COMMISSIONING and maintenance

of electrical equipment
EP-5221
2-1-3

Ethiopian Defence university, College of

Engineering
Department of Electrical Power Engineering
 Chapter-3
Commissioning and Maintenance of
Induction Motor

2
 Introduction
 Induction motors are widely used as industrial drives because
of simplicity, reliability and low cost. Induction motors works
with better efficiency, appreciable over-load capacity and
maintenance required is minimum.
Induction motor types:

1. Squirrel cage type:

Rotor winding is composed of copper bars embedded in
the rotor slots and shorted at both end by end rings
Simple, low cost, robust, low maintenance

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 Cont.…
2. Wound rotor type:
Rotor winding is wound by wires. The winding
terminals can be connected to external circuits
through slip rings and brushes.
Easy to control speed, more expensive.

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 Types of Single-Phase Motors

Single-phase motors are generally built in the fractional-

horsepower range and may be classified into the following
four basic types:

1. Single-phase induction motors

a) split-phase type
b) capacitor type
c) shaded-pole type
2. A.C. series motor or universal motor
3. Repulsion motors
a) Repulsion-start induction-run motor
b) Repulsion-induction motor
4. Synchronous motors
a) Reluctance motor
b) Hysteresis motor 5
 Application of 3-Phase Induction Motors
 mostly used in industrial applications. The squirrel cage
induction motors are used in residential as well as
industrial applications especially where the speed control of
motors is not needed such as:
• Pumps and submersible
• Pressing machine
• Lathe machine
• Grinding machine
• Conveyor
• Flour mills
• Compressor
• And other low mechanical power applications

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 Cont.…
 The slip ring motors are used in heavy load
applications where the high initial torque is needed
such as:

• Steel mills
• Lift
• Crane Machine
• Hoist
• Line shafts
• and other heavy mechanical
workshops etc

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 Factors to be Considered
The factors to be considered while selecting a motor include
• Supply system • AC or DC supply
• Drive • Constant speed or variable speed
• Rating • W,KW,MW
• Special conditions if any • High starting torque,Hazardious location,
traction duty etc..
• Users requirement's of • Local conditions,duty cycle,noise
loads level,load characteristics etc..
• Environmental conditions

• Enclosure ,cooling
requirements, mounting

• Applicable standards
• Cost considerations
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 Design Standards
In accordance with NEMA standards, poly phase squirrel-cage
integral horse power induction motors are designated by design
letters:
• Design A: A squirrel-cage motor designed to withstand full-
voltage starting and develop a starting torque of
110%–120%, starting locked rotor current of 6–10
times rated, and having a slip at rated load of less
than 5%.
• Design B: Similar to design A motor with the same starting
torque, however, the locked rotor current is limited
to five times.

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 Cont.…
• Design C: A squirrel-cage motor designed to withstand full-
voltage starting, developing a high starting torque
of 200% and locked rotor current less than the
standard type of motor, and having a slip at rated
load of less than 5%.
• Design D: A squirrel-cage motor designed to withstand full-
voltage starting, developing a very high locked
rotor torque of 300%, low lock rotor current, and
having a slip at rated load of 5% or more.
• Design F: A squirrel-cage motor built to withstand full-voltage
starting, developing a low starting torque, very low
locked rotor current, and a slip at rated load of less
than 5%.

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 Cont.…
 Alternating single-phase motors designated by design letters
similar to poly phase motors. These design letters are the
following:

• Design N/O: A single-phase fractional-horsepower motor

designed to withstand full-voltage starting and with
a locked rotor current not to exceed the values
shown in NEMA standard MG1.
• Design L/M: A single-phase integral-horsepower motor
designed to withstand full-voltage starting and to
develop a breakdown torque as shown in NEMA
standards MG1 and locked rotor current not to
exceed values shown in MG1.

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Specifications of 3-phase Induction Motors
 Output rating: The preferred output rating for induction
motors up to and including 110 KW are 0.06,
0.09, 0.12, 0.18, 0.25, 0.37, 0.55, 0.75, 1.1,
1.5 ,2.2, 3.7, 5.5, 7.5, 11, 15, 18.5, 22, 30, 37,
45, 55, 75' 90,100 KW.
 Type of mounting: The mounting is to be specified like
foot mounting, bed mounting, etc.
 Rated voltage and rated frequency with variations:
 Motors shall be able to deliver rated
output with; a terminal voltage differing from its
rated value by not more than ± 6 percent or,
 The frequency differing from its rated
value by not more than ± 3 percent .

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 Cont.…
 The preferred voltages shall be in accordance with IS
5851962. The voltages preferred for 3 phase, 50Hz
machines are 415V, 3.3KV, 6.6KV and l1KV.
 Site and operating conditions
 Type of enclosure
 Type of duty
 Method of cooling
 Type of construction
 Frequency in Hz
 No. of phases
 Mechanical output in KW
 Rated voltage and permitted variation

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 Cont.…
 Class of insulation
 Speed in revolutions per minute, approximate, at the rated output
 Direction of rotation, looking from the driving end.
 Unit or bidirectional of rotation required.
 The maximum temperature of air and water used for cooling.
 Maximum permissible temperature rise
 The height at which the motor is intended to work
 Variation of voltage, current, frequency and speed
 Particulars of tests required and where the tests are to be carried
out

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 Name Plate of Induction Motor
 Name of the  Rated voltage and winding
manufacturer connections
 Manufacturer's  Rated output in KW
number and frame
reference
 Type of duty  Current in amperes at rated output

 Class of insulation  Rotor (secondary) voltage and

winding connections
 Frequency in Hz  Rotor (secondary) current in amperes
at rated output and
 Number of phases  Ambient temperature when above
40°C.
 Speed in rpm 15
 A nameplate contains a large
amount of useful information
relating to the motor including the
type, RPM. frame size and power of
the motor.
Number of Phases
shows the type of power supply for
which the motor is designed.

Rated Operating Voltage (Volts) shows at which voltage is the motor is

designed to operate most efficiently. Motors are designed to operate at +/-10%
tolerance of this value.
Service Duty: This is shown as “CONT” for continuous duty 24/7 but they
can also have a short-time rating from 5 to 60 minutes, most motors are rated for
continuous duty. S1 shows that this is a continuous duty motor that works at a
constant load for enough time to reach temperature equilibrium.
Efficiency Code shows the percentage of the input power that is actually
Converted to work output from the motor shaft.
•IE1 – Standard Efficiency
•IE 2 – High Efficiency
•IE 3 – Premium Efficiency
•IE 4 – Super Premium Efficiency 16
Frame Size shows the frame size. The frame size determines
the mounting dimensions such as the foot openings pattern and the shaft height.
Degree of Protection
The IEC uses a two-digit ingress protection (IP) rating to measure how well the
motor is protected from the environment. NEMA uses an enclosure description that
is of a similar standard. IP of 55 tells us that the motor is „protected against dust‟
and „protected against jets of water from all directions.

Insulation Class
The insulation class shows the motor‟s ability to withstand temperatures over time.
In the example, we can see that the motor has an insulation class of F, indicating
that the motor‟s thermal tolerance is 155c/ Maximum Hot Spot Temperature Allowed.
Class A – 105oC
Class E -120oC
Class B – 130oC
Class F – 155oC
Class H – 180oC
Temperature Rise
Each class of insulation has a maximum motor winding temperature rise and a maximum
temperature rating. In addition, a hot spot temperature rise is specified which pertains to17
motor windings that are surrounded by other windings.
18
Frequency (Hz)
shows the input electricity frequency that the motor is designed to operate at.
Motor Rated Power

kW is an expression of the motor‟s mechanical output rating – its ability to deliver

the torque needed for the load at rated speed.

Full Load Speed (RPM)

Full-load speed is the speed at which rated full-load torque is delivered at rated
power output, this speed is sometimes called slip-speed or actual rotor speed.

Rated Operating Current

Power Factor
Power factor is indicated on the nameplate as either “PF” or “P .F” or cos φ .
Power factor is an expression of the ratio of active power (W) to apparent power
(VA) expressed as a percentage.
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Ambient Temperature
 The maximum ambient temperature (AMB) lists the
temperature at which the motor can operate and still be
within the tolerance of the insulation class at the maximum
temperature rise.
 In this example, the ambient temperature of the motor is
40c.
Service Factor
 This Indicates the amount of overload a motor can handle.
a motor with 1.0 service factor cannot be expected to handle
more than its nameplate kW. A motor with service factor 1.15
can be expected to safely handle infrequent loads to 15% past
it‟s rated kW.
 Altitude Motor Weight
 Serial Number 20
 Types of enclosures:

 Open ventilated motor

 Ventilated motor 
 Open Drip proof motor (ODP)
 Water protected motor
 Totally enclosed water –to-air cooled
motor (TEWAC)
 Totally enclosed fan cooled motor
(TEFC)
 Totally enclosed non ventilated (TENV)
 Environment proof motor
 Weather proof motor (WPI) OR (WPII)

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Types of Mounting

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 Environmental Conditions
 The usual service conditions that a motor is exposed to are
the following:
• Ambient temperature not to exceed 40°C and areas with
adequate ventilation
• Altitude not to exceed 3300 ft
• Machine installed on a rigid mounting and with belt, chain,
or gear drive
 Unusual service conditions for motor operation or exposure
can be listed as the following:
• Combustible, explosive, abrasive, or conducting dust
• Excessively dirty operating conditions where accumulation
of dirt will interfere motor ventilation

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 Cont.…
• Chemical fumes and explosive or flammable gases
• Abnormal shock, vibration, or mechanical loading from
external sources
• High humidity areas, oil vapors, steam, or salt-laden air
• Excessive departure from rated voltage, frequency, or
both
• Supply voltage is unbalanced
• Operation above rated speed
• Poor ventilation

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 Cont.…

Drying of windings:The insulation of rotating machines is

hygroscopic in nature .absorbs moisture. The moisture reduces
the insulation resistance. It is essential to remove the moisture
prior to the commissioning of the motor by drying out.
During drying
 first phase the insulation resistance starts decreasing due to
the distribution of the moisture in the entire insulation.
 The second phase is a steady temperature phase over
certain time and the insulation resistance remains almost
constant.
 In the third and last phase the insulation resistance drastically
increases thereby indicating that the moisture is expelled.

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 Testing of induction motors
1)Type tests: These tests are conducted on the first machine
manufactured to confirm the design.
2)Routine tests: These tests are conducted on each motor to
confirm proper manufacture and to ensure smooth
performance, at manufacturer's premises (factory) or/ and at
site.
3)Commissioning tests: These' tests are conducted at site, after
installation, before final commissioning to ensure desired
performance under practical conditions.
4)Special tests: These tests are conducted for special
investigation as per the contract made between the
manufacturer and purchaser.

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 Cont.…
5)Development test: These tests are conducted to analyze for
design parameters and stresses. These are helpful in
development/improvement of the earlier machine or new
machine.
6)Reliability tests: These tests are conducted to ascertain
reliability of the motor under operating conditions.
7)Periodic maintenance checks and tests: These tests are
included in the preventive maintenance schedule which
depends on the service conditions.

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 Routine Tests
Depending on the size of the motor, some or all of the
following tests could constitute routine tests:
• Winding resistance measurement
 No-load running current and power Noise
• High-potential test Vibration
• Locked-rotor test
• Air-gap measurement
• Direction of rotation and phase sequence
• Current balance
• Insulation resistance measurement
• Bearing temperature rise
• Magnetic center at no-load
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 Prototype Tests
The purpose of a prototype test is to evaluate all the
performance
characteristics of the motor. This test consists of the following
tests in
addition to the routine tests:

• No-load saturation characteristic

• Locked rotor saturation characteristic
• Locked rotor torque and current
• Loss measurement including stray load loss
• Determination or measurement of efficiency
• Temperature rise determination
• Surge withstand test
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 Pre -Commissioning tests
Prior to the commissioning of induction motors, the following
are to be carried out to get trouble free performance.
• Measurement of resistance of • Performance tests viz. no-load,
windings full load, short circuit speed
control, speed-torque
characteristics, starting;
stopping/reversing/braking etc.
• Measurement of insulation • Special tests viz. vibration tests,
resistance of winding insulation oscillographic tests to record
starting currents, switching
voltages etc.
• Power frequency high voltage test
• Trial start
• No load tests
• load tests
• Tests on cooling system
• Tests on lubricating system 35
 Steps for installation and commissioning
• Acceptance and storage at site • Trial run, no load run under
closed supervision
• Foundation and civil work • Settings of protective relays
• Lying supply and control cables • Final commissioning and
handing over to customer‟s
• Making the motor ready for
installation
• Installation of the motor/machine and
the driven machine,allignment of
shafts
• Installation of cooling system for
large machines
• Checking the insulation of the motor,
starter and supply/control cables
• Drying out
• Checks, test on motors, starter and
associated equipment's 36
 Steps for commissioning

• Visual inspection • Start up

• Mechanical checks • Load testing
• Electrical connections • Temperature checks
• Insulation resistance test • Operational checks
• Polarization index test • Documentation
• Bearing checks
• Alignment
• Vibration analysis
• Phase rotation check

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38
 Induction Motor Maintenance
The failure mechanisms of the motor can be divided into
stator winding, rotor winding, and exciter , with the following
causes:
e deterioration,
 Age deterioration
 electrical cause
 mechanical causes,
 thermal causes, and
 environmental contamination.
The most significant parts on which inspection should be
made are
(1) armature (or stator) windings,
(2) field winding (or rotor),
(3) brush rigging and collector rings
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 Possible Causes and Remedies
Fault Cause
Motor does a) No supply voltage
not start b) Driven equipment jam
on load. c) Motor shaft jammed.
Motor starts a) Timer setting on lowest step
and gets tr b) Relay setting on lower reading
ips (star del than rated current.
ta starter) c) Terminal voltage is low.
d) Backup fuse blowing
e) Starting current is high due to
heavy inertia.
f) Misalignment.
Remedies
a) Check voltage at Motor
Terminals.
b) Ensure freeness of driven
equipment
c) Check freeness of motor
shaft
a) Set timer on proper setting.
b) Set overload relay at 110%
of rated full load current
punched on Nameplate.
c) Ensure rated voltage OR
increase realy setting slightly.
d) Correct rating of back
up fuse to be used.
e) Start stop the relay
continously till motor, pick up
full speed.
f) Ensure proper alignment
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Fault Cause Remedies

Motor connected a) No supply of voltage a) Check voltage between each

but does not b) Motor jam two phases.
picks up full c) Motor may be b) Check freeness of motor without
speed. overloaded coupling it to load.
d) Loose connection. c) Reduce load.
d)Tight connection properly.

Motors runs and a) Power failure a) Check loose connection to the

then stops b) Unbalance incoming line of fuses and starter in the
3 Phase voltage to motor. motor Terminals.
c) Overload b)1) Check loose connection. 2)Chec
k the unbalance voltage and inform
to Electricity Board people.
c)Check all 3 fuses are proper
rating.
d) Examine overload relay and see
that they are set correctly to appro
ximately 110% full load current pun
ched on nameplate.

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Fault Cause
Motor does not a) Wrong KW / HP Selection.
achieve full b) Voltage too low at motor
speed. terminals because voltage
drop.
c) Starting load too high.
d) Wrong connection.
Motor takes a) Excess loading
too long to b) Applied voltage too low
accelerate c) Centrifugal switch open.
Remedies
a) Consult supplier for
proper type of motor.
b) Use higher voltage tap on trans
former terminals or increase cable
size.
c) Reduce load, check the load,
motor is supposed to start.
d) Do the connection as
per connection diagram provided
inside the Terminal box.
a) Reduce load if motor is driving a
heavy load or select higher rating
motor
b) Contact Electric Board to
increase voltage tap.
c) Check contact of centrifugal
switch.
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Fault Cause Remedies
Windin a) Faulty starter (All 3 contact strip may a) Replace the starter.
g burnt not b) 1)Replace the cable.
due t contact properly.) 2)Use single phase prevent
o b) Discontinuity in or
single cable/cable short. c) Replace fuse of
phasin c) One fuse blown correct rating.
g d) Loose connection in d) Ensure proper tightness
starter or motor. of connection.
Wrong a) Wrong sequence of phases. a) Reverse any two leads (
rotatio b) Connection not as per diagram provided. phase)connections of motor
n or at switch board
diagram given inside the Ter
minal Box
Motor a) Fan not rotating due to touching with Fan a) Replace Fan / Fan cover.
shaft cover. b) Remove the dust, dirt an
not b) Dust, dirt and foreign particle got stuck b d foreign particles.
free etween the Oil seal / O ring seal and shaft. c) Open the motor and refit.
c) Rotor end Open the motor and refit t
rings fins obstructing with bearing cover nut he bearing cover correctly.
s due to bearing cover fitted wrongly.
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Fault Cause Remedies
Excess Full a) Excess loading. a) Consult equipment manufacturer to
Load curre b) Low voltage ensure correct HP.
nt. c) Driven Equipment jammed. b) Ensure voltage at motor terminal as
d) Contact strip of starter rusty. per nameplate details.
e) Misalignment c) Contact equipment manufacturer.
d) Replace starter.
e) Ensure proper alignment.
Excess no a) Load of mechanism coming on motor. a) De-couple the motor from the
load curre mechanism verify the current with
nt b) The range of instrument Test Certificates.
selected for Checking the current is not b) Select instrument having range
suitable. 2 to 3 times of value to be measured.
c) Voltage at motor Terminals may be m c) Correct the supply voltage by auto
ore than rated voltage of motor. transformer.
d) Supply frequency less than rated freq d) Check the supply frequency and cor
uency of motor. rect the supply voltage at terminals by
e) Unbalance supply voltage. using following formula at 50hz-
f) Loose connection in supply cables. 415v site frequency. Test volts = (415
g) Wrong connection in stator. x 50)/(Supply Frequency)
e) While run in full load, the current sh
ould be within the rated value.
f) Locate and tightened a screw.
g) Correct the connection.
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Fault Cause Remedies
Abnormal a) Unbalanced voltage. a) Please correct voltage balance in
unbalanced all 3 phases and connected load. 2)
current in Loose connection at starter. 3)Ensure
3 phases. fuses are proper size in all 3 phases
Motor over a) Overload a) Reduce load / overload protection to b
heats while b) Fan blades may clogged with dirt e given.
running on l and improper ventilation to motor. b) Ensure the Cleaning of fan and contin
oad. c) Motor may have one phase open uous circulation of air over the motor for
proper cooling.
c) Ensure that all leads are well connecte
d and 3 phases supply is available.
Noise a) Foundation is not Rigid. a) Ensure rigidity.
b) Belt pulley misalignment. b) Correct the alignment.
c) Noise due to solidification of c) Remove the grease and re-
Grease apply the new high temperature grease o
d) Noise due to driven equipment. r replace the bearing.
e) Noise due to water / oil ingress in d) Check noise level of Bare motor.
to the bearings. e) Change Oil
f) Bearing noise due to punch seal to avoid liquid ingress into the Beari
marks in bearing housing by un ng.
authorized person. f) Replace Flange OR End cover.
g) Humming noise in motor g) Certain amount of magnetic noise is in
herent in some low speed design motor.
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Fault Cause
Noise a) Motor misaligned
after connecti b) Coupling between driven me
on have bee mber and motor shaft is out of
n made. balance.
c) Driven equipment un-
balanced or balanced with full k
ey.
d) Defective ball bearing.
e) Vibration due to fan
cover touches Bottom.
Shaft broken a) Misalignment of pulley.
b) Impact / sudden load or sudd
en reversal of direction or no. of
start / stops are more than 6 p
er hour.
c) Foundation not rigid.
Remedies
a) Realign
b) Balance the coupling.
c) Rebalance driven
equipment or balance with half k
ey.
d) Replace bearings.
e) Ensure that there is a gap of 1
mm between fan
cover and base.
a) Ensure proper alignment of mo
tor and driven equipment.
b) Please inform during procurem
ent of motor to select suitable sh
aft material with proper heat trea
tment.
c) Make foundation rigid.
d) Use flexible coupling if there is
slight mis-alignmnet.
e) Replace Rotor Shaft.
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