – 현장 특화 기능 ......................................................................................3-1
표 3-2 기능집합 1-2 – 지침 문서와 담당자 연락처 ...................................................................3-7
표 3-3 기능집합 1-3 – 전동기 일반 지식...................................................................................3-8
표 3-4 기능집합 1-4 – 전동기 명판 정보...................................................................................3-9
표 3-5 기능집합 1-5 – 내부 형식과 재질.................................................................................3-10
표 3-6 기능집합 1-6 – 전동기 성능 데이터에 관한 기본 지식 .................................................3-11
표 3-7 기능집합 1-7 – 온도 감시 기술과 설계에 관한 기본 지식 ............................................3-13
표 3-8 기능집합 1-8 – 계측/감시 기술에 관한 기본 지식 ........................................................3-14
표 3-9 기능집합 1-9 – 고정자 권선 히터 기술과 설계에 관한 기본 지식.................................3-15
표 3-10 기능집합 1-7 – 베어링 기술과 설계에 관한 기본 지식 ...............................................3-16
표 3-11 기능집합 1-11 – 윤활 시스템, 윤활의 형태와 양에 관한 기본 지식............................3-18
표 3-12 기능집합 1-12 – 냉각 시스템 설계에 관한 기본 지식.................................................3-20
표 3-13 기능집합 1-13 – 권선/절연 시스템에 관한 기본 지식.................................................3-21
표 3-14 기능집합 1-14 – 전동기의 저장 .................................................................................3-22
기능집합 2 – 표 3-15에서 3-29까지
표 3-15 기능집합 2-1 – 계통 설계와 운영에 관한 지식 ...........................................................3-23

표 3-16 기능집합 2-2 – 전동기 도면(전기, 계측, 기계)에 관한 지식 .......................................3-24
표 3-17 기능집합 2-3 – 전동기 프로그램 지침에 관한 지식....................................................3-26
표 3-18 기능집합 2-4 – 중장기 전동기 계획에 관한 지식 .......................................................3-28
표 3-19 기능집합2-5 – 전동기 예비품에 관한 지식 ................................................................3-29
표 3-20 기능집합 2-6 – 정비절차서 및 검사지침서에 관한 지식 ............................................3-30
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표 3-21 기능집합 2-7 – 전동기 예측 및 예방 정비 프로그램에 관한 지식...............................3-31
표 3-22 기능집합 2-8 – 전동기 기술 도서관에 있는 문서들의 내용에 관한 지식 ....................3-32
표 3-23 기능집합 2-9 – 전동기의 문제해결 지침에 관한 지식 ................................................3-33
표 3-24 기능집합 2-10 – 전동기 열형상 및 초음파 감시에 관한 지식 .....................................3-34
표 3-25 기능집합 2-11 – 전동기 커플링 설계에 관한 지식 .....................................................3-35
표 3-26 기능집합 2-12 – 전동기 윤활 프로그램에 관한 지식..................................................3-36
표 3-27 기능집합 2-13 – 전동기 축 설계에 관한 지식 ............................................................3-37
표 3-28 기능집합 2-14 – 다른 전동기 설계에 관한 일반 지식.................................................3-38
표 3-29 기능집합 2-15 – 냉각 코일 설계에 관한 일반 지식 ....................................................3-39
기능집합 3 – 표 3-30에서 3-49까지
표 3-30 기능집합 3-1 – 일반규격부품(CGI)의 품질검증과 전동기 설비개선 프로세스...........3-40
표 3-31 기능집합 3-2 – 동일 유형 전동기 교체 평가에 관한 지식 ..........................................3-41
표 3-32 기능집합 3-3 – 전동기 차단회로외 보호계전기에 관한 지식 .....................................3-42
표 3-33 기능집합 3-4 – 전동기 시험설비에 관한 지식 ............................................................3-43
표 3-34 기능집합 3-5 – 특별 교육훈련 ...................................................................................3-44
표 3-35 기능집합 3-6 – 중장기 전동기 계획의 오너십 ............................................................3-45
표 3-36 기능집합 3-7 – 중요 예비 전동기의 구매와 보존 .......................................................3-47
표 3-37 기능집합 3-8 – 전동기 프로그램 평가........................................................................3-48
표 3-38 기능집합 3-9 – 전동기 수리, 재정비, 재권선 사양서에 관한 지식..............................3-49

표 3-39 기능집합 3-10 – 전동기 성능 추이에 관한 지식 .........................................................3-51
표 3-40 기능집합 3-11 – 전동기 서비스실 프로세스와 관리...................................................3-52
표 3-41 기능집합 3-12 – 다른 전동기 설계에 관한 상세 지식.................................................3-53
표 3-42 기능집합 3-13 – 전동기 절연 시스템 설계 차이에 관한 지식 .....................................3-54

표 3-43 기능집합 3-14 – 전동기 단자 및 절연 기술에 관한 지식 ............................................3-55
표 3-44 기능집합 3-15 – 전동기 리드 사양, 설계, 시험에 관한 지식 ......................................3-57
표 3-45 기능집합 3-16 – 전동기 베어링 설계에 관한 지식 .....................................................3-58
표 3-46 기능집합 3-17 – 전동기 회전자 설계에 관한 지식 .....................................................3-62
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표 3-47 기능집합 3-18 – 전동기 축 재질 및 수리 프로세스에 관한 지식 ................................3-64
표 3-48 기능집합 3-19 – 오일 및 공기 냉각 코일 설계, 시험 기술 및 승인 기준에 관한 지식 .3-65
표 3-49 기능집합 3-20 – 증거 보존과 표면 원인 분석 ............................................................3-66
기능집합 4 – 표 3-50에서 3-67까지
표 3-50 기능집합 4-1 – 전동기 프로그램 지침의 오너십 ........................................................3-68
표 3-51 기능집합 4-2 – 모든 전동기 문제에 대한 관리자들에게 공식 연락원이 되기.............3-70
표 3-52 기능집합 4-3 - 10CFR50.59 교육 이수........................................................................3-71
표 3-53 기능집합 4-4 – 설계 변경 이슈에 관한 지식 ..............................................................3-72
표 3-54 기능집합 4-5 – 전동기 고정자 코어 시험 및 설계에 관한 지식 ..................................3-73
표 3-55 기능집합 4-6 – 모터 절연 시스템에 대한 자세한 지식 ...............................................3-75
표 3-56 기능집합 4-7 - INPO, NRC, NEIL 이슈에 관한 지식....................................................3-79
표 3-57 기능집합 4-8 – 전동기 성능 곡선에 관한 상세 지식...................................................3-80
표 3-58 기능집합 4-9 – 전동기 기술 평가 및 운전가능성 평가 ...............................................3-81
표 3-59 기능집합 4-10 – 근본원인분석 교육 이수 ..................................................................3-82
표 3-60 기능집합 4-11 – 전동기 내환경검증(EQ) 프로세스에 관한 지식 ...............................3-83
표 3-61 기능집합 4-12 – 전동기 보호 코팅과 서비스 레벨 1에 관한 지식 ..............................3-84
표 3-62 기능집합 4-13 – 전동기 동력계 시험에 관한 지식 .....................................................3-85
표 3-63 기능집합 4-14 – 전동기 전성능시험(IEEE 112)에 관한 지식.....................................3-86
표 3-64 기능집합 4-15 – 산업계 문서 작성 참여.....................................................................3-87
표 3-65 기능집합 4-16 – 주요 전동기 산업계 그룹의 리더쉽 확보 .........................................3-88
표 3-66 기능집합 4-17 – 전동기 교육훈련 개발 및 제공 .........................................................3-89
표 3-67 기능집합 4-18 – 차세대 전동기 전문가를 위한 조언자 되기 ......................................3-90
기능집합 이수표
표 3-68 기능집합 이수표 (기능집합 1) .....................................................................................3-91
표 3-69기능집합 이수표 (기능집합2) .......................................................................................3-93
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표 3-70기능집합 이수표 (기능집합3) .......................................................................................3-95
표 3-71기능집합 이수표 (기능집합4) .......................................................................................3-98
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Centro de Aplicaciones de Mantenimiento

para Centrales Nucleares: directrices para
la formación de especialistas en motores
eléctricos
1021427
Informe final, diciembre de 2010
Gestor de proyectos de EPRI

W. Johnson

3420 Hillview Avenue, Palo Alto, California 94304-1338 ▪ PO Box 10412, Palo Alto, California 94303-0813 ▪ Estados Unidos
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DESCRIPCIÓN DEL PRODUCTO
En el sector de la energía, los responsables de motores eléctricos reciben distintas denominaciones:

especialistas en motores, ingenieros de componentes, técnicos de motores y técnicos eléctricos, entre
otras. A pesar de que las tareas y responsabilidades relacionadas con los motores se reparten entre
diversos departamentos (como por ejemplo Mantenimiento, Operación, Ingeniería y Compras), el
especialista en motores es el encargado de garantizar la fiabilidad y buen estado de los motores.
El presente informe plantea un enfoque gradual para desarrollar las habilidades y conocimientos
necesarios para convertirse especialista en motores eléctricos. Además, el documento incluye conjuntos
de habilidades recomendadas, oportunidades de participación en diversos programas del sector, opciones
de formación, información sobre asesoramiento y materiales de referencia acerca de motores. Aunque el
informe se centra en información específica de la industria nuclear, cualquier organización o individuo
puede utilizarlo para desarrollar sus destrezas en el área de los motores eléctricos obviando las áreas que
no sean de aplicación a su sector.
Resultados y hallazgos
Los motores eléctricos son elementos críticos para garantizar la operación ininterrumpida de las
instalaciones industriales, en particular las centrales eléctricas. Sin embargo, no existe un proceso
coherente que garantice la correcta formación de los encargados de los motores a medida que las
instalaciones envejecen. Este informe plantea un enfoque gradual para el desarrollo de futuros
especialistas en motores eléctricos en el cual se establecen conjuntos de habilidades que se refuerzan con
las áreas de conocimiento necesarias a las que se recurre con mayor frecuencia en la operación y
mantenimiento de motores eléctricos.
El Grupo de Usuarios de Motores Eléctricos Grandes (LEMUG, por sus siglas en inglés) del Instituto de
Investigación de Energía Eléctrica de los Estados Unidos (EPRI) ha elaborado este informe con el fin de
identificar los conocimientos sobre motores que pueden obtenerse a partir de:
 Actividades de formación formales
 Observación directa
 Participación en actividades específicas sobre motores
 Participación en programas/eventos del sector
 Utilización de matrices de conjuntos de habilidades
Los conjuntos de habilidades incluidos en este informe pueden emplearse para acelerar el desarrollo de
los especialistas en motores eléctricos.
Retos y objetivos
Los debates mantenidos con diversas empresas con representación en el LEMUG hicieron patente que el
envejecimiento y las bajas que afectan al personal estaban contribuyendo a la pérdida de un gran número
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de especialistas en motores del sector. Además, se puso de manifiesto la dificultad que conlleva encontrar
un plan que permita contratar sustitutos con las capacidades necesarias.
El objetivo de este informe es señalar las diversas habilidades y áreas de conocimiento necesarias para
convertirse en un especialista en motores eléctricos y ofrecer directrices para la elaboración de un plan de
desarrollo profesional.
Aplicaciones, utilidad y utilización

Debido a la variedad y diversidad de las habilidades requeridas, convertirse en especialista en motores
eléctricos es una labor que puede llevar años. Un motor eléctrico es mecánico en aproximadamente un
70% y eléctrico en cerca de un 30%, por lo que es necesario que los especialistas cuenten con una
formación multidisciplinar. Este informe presenta los atributos mecánicos y eléctricos que deben
dominarse para poder realizar un mantenimiento adecuado de los motores y maximizar su vida útil. Es
responsabilidad de cada usuario del presente informe incorporar las recomendaciones pertinentes para
satisfacer sus propias necesidades y requisitos de formación.
La perspectiva de EPRI
El carácter progresivo de las recomendaciones incluidas en este informe fomenta las aportaciones y
minimiza el riesgo de realizar un mal trabajo como consecuencia de no disponer de un conocimiento
adecuado o de no estar convenientemente familiarizado con los equipos. El informe no pretende validar o
invalidar ningún tipo de cualificación, sino que trata de ofrecer un marco para el desarrollo individual
continuo.
EPRI espera que cada emplazamiento revise el informe e identifique el subconjunto de información
necesaria para cumplir las necesidades específicas de su instalación y su sector.
El documento resultante abarca cuatro conjuntos de habilidades progresivas y remite a las opciones de
formación recomendadas (y a sus alternativas) para facilitar el cumplimiento de los requisitos de
especialización propios de cada organización.
Enfoque
Para poder desarrollar las áreas de conocimiento propias de cada conjunto de habilidades y garantizar la
progresión de dichas habilidades en los cuatro conjuntos descritos en el presente documento, se consultó
al personal responsable del mantenimiento de motores en las empresas, así como a distintos fabricantes de
motores y especialistas en motores con experiencia. Este informe, que ayudará a las empresas a
desarrollar a aquellos individuos conocidos como especialistas en motores, constituye un resumen de las
recomendaciones de todos estos participantes.
Palabras clave
Ingeniero de componentes
Motor eléctrico
Ingeniero de motores
Especialista en motores
Pruebas
Formación
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CONTENIDOS
1 INTRODUCCIÓN ....................................................................................................................1-1
2 DEBATE GENERAL SOBRE EL DESARROLLO DE ESPECIALISTAS EN

MOTORES.................................................................................................................................2-1
2.1 Participación del sector................................................................................................2-3
2.2 Diferentes áreas de un programa de motores eficaz ..................................................2-4
3 UTILIZACIÓN DE MATRICES DE CONJUNTOS DE HABILIDADES ..................................3-1

Conjunto de habilidades 1: especialista en motores principales y especialista en
motores de reserva ...............................................................................................................3-1
Conjunto de habilidades 2: especialista en motores principales y especialista en
motores de reserva .............................................................................................................3-23
Conjunto de habilidades 3: especialista en motores principales.........................................3-40
Conjunto de habilidades 4: especialista en motores principales.........................................3-68
4 RESUMEN ..............................................................................................................................4-1
5 DOCUMENTOS DEL SECTOR..............................................................................................5-1

5.1 Documentos de EPRI .................................................................................................5-1
5.1.1 Evaluaciones.......................................................................................................5-1
5.1.2 Cojinetes .............................................................................................................5-1
5.1.3 Cables .................................................................................................................5-1
5.1.4 Otros documentos sobre mantenimiento eléctrico..............................................5-1
5.1.5 Cualificación ambiental .......................................................................................5-2
5.1.6 Fiabilidad de equipos ..........................................................................................5-2
5.1.7 Análisis e identificación y resolución de fallos ....................................................5-2
5.1.8 Intercambiadores de calor...................................................................................5-2
5.1.9 Gestión del ciclo de vida .....................................................................................5-3
5.1.10 Lubricación..........................................................................................................5-3
5.1.11 Otros documentos sobre mantenimiento mecánico............................................5-3
5.1.12 Revestimientos nucleares ...................................................................................5-3
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5.1.13 Operación y Mantenimiento ................................................................................5-3

5.1.14 Mantenimiento preventivo y predictivo................................................................5-3
5.1.15 Adquisición de motores nuevos ..........................................................................5-4
5.1.16 Relés de protección ............................................................................................5-5
5.1.17 Reparación y reacondicionamiento.....................................................................5-5
5.1.18 Transporte y almacenamiento.............................................................................5-5
5.1.19 Informes sobre el estado de salud de componentes y sistemas ........................5-5
5.2 Documentos de IEEE...................................................................................................5-6
5.3 Documentos de INPO ..................................................................................................5-7
5.4 Documentos de EASA .................................................................................................5-7
5.5 Asociación Nacional de Fabricantes de Equipos Eléctricos de los Estados
Unidos .........................................................................................................................5-7
5.6 Código de Normativas Federales (CFR)......................................................................5-7
5.7 Documentos de ASTM.................................................................................................5-7
5.8 Documentos de NFPA .................................................................................................5-8
5.9 Documentos de ANSI ..................................................................................................5-8
5.10 Documentos de ABMA.................................................................................................5-8
5.11 Otros documentos .......................................................................................................5-8
A GLOSARIO ........................................................................................................................... A-1
B POSIBLES OPORTUNIDADES DE FORMACIÓN Y LECTURAS RECOMENDADAS ...... B-1

B.1 Formación de EPRI .................................................................................................... B-1
B.1.1 Formación informatizada.................................................................................... B-1
B.1.2 Módulos de formación técnica en ingeniería ..................................................... B-1
B.1.3 Cualificación de equipos .................................................................................... B-1
B.1.4 Intercambiadores de calor.................................................................................. B-1
B.1.5 Ingeniería de mantenimiento.............................................................................. B-1
B.1.6 Programas de mantenimiento ............................................................................ B-2
B.1.7 Programa de evaluación no destructiva............................................................. B-2
B.1.8 Revestimientos nucleares .................................................................................. B-2
B.2 Formación de EASA ................................................................................................... B-2
B.3 Formación de proveedores ......................................................................................... B-2
B.4 Formación específica de emplazamientos.................................................................. B-2
B.5 Otras oportunidades de formación.............................................................................. B-3
B.6 Organizaciones del sector .......................................................................................... B-3
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LISTA DE FIGURAS
Figura 2-1 Áreas recomendadas para programas de motores ..................................................2-5
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LISTA DE TABLAS
Conjunto de habilidades 1: tablas 3-1 a 3-14

Tabla 3-1 Conjunto de habilidades 1-1: habilidades específicas del emplazamiento................3-1
Tabla 3-2 Conjunto de habilidades 1-2: documentos y contactos orientativos ..........................3-7
Tabla 3-3 Conjunto de habilidades 1-3: conocimientos generales sobre motores ....................3-8
Tabla 3-4 Conjunto de habilidades 1-4: información de las placas de identificación de
motores ..............................................................................................................................3-9
Tabla 3-5 Conjunto de habilidades 1-5: tipos y materiales de carcasas..................................3-10
Tabla 3-6 Conjunto de habilidades 1-6: conocimientos básicos sobre datos de
funcionamiento de motores..............................................................................................3-11
Tabla 3-7 Conjunto de habilidades 1-7: conocimientos básicos sobre tecnologías y
diseño de equipos de monitorización de la temperatura..................................................3-13
Tabla 3-8 Conjunto de habilidades 1-8: conocimientos básicos sobre tecnologías de
sensores/equipos de monitorización................................................................................3-14
diseño de calentadores de bobinas de estator ................................................................3-15
diseño de cojinetes ..........................................................................................................3-16
Tabla 3-11 Conjunto de habilidades 1-11: conocimientos básicos sobre sistemas de
lubricación, tipos de lubricación y dosificación.................................................................3-18
Tabla 3-12 Conjunto de habilidades 1-12: conocimientos básicos sobre diseño de
sistemas de refrigeración .................................................................................................3-20
Tabla 3-13 Conjunto de habilidades 1-13: conocimientos básicos sobre tipos de
sistemas de bobinado/aislamiento ...................................................................................3-21
Tabla 3-14 Conjunto de habilidades 1-14: almacenamiento de motores.................................3-22

Tabla 3-15 Conjunto de habilidades 2-1: conocimientos sobre diseño y operación de
sistemas ..........................................................................................................................3-23
Tabla 3-16 Conjunto de habilidades 2-2: conocimientos sobre diagramas de motores
(eléctricos, mecánicos y de instrumentación) ..................................................................3-24
Tabla 3-17 Conjunto de habilidades 2-3: conocimientos sobre guías de programas de
motores ............................................................................................................................3-26
Tabla 3-18 Conjunto de habilidades 2-4: conocimientos sobre planes de motores a largo
plazo.................................................................................................................................3-28
Tabla 3-19 Conjunto de habilidades 2-5: conocimientos sobre motores de repuesto .............3-29
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Tabla 3-20 Conjunto de habilidades 2-6: conocimientos sobre procedimientos de

mantenimiento e instrucciones de vigilancia....................................................................3-30
Tabla 3-21 Conjunto de habilidades 2-7: conocimientos sobre programas de
mantenimiento predictivo y preventivo de motores ..........................................................3-31
Tabla 3-22 Conjunto de habilidades 2-8: conocimientos sobre el contenido de los
documentos de la Biblioteca Técnica de Motores............................................................3-32
Tabla 3-23 Conjunto de habilidades 2-9: conocimientos sobre directrices de
identificación y resolución de problemas en motores ......................................................3-33
Tabla 3-24 Conjunto de habilidades 2-10: conocimientos sobre monitorización de
motores mediante termografía y ultrasonido ...................................................................3-34
Tabla 3-25 Conjunto de habilidades 2-11: conocimientos sobre diseños de acoplamiento
de motores .......................................................................................................................3-35
Tabla 3-26 Conjunto de habilidades 2-12: conocimientos sobre programas de
lubricación de motores .....................................................................................................3-36
Tabla 3-27 Conjunto de habilidades 2-13: conocimientos generales sobre diseños de
ejes de motores................................................................................................................3-37
Tabla 3-28 Conjunto de habilidades 2-14: conocimientos generales sobre distintos
diseños de motores..........................................................................................................3-38
Tabla 3-29 Conjunto de habilidades 2-15: conocimientos generales sobre diseños de
serpentines de refrigeración.............................................................................................3-39

Tabla 3-30 Conjunto de habilidades 3-1: procesos de homologación de componentes y
mejora de motores ..........................................................................................................3-40
Tabla 3-31 Conjunto de habilidades 3-2: conocimientos sobre evaluaciones de
sustitución de motores equivalentes ................................................................................3-41
Tabla 3-32 Conjunto de habilidades 3-3: conocimientos sobre circuitos de disparo de
motores y relés de protección ..........................................................................................3-42
Tabla 3-33 Conjunto de habilidades 3-4: conocimientos sobre equipos de prueba para
motores ............................................................................................................................3-43
Tabla 3-34 Conjunto de habilidades 3-5: formación especializada .........................................3-44
Tabla 3-35 Conjunto de habilidades 3-6: responsabilidad sobre planes de motores a
largo plazo........................................................................................................................3-45
Tabla 3-36 Conjunto de habilidades 3-7: adquisición y conservación de motores de
repuesto críticos...............................................................................................................3-47
Tabla 3-37 Conjunto de habilidades 3-8: evaluaciones de programas de motores .................3-48
Tabla 3-38 Conjunto de habilidades 3-9: conocimientos sobre especificaciones de
reparación, reacondicionamiento y rebobinado de motores ...........................................3-49
Tabla 3-39 Conjunto de habilidades 3-10: conocimientos sobre determinación de
tendencias sobre el funcionamiento de motores..............................................................3-51
Tabla 3-40 Conjunto de habilidades 3-11: procesos y controles para talleres de
reparación de motores .....................................................................................................3-52
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Tabla 3-41 Conjunto de habilidades 3-12: conocimientos específicos sobre distintos

diseños de motores..........................................................................................................3-53
Tabla 3-42 Conjunto de habilidades 3-13: conocimientos sobre diferencias en el diseño
de sistemas de aislamiento para motores........................................................................3-54
Tabla 3-43 Conjunto de habilidades 3-14: conocimientos sobre técnicas de finalización y
aislamiento de motores ....................................................................................................3-55
Tabla 3-44 Conjunto de habilidades 3-15: conocimientos sobre especificaciones, diseño
y prueba de conexiones de motores ................................................................................3-57
Tabla 3-45 Conjunto de habilidades 3-16: conocimientos sobre diseños de cojinetes de
motores ............................................................................................................................3-58
Tabla 3-46 Conjunto de habilidades 3-17: conocimientos sobre diseño de rotores de
motores ............................................................................................................................3-62
Tabla 3-47 Conjunto de habilidades 3-18: conocimientos sobre materiales de ejes de
motores y procesos de reparación...................................................................................3-64
Tabla 3-48 Conjunto de habilidades 3-19: conocimientos sobre diseños, pruebas,
técnicas y criterios de aceptación de serpentines de refrigeración por aceite y aire .......3-65
Tabla 3-49 Conjunto de habilidades 3-20: conservación de pruebas y análisis de causa
aparente ..........................................................................................................................3-66

Tabla 3-50 Conjunto de habilidades 4-1: responsabilidad sobre guías de programas de
motores ............................................................................................................................3-68
Tabla 3-51 Conjunto de habilidades 4-2: formación de puntos de contacto oficiales entre
la dirección y los responsables de los asuntos relacionados con motores ......................3-70
Tabla 3-52 Conjunto de habilidades 4-3: formación en Título 10, Sección 50.59 del CFR .....3-71
Tabla 3-53 Conjunto de habilidades 4-4: conocimientos sobre problemas derivados de
modificaciones de diseño.................................................................................................3-72
Tabla 3-54 Conjunto de habilidades 4-5: conocimientos sobre diseño y prueba de
núcleos de estator de motores.........................................................................................3-73
Tabla 3-55 Conjunto de habilidades 4-6: conocimientos específicos sobre sistemas de
aislamiento de motores ....................................................................................................3-75
Tabla 3-56 Conjunto de habilidades 4-7: conocimientos sobre todas las publicaciones de
INPO, NRC y NEIL ...........................................................................................................3-79
Tabla 3-57 Conjunto de habilidades 4-8: conocimientos específicos sobre curvas de
funcionamiento de motores..............................................................................................3-80
Tabla 3-58 Conjunto de habilidades 4-9: evaluaciones técnicas y de operabilidad de
motores ............................................................................................................................3-81
Tabla 3-59 Conjunto de habilidades 4-10: formación en análisis de causa raíz......................3-82
Tabla 3-60 Conjunto de habilidades 4-11: conocimientos sobre cualificación ambiental
de motores .......................................................................................................................3-83
Tabla 3-61 Conjunto de habilidades 4-12: conocimientos sobre revestimientos
protectores para motores y revestimientos de nivel 1 para reparaciones........................3-84
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Tabla 3-62 Conjunto de habilidades 4-13: conocimientos sobre pruebas con

dinamómetros en motores ...............................................................................................3-85
Tabla 3-63 Conjunto de habilidades 4-14: conocimientos sobre pruebas integrales en
motores (IEEE 112)..........................................................................................................3-86
Tabla 3-64 Conjunto de habilidades 4-15: participación en la elaboración de documentos
del sector..........................................................................................................................3-87
Tabla 3-65 Conjunto de habilidades 4-16: ejercicio de puestos de dirección en los
principales grupos de motores del sector .......................................................................3-88
Tabla 3-66 Conjunto de habilidades 4-17: desarrollo e impartición de formación sobre
motores ............................................................................................................................3-89
Tabla 3-67 Conjunto de habilidades 4-18: desarrollo de mentores para la siguiente
generación de especialistas en motores ..........................................................................3-90
Matriz de finalización del conjunto de habilidades

Tabla 3-68 Matriz de finalización del conjunto de habilidades (conjunto de habilidades 1).....3-91
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2010 TECHNICAL REPORT

Nuclear Maintenance Applications Center:

Final Report, December 2010

EPRI Project Manager

ELECTRIC POWER RESEARCH INSTITUTE

(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I)

(B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER

THE FOLLOWING ORGANIZATION, UNDER CONTRACT TO EPRI, PREPARED THIS REPORT:

Honeycutt Consulting, LLC

This report describes research sponsored by EPRI.

Nuclear Maintenance Applications Center: Guidance for Developing an Electric Motor

Results and Findings

Challenges and Objectives

Applications, Value, and Use

2 GENERAL DISCUSSION FOR MOTOR SPECIALIST DEVELOPMENT..............................2-1

3 USE OF THE SKILL SET MATRICES ...................................................................................3-1

5 INDUSTRY DOCUMENTS .....................................................................................................5-1

A GLOSSARY .......................................................................................................................... A-1

B POTENTIAL TRAINING OPPORTUNITIES AND RECOMMENDED READING ................. B-1

繁體中文 (Chinese – Traditional).......................................................................................... C-2

简体中文 (Chinese – Simplified) .......................................................................................... C-12

Français (French) ............................................................................................................... C-24

日本語 (Japanese) ............................................................................................................. C-34

한국어 (Korean).................................................................................................................. C-46

Figure 2-1 Suggested Motor Program Areas .............................................................................2-5

Skill Set 1 – Tables 3-1 to 3-14

Skill Set 2 – Tables 3-15 to 3-29

Skill Set 3 – Tables 3-30 to 3-49

Skill Set 4 – Tables 3-50 to 3-67

Skill Set Completion Matrix

As a follow-up document, INPO published an Engineering Program Guide (EPG-13) to define

Mentoring can greatly accelerate the development of a motor specialist. Mentoring is a

As with any development of a specialist, an individual needs to be dedicated predominately to a

2.1 Industry Participation

2.2 Motor Program Areas of an Effective Motor Program

The Skill Sets are divided into 6 distinct columns.

Skill Set 1 – Primary Motor Specialist and Back-Up Motor Specialist

Topics Knowledge Development Training Site and Industry Comments

Table 3-1 (continued)

Topics Knowledge Development Training Site and Industry Comments

Table 3-1 (continued)

Topics Knowledge Development Training Site and Industry Comments

Table 3-1 (continued)

Topics Knowledge Development Training Site and Industry Comments

Table 3-1 (continued)

Topics Knowledge Development Training Site and Industry Comments

Table 3-1 (continued)

Topics Knowledge Development Training Site and Industry Comments

Topics Knowledge Development Training Site and Comments

Topics Knowledge Development Training Site and Comments

Topics Knowledge Development Training Site and Comments

Topics Knowledge Development Training Site and Comments

Topics Knowledge Development Training Site and Comments

Table 3-6 (continued)

Topics Knowledge Development Training Site and Comments

Topics Knowledge Development Training Site and Industry Comments

Topics Knowledge Development Training Site and Comments

Topics Knowledge Development Training Site and Comments