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
buildingboilers,
chillers,
air
handlers, pumps, and cooling towers,
to name a fewrelies 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 motors
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

Parts of Electrical Motor

1. Centrifugal Switch

2.
3.
4.
5.
6.
7.
8.

Bearing
Terminal Box
Power Supply
Cooling Fan
Drive Pulley
Rotor
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
Apower supplyis a device
that
supplieselectric
powerto anelectrical load.

COOLING FAN
Is a self coolingelectric motor. Fan
cooled motors feature anaxial
fanattached to therotorof 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 therotorwhich 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
thestator,
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 motoroperated 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
motormaintenance
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
powerthat
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 motors
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

Motor
use/sequencing
Maintenance
Frequency Turn off or sequence unnecessary motors.
Overall
visual inspection
Verify equipment is operating
Weekly
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
on weekly inspections)
or vibration, and compare to baseline values.
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.
Check Annually
for balanced
Troubleshoot unbalanced motor circuit and
Annually
three-phase
power
fix Troubleshoot
problems if the
voltage
imbalance
exceeds
1%.
Annually
Check for overor
motor
circuit
and fix problems
under- voltage conditions
if the supply voltage differs
significantly from rated voltages.

Working
Procedure
s

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
overlubricate.
Excessive
grease and oil creates dirt
and can damage bearings.

Lubrication

Lubrication
Factor
y
lubed
ball
bearin
g

Lubrication
Factor
y Lube
in
housin
g

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, motorgenerator sets, fans, pumps.

Motor Operating Conditions

Severe Duty: Extremely

harsh,
dirty
motor
applications.
Severe
vibration
and
high
ambient conditions often
exist.

Heat
4EXCESSIVE
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 theyll take care of you!