Maintenance

for
Generators and Motors
 Objectives
• Identify characteristics of periodic motor/
Generators maintenance.
• Identify the major components of an AC motor/
Generator.
• Perform pre maintenance testing.
• An effective implementation of electrical motor
maintenance will translate into savings from
production availability, reduced equipment
repair costs and improved energy costs.
 Objectives
• To have an appreciation and
understanding to perform optimal
diagnoses and repairs.
• Learning the techniques and obtain
valuable information to detect motor/
Generators problems prior to failure,
avoiding costly downtime.
 Introduction
• Rotating electrical machines can be divided
into:
• Motors: which convert electrical energy into
mechanical energy.
• Generators: which convert mechanical
energy into electrical energy.
• Both types operate through the interaction
between a magnetic field and a set of
windings.
Electrical Motors
Generator
 Electrical Motors
• Electric motors convert electrical energy
into useful mechanical energy by running
electrical current through a coil, resulting
in the torque needed to turn a shaft.
Almost every major piece of equipment in
a commercial building—boilers, chillers,
air handlers, pumps, and cooling towers,
to name a few—relies on electric motors.
Electrical Motors
Electrical Motors
 Electrical Motors
• As they run, motors can become less efficient
because of wear, breakdown of lubricants,
and misalignment. Good motor-maintenance
practice helps avoid or postpone these
problems. A lack of maintenance can reduce
a motor’s energy efficiency and increase
unplanned downtime. Scheduled
maintenance is the best way to keep the
motors operating efficiently and reliably.
 Common Motor Applications
• Pumps Fans
• Conveyors  Extruders
• Agitators Crushers
• Mills Grinders
• Elevators
• Many, many more……………….
 Parts of Electrical Motor
1. Centrifugal Switch
2. Bearing
3. Terminal Box
4. Power Supply
5. Cooling Fan
6. Drive Pulley
7. Rotor
8. Stator
Parts of Electrical Motor
 CENTRIFUGAL SWITCH
A type of switch that operates using
the centrifugal force created from the
rotating shaft. The centrifugal switch
activates and de-activates depending
on the speed of the motor.
 BEARING
A device that supports, guides, and
reduces the friction of motion
between fixed and moving machine
parts.
 TERMINAL BOX
On a piece of electric equipment
(such as a motor), a box within which
the leads from the piece of
equipment are connected to the leads
supplying the equipment with power;
usually provided with a removable
cover plate for access.
 POWER SUPPLY
A power supply is a device that
supplies electric power to
an electrical load.
 COOLING FAN
Is a self cooling electric motor. Fan
cooled motors feature an axial
fan attached to the rotor of the motor
(usually on the opposite end as the
output shaft) that spins with the
motor, providing increased airflow to
the motor's internal and external
parts which aids in cooling.
 ROTOR
In an electric motor the moving part
is the rotor which turns the shaft to
deliver the mechanical power. The
rotor usually has conductors laid into
it which carry currents that interact
with the magnetic field of the stator
to generate the forces that turn the
shaft.
 STATOR
The stationary part is the stator,
usually has either windings or
permanent magnets.
 Electric Motors
Care and Maintenance
o Why and when invest resources to
maintain Electric Motors ?
o What strategies can be implemented?
o What have other motor users done to
maintain their motors
o What support resources and tools are
available ?
 Motor Enemies
Heat
Time
Power Supply Issues
Humidity
Improper Lubrication
Unusual Mechanical Loads
Leading causes of Motor Failures
Bearings 51%
Stator Winding 16%
External 16%
Unknown 10%
Rotor Bar 5%
Shaft/Coupling 2%
Common Causes For Motor Failures
Operation and Maintenance of
Motors & Generators
 SAFETY FIRST
 High voltage and rotating parts
can cause serious or fatal injury.
Safe installation, operation, and
maintenance must be performed by
qualified personnel. Familiarization
with and adherence to NEMA MG2,
the National Electrical Code (NEC)
and local codes is required.
 SAFETY FIRST
It is important to observe safety
precautions to protect personnel from
possible injury. Personnel should be
instructed to:
1. Be familiar with the equipment and
read all instructions thoroughly before
installing or working on equipment.
 SAFETY FIRST
2. Avoid contact with energized circuits
or rotating parts.
3. Disconnect all power sources before
initiating any maintenance or repair.
4. Act with care in accordance with
prescribed procedures in handling and
lifting this equipment.
 SAFETY FIRST
5. Be sure unit is electrically grounded in
accordance with code requirements.
6. Be sure equipment is properly
enclosed or protected to prevent access
by children or other unauthorized
personnel in order to prevent possible
accidents.
 SAFETY FIRST
7. Be sure shaft key is fully captive
before unit is energized.
8. Avoid contact with capacitors until
safe discharge procedures have been
completed.
 SAFETY FIRST
9. Provide proper guarding for
personnel against rotating parts and
applications involving high inertia
loads which can cause over speed.
10. Avoid extended exposure to
equipment with high noise levels.
 Safety Issues
 Before servicing motors and motor-
operated equipment, disconnect the
power supply to the motor and
accessories. An electrical lockout/
tagout procedure is recommended,
where every piece of equipment
serviced is logged, and electrical
disconnects are physically disabled.
 Best Practices
for Efficient Operation
The following best practices will
reduce the cost of operation and
maintenance:
 Turn Off Unneeded Motors
 Identify motors that run unnecessarily,
and turn them off when appropriate.
Examples include exhaust fans running
when ventilation needs are met, and
escalators operating after closing. You
may need to reprogram the building
control systems to accomplish this.
 Reduce the Use
of the Motor System
Increasing the efficiency of
mechanical systems can reduce the
amount of time that associated
motors need to run.
 Reduce the Use
of the Motor System
Increasing the efficiency of mechanical
systems can reduce the amount of time
that associated motors need to run.
 For example, improving the
performance of a cooling tower can
reduce the run time that the fans need
to reject the same amount of heat.
 Reduce the Use
of the Motor System
 Eliminating excessive starts and
stops is also worthwhile. Starting
and stopping a motor stresses its
parts and degrades its performance.
Frequent stops and starts increase
the need for maintenance.
 Best Practices for Maintenance
Properly selected and installed
motors can operate for many years
with minimal maintenance.
Nonetheless, regular care will
extend their life and maximize their
energy efficiency.
 Best Practices for Maintenance
 In addition to periodic upkeep,
good recordkeeping and smart
replacement planning are key
elements of a good motor-
maintenance program.
 Regular Upkeep
 Clean motor surfaces and
ventilation openings periodically.
Heavy accumulations of dust and
lint will result in overheating and
premature motor failure.
 Properly lubricate moving parts
 Some motors have sealed
bearings that require no servicing.
For others, regular lubrication will
avoid unnecessary wear. Be sure to
apply appropriate types and
quantities of lubricant. Applying too
little or too much can harm motor
components.
 Keep motor couplings properly
aligned
 Correct shaft alignment ensures
smooth, efficient transmission of
power from the motor to the load.
Incorrect alignment puts strain on
bearings and shafts, shortening
their lives and reducing system
efficiency
 Keep motor couplings properly
aligned
Shafts should be parallel and
directly in line with each other.
Shaft alignment should be checked
and adjusted regularly. Many
couplings have hard rubber inserts
that can degrade, so rubber dust on
the equipment base may indicate
problems.
 Keep motor couplings properly
aligned
Properly align and tension belts and
pulleys when they are installed, and
inspect them regularly to ensure
that alignment and tension stay
within tolerances.
 Keep motor couplings properly
aligned
Abnormal wear patterns on belts may
indicate problems. Loose belts may
squeal and will slip on the pulley,
generating heat.
Correctly tensioned pulleys run cool.
Excessive tension strains bearings and
shafts, and shortens their lives.
 Maintain bearings by keeping
them clean, lubricated, and
loaded within tolerances.
 Proper belt tension or shaft
alignment minimizes strain on the
bearings and helps them achieve
their expected life.
 Maintain bearings by keeping
them clean, lubricated, and
loaded within tolerances.
 These can be prone to shaft
currents, which can cause serious
damage to the bearings.
Fortunately, there are several
technologies that can mitigate
shaft-current problems.
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
Bearing Failures in Motors
 Check for proper supply voltages
 Unbalanced power—that is, three-
phase motors where the supply voltage
to the phases varies by more than
1%—can lead to overheating and
reduced motor life. So too can
situations where the supply voltage is
much higher or lower than the motor’s
rated voltage.
 Avoid painting motor housings
 Paint acts as insulation,
increasing operating temperatures
and shortening motor life. One coat
of paint has little effect, but years of
paint buildup can have a significant
effect.
 Periodically inspect
commutators visually
 Potential problems with
commutators (which are only
required for DC motors with
brushes) will be seen as
discolorations, flat spots, or burn
marks.
 Periodically inspect
commutators visually
Color patterns can be normal as
long as they appear around the
entire commutator. If you notice
problems, remove and repair the
commutator, or replace key
components.
 Good Recordkeeping
 Maintain an up-to-date motor
inventory.
 The inventory should include all
substantial motors, but can begin
with the largest and those with the
longest run times.
 Good Recordkeeping
 This inventory lets facility
managers make informed choices
about replacement, either before or
after a motor fails. Field-testing
motors before they fail can help
ensure that replacements are
properly sized.
Keep maintenance logs
 Keep maintenance logs
These logs should contain vital
information such as the make,
model, serial number, type, and
specifications of each motor; the
locations and specifications for
belts, pulleys, etc.; and a historical
record of maintenance activities.
 Keep maintenance logs
 This helps the maintenance staff
remember when tests, inspections, or
servicing are due. It also allows the
staff to quickly identify spare parts or
replacements when needed. In
addition, comparing recent test results
to past values can provide early
indications of reduced motor
performance.
 Maintenance Schedule for Motors
Description Comments Maintenance Frequency
Motor use/sequencing Turn off or sequence unnecessary motors. Weekly
Overall visual inspection Verify equipment is operating Weekly
and safety systems are in place.
Check bearings Inspect for wear, and adjust, repair Weekly
and drive belts or replace as necessary.
Motor alignment Look for rubber or steel savings under Weekly
couplings, or listen for odd noises,
as these may indicate a problem).
Motor condition Check condition by analyzing temperature Quarterly (or as needed
or vibration, and compare to baseline values. on weekly inspections)
Cleaning Remove dust and dirt to facilitate cooling. Quarterly
Check lubrication Ensure bearings are lubricated Annually
(or based on run hours)
as recommended by manufacturer.
Check mountings Secure any loose mountings. Annually
Check terminal tightness Tighten any loose connections. Annually
Check for balanced Troubleshoot unbalanced motor circuit and Annually
three-phase power fix problems if the voltage imbalance exceeds 1%.
Check for over- or Troubleshoot motor circuit and fix problems Annually
under- voltage conditions if the supply voltage differs
significantly from rated voltages.
 Working
Procedures
Dirt and Corrosion
 Dirt and Corrosion
 Wipe, brush, vacuum or blow
accumulated dirt from the frame and
air passages of the motor. Dirty motors
run hot when thick dirt insulates the
frame and clogged passages reduce
cooling air flow. Heat reduces
insulation life and eventually causes
motor failure.
 Dirt and Corrosion
Feel for air being discharged from
the cooling air ports. If the flow is
weak or unsteady, internal air
passages are probably clogged.
Remove the motor from service and
clean.
 Dirt and Corrosion
Check for signs of corrosion. Serious
corrosion may indicate internal
deterioration and/or a need for
external repainting. Schedule the
removal of the motor from service
for complete inspection and
possible rebuilding.
 Dirt and Corrosion
 In wet or corrosive environments,
open the conduit box and check for
deteriorating insulation or corroded
terminals. Repair as needed.
Lubrication
 Lubrication
 Lubricate the bearings only when
scheduled or if they are noisy or
running hot. Do NOT over-lubricate.
Excessive grease and oil creates dirt
and can damage bearings.
Lubrication
Lubrication

Factory
lubed
ball
bearing
Lubrication

Factory
Lube in
housing
 Lubrication

Typical lube after time

 Lubrication

Contaminated Lube
 Heat, Noise and Vibration
 Feel the motor frame and
bearings for excessive heat or
vibration. Listen for abnormal noise.
All indicate a possible system
failure. Promptly identify and
eliminate the source of the heat,
noise or vibration.
 Heat
 Excessive heat is both a cause of
motor failure and a sign of other
motor problems.
Overheating results from a variety
of different motor problems.
 Heat
- They can be grouped as follows:
1- WRONG MOTOR: It may be too
small or have the wrong starting
torque characteristics for the load.
This may be the result of poor initial
selection or changes in the load
requirements.
 Heat
2- POOR COOLING: Accumulated dirt
or poor motor location may prevent
the free flow of cooling air around the
motor. In other cases, the motor may
draw heated air from another source.
Internal dirt or damage can prevent
proper air flow through all sections of
the motor.
 Heat
- Dirt on the frame may prevent
transfer of internal heat to the cooler
ambient air.
 Heat
3- OVERLOADED DRIVEN MACHINE:
Excess loads or jams in the driven
machine force the motor to supply
higher torque, draw more current and
overheat.
Motor Operating Conditions
 Motor Operating Conditions
Light Duty: Motors operate
infrequently (1 hour/day or less) as
in portable floor sanders, valves,
door openers.
Standard Duty: Motors operate in
normal applications (1 or 2 work
shifts).
 Motor Operating Conditions
 Examples include air conditioning
units, conveyors, refrigeration
apparatus, laundry machinery,
woodworking and textile machines,
water pumps, machine tools, garage
compressors.
 Motor Operating Conditions
Heavy Duty: Motors subjected to
above normal operation and
vibration (running 24 hours/day,
365 days/year). Such operations as
in steel mill service, coal and mining
machinery, motor-generator sets,
fans, pumps.
 Motor Operating Conditions
Severe Duty: Extremely harsh, dirty
motor applications. Severe vibration
and high ambient conditions often
exist.
 Heat
4- EXCESSIVE FRICTION: Misalignment,
poor bearings and other problems in
the driven machine, power
transmission system or motor
increase the torque required to drive
the loads, raising motor operating
temperature.
 Heat
5- ELECTRICAL OVERLOADS: An electrical
failure of a winding or connection in
the motor can cause other Windings
or the entire motor to overheat.
 Noise and Vibration
 Noise indicates motor problems but
ordinarily does not cause damage.
Noise, however, is usually accompanied
by vibration.
 Noise and Vibration
 Vibration can cause damage in several
ways.
 It tends to shake windings loose and
mechanically damages insulation by
cracking, flaking or abrading the
material.
 Winding Insulation
 When records indicate a tendency
toward periodic winding failures in the
application, check the condition of the
insulation with an insulation resistance
test. Such testing is especially important
for motors operated in wet or corrosive
atmospheres or in high ambient
temperatures.
 Cleaning and Drying Windings
 Motors which have been flooded or
which have low megger readings
because of contamination by moisture,
oil or conductive dust should be
thoroughly cleaned and dried. The
methods depend upon available
equipment.
 Cleaning and Drying Windings
A hot water hose and detergents are
commonly used to remove dirt, oil, dust or
salt concentrations from rotors, stators and
connection boxes. After cleaning, the
windings must be dried, commonly in a
forced-draft oven. Time to obtain
acceptable megger readings varies from a
couple hours to a few days.
Tools and Equipment in Electric Motor Maintenance
Basic tools
Vibration measurement tools
Vibration measurement tools
Electrical discharge detector
Thermal scanner
Thermal image
Lubricants
 Take care of your bearings
and they’ll take care of you!