PERFORMANCE IMPROVEMENT

WORKSHOP

REDUCTION OF MOTOR FAILURES

IN DSP
 REASONS FOR MOTOR FAILURE
MISCALENOUS 9%

OLD AGE 10%

OVERLOAD 30%

44% of motor failures are preventable by monitoring power and loading!

CONTAMINANTS
19%
VOLTAGE
CONDITION 14%
ROTOR FAILURES
5% BEARING FAILURE 13%
CAUSES OF MOTOR FAILURE
MOTOR BEARING FAILURES
EXCESSIVE VIBRATION
HARSH ENVIRONMENT
IMPROPER MOTOR SPECIFICATION
MISCELLANEOUS ELECTRICAL PROBLEMS
INADEQUATE MAINTENANCE

MECHANICAL REASONS

MOTOR REPAIRING
MOTOR BEARING FAILURES

VIBRATION / MISALIGNMENT

IMPROPER SELECTION OF BEARING

EMPLOYMENT OF IMPROPER FITTING TECHNIQUE

STARVATION OF LUBRICANT (OIL/GREASE)

LUBRICANT INCOMPATIBILITY

POOR QUALITY OF BEARING MATERIAL

GREASE CAP FAILURE

EXCESSIVE VIBRATION

DEFECTIVE BALL OR SLEEVE BEARINGS

MISALIGNMENT

UNBALANCED MOTOR ROTOR

UNBALANCED ROTATION OF MOTOR COOLING FAN

BENT IN ROTOR SHAFT

UNBALANCED ROTATING LOAD

ECCENTRIC / LOOSE COUPLING / BRAKE DRUM / PULLEY

EXCESSIVE VIBRATION

EXCESSIVE BELT TENSION

MISMATCH IN TAPER RATIO BETWEEN SHAFT AND

COUPLING/ BRAKE DRUM

WORN OUT BEARING SEAT ON ROTOR SHAFT/ HOUSING ON

END SHIELDS

WEAK/ DAMAGED MOTOR BASE STRUCTURE

LOOSE FOUNDATION BOLTS

HARSH ENVIRONMENT
DUSTY ATMOSPHERE

CONGESTED MOTOR LOCATION

PRESENCE OF MOISTURE

CORROSIVE FUMES OR VAPOURS

SALT-LADEN AIR

HIGH AMBIENT TEMPERATURE

DIRECT WATER INGRESS

DIRTY / DUSTY MOTOR BODY

WATER INGRESS

GLAND WATER
LEAKAGE LOGGING
IN IN PUMP
PUMPS HOUSES

RAIN PIPELINE
WATER LEAKAGE
SEEPAGE S
MOTOR SPECIFICATION/ SELECTION

UNDER RATED/ DUTY MOTOR

DELIBERATE MALOPERATION

MALFUNCTIONING OF PRESSURE SWITCH

ABSENCE OF UNLOADING VALVE IN COMPRESSOR AND

PUMPS

MALFUNCTIONING OF LIQUID LEVEL SENSORS

MISCELLAENOUS ELECTRICAL PROBLEMS

EXCESSIVE SOURCE VOLTAGE DEVIATION

OVER VOLTAGE / SURGE

UNBALANCED/ IMPROPER SUPPLY VOLTAGE

SUSTAINED OVERLOADING OF MOTOR

UNBALANCED/ IMPROPER SUPPLY VOLTAGE

CONTACTOR / ISOLATOR / MCCB / MCB

BIMETAL O/L RELAY

CABLE TERMINATION

TRAILING CABLE

CABLE FAULT

Cu – Al JOINTS

INTERNAL FAULT
SUSTAINED OVERLOADING OF MOTOR

IMPROPER
O/L SETTING

LOW TAMPERIN WITH

VOLTAGE O/L SETTING

MALFUNCTIO
NING OF O/L
UNIT
INADEQUATE MAINTENANCE

SMP NEEDS TO BE
FOLLOWED
RIGOROUSLY
MECHANICAL REASONS

AXIAL SHIFT OF COUPLED LOAD

AXIAL PLAY OF COUPLED LOAD
AXIAL THRUST OF COUPLED LOAD
DRIVEN LOAD (GEAR BOX) BRG. FAILURE
BEARING HOUSING AND SEATING FAILURE
LOAD JAMMING OR OVERLOADING
MISALIGNMENT OR/AND VIBRATION
MECHANICAL REASONS

POOR VENTILATION SYSTEM

POOR ASSEMBLY FITTING

POOR COUPLING FITTING

IMPROPER / MALFUNCTION OF BRAKE

FALL OF FOREIGN MATERIALS ON MOTOR

FALL OF MOTOR FROM HEIGHT

MOTOR REPAIRING
PUNCH MARKING ON BEARING SEAT/ HOUSING

LIMITATION OF VARNISHING IN ERS

BAD WORKMANSHIP DURING REWINDING/ ASSEMBLING / MEDIUM

REPAIR

IMPROPER COUPLING FITTING

ABSENCE OF COOLING FAN/ FAN COVER AFTER REPAIRING

DEGENERATION OF STATOR/ ROTOR CORE STAMPING

LOCALISED HEATING OF STATOR / ROTOR CORE

DIRTY/ DUSTY MOTOR BODY

DC MOTOR SPECIFIC CAUSES

SPARKING AT COMMUTATOR

OVER SPEEDING

LOOSE FIELD COILS

RUPTURE OF ARMATURE BANDAGE

DRYING OF BEARING GREASE RESULTING MOTOR
JAMMING
FIELD FAILURE

NEUTRAL AXIS SHIFTING

SPARKING AT COMMUTATOR

DIRTY OR CORRODED COMMUTATOR

INCORRECT SEATING OF BRUSHES

LOSS OF BRUSH SPRING TENSION

UNEQUAL SPACING OF HOLDERS

BRUSHES STICKING IN BRUSH HOLDER

SHIFTING OF NEUTRAL AXIS

ROUGH COMMUTATOR SURFACE

HIGH OR FEATHER-EDGED MICA

SPARKING AT COMMUTATOR

INTERPOLES FAILURE OR IMPROPER

ADJUSTMENT
INTER-SEGMENT SEPARATOR LEVEL HIGH

POOR INTER-SEGMENT INSULATION

SHORT CIRCUIT/ DRY SOLDER AT RISER

CARBON DEPOSITION IN GROOVES

POOR V-RING INSULATION

SPARKING AT COMMUTATOR

LOOSE COMPOLE CONNECTION

LOOSE EQUALISING RING CONNECTION

COIL INSULATION FAILURE

UNIT OVERLOAD

INADEQUATE DESIGN/ UNDERATING

SRIM MOTOR SPECIFIC CAUSES

FAILURE OF BRUSH / BRUSH HOLDER

SHORTED STARTING RESISTANCE

MALFUNCTIONING OF ROTOR CIRCUIT TIMER

ROTOR LEAD CUT FROM SLIP RING

SLIP RING DISLOCATION

SHORT CIRCUIT OF SLIP RINGS

TIPS TO PREVENT MOTOR FAILURE
CGT (CLEANING, GREASING, TIGHTENING)

USE OF OVERLOAD PROTECTION RELAYS

REPLACEMENT WITH ELECTRONIC OLRs OF
CONVENTIONAL OLRs.
USE OF MICROCONTROLLER BASED EMPRs FOR BIGGER
MOTORS
ISOLATION & RECTIFICATION OF EARTH FAULT
USE OF MPCB & EARTH FAULT MODULE FOR INDIVIDUAL
DRIVES
INSTALLING AMMETERS

INSTALLING CHUTE JAM SENSORS IN CONVEYORS

REGULAR MAINTENANCE OF PROTECTIVE RELAYS &
CONTACTORS
TIPS TO PREVENT MOTOR FAILURE
REGULAR MAINTENANCE OF PROTECTIVE RELAYS &
CONTACTORS
PERIODIC INSPECTION OF ROTOR CIRCUIT RESISTANCES AND
ROTOR CIRCUIT TIMER (for SRIM)
IMPROVING L/R RATIO FOR D.C. MOTORS

INSTALLATION OF STALL SENSORS AND PROTECTION

USE OF SOFT STARTERS & V.V.V.F.

INSTALLING CHOKE COIL WERE EVER DIGITAL DRIVES ARE
INSTALLED
INSTALLING FIELD FAILURE RELAY FOR DC. MOTORS
INSPECTION OF PLUGGING/ BRAKING RESISTANCE AND DELAY
TIMER
TIPS TO PREVENT MOTOR FAILURE
USE OF TEMP SENSORS AND THERMAL CAMERAS WHILE
INSPECTING PANELS AND MOTOR CONNECTIONS

USE OF VIBRATION MONITORING DEVICE

USE OF SHOCK PULSE METHOD FOR BEARING ANALYSING

IMPLEMENTING CONDITION BASED MONITORING SYSTEMS
INCLUDING SPECTRUM ANALYSIS AND CURRENT SIGNATURE
ANALYSIS
REPLACING OR OVER HAULING OF FESTOON CARRIERS AND
CABLES HAVING MORE NUMBER OF JOINTS
INSTALLING DOUBLE PRESSURE SWITCHES IN PLACE OF
SINGLE DIFFERENTIAL PRESSURE SWITCH FOR HIGHER
RATING APPLICATION
INSTALLING LIQUID LEVEL SENSORS AND AUDIO ALARM IN
PUMP HOUSES
TIPS TO PREVENT MOTOR FAILURE
USING FLEXIBLE CABLE FOR TERMINATION AT MOTOR
T.B.
USE OF CABLE GLANDS
USE OF PROTECTIVE COVER DEPENDING UPON THE
AMBIENCE
COVERING OUTDOOR MOTORS AND PUMP MOTORS
EMPHASIZING ON MOTORS REPAIRING WITH FAN AND FAN
COVER
MINIMIZE INCHING WHILE SUSPECTING FAULT

AVOIDING TAMPER WITH O/L SETTING

TIPS TO PREVENT MOTOR FAILURE
CONSTANT INTERACTION BETWEEN OPERATION AND
ELECTRICAL PERSONALS

PERIODICALLY EMPLOYING BOTH THE PUMP MOTORS IN PUMP

HOUSES

EMPHASIZING CONDITION BASED MAINTENANCE AND SERVICE

HISTORY RECORD

ADHERING TO MAINTENANCE SCHEDULES & SMPs

UPRATING MOTORS WHERE EVER LOADING IS PERSISTENTLY

HIGH
EMPHASIZING RUNNING INSPECTION OF CRITICAL DRIVES AND
JUDGING ABNORMALITY BY COMPARING IT WITH LAST
INSPECTION (FEEL & SOUND test)
RUNNING INSPECTION
Any abnormalities in panel operation is present.

Balance nominal current drawn by the motor

Generation of any abnormal sound from motor

Whether any vibration is felt by hand and meters

Monitoring of motor body and bearing temperature

Observation of any crack on the body of the motor

Monitoring of motor bearing lubrication oil level

In case of double motor drive load is equally shared by each motor

SMPS FOR MOTOR MAINTENANCE
ANALYSE SERVICE HISTORY

INTERIOR CLEANING OF MOTOR

CLEANING OF MOTOR BODY

FREE ROTATION OF ROTOR OR ARMATURE TO BE CHECKED

INSPECTION OF COOLING AND VENTILATION SYSTEM

CHECKING BRAKE DRUM AND SHOE

CHECKING CONNECTION AND ALL BODY BOLTS TIGHTNESS

ENSURING PROPER EARTHING

MEGGERING & RESISTANCE CHECKING

SMPS FOR DC MOTOR MAINTENANCE
ENSURING NO BRUSH JAMMING

PROVIDING BRUSH OF PROPER SIZE & GRADE

ENSURING OPTIMUM BRUSH TENSION

BRUSH HOLDER CLEARANCE TO COMMUTATOR

COMMUTATOR CLEANING WITH CANVAS PADS OR LIGHT SAND
PAPER
CHECKING BEARING AND ADHERING TO LUBRICATION
SCHEDULE FOR OPTIMUM GREASING WITH PROPER
LUBRICANT
INSPECTING ALIGNMENT OF MAGNETIC NEUTRAL AXIS

TRIAL RUN FOR MORE THAN 25 MINS & CONFIRMING DOR

SMPS OF SRIM MAINTENANCE

CHECK BRUSH / BRUSH HOLDER

CHECK ROTOR LEAD CUT FROM SLIP RING

CHECK SLIP RING DISLOCATION

CHECK SHORT CKT OF SLIP RING

TRIAL RUN FOR MORE THAN 25 MINS & CONFIRMING DOR

ANY QUERRY OR DISCUSSION
THANK YOU.