MOTOR MAINTENANCE

PARADEEP PHOSPHATES LIMITED

 PRESENTATION
ON
MOTOR MAINTENANCE

By
MR. SUSHANTA KUMAR PANDA
P.N.: 2686
MRSS & CENTRAL SHIFT
 DEPARTMENT : ELECTRICAL

A motor converts electrical energy into

mechanical energy. It is estimated that nearly half of
the world's energy consumption is consumed by motors.
Therefore, increasing motor efficiency is expected to
have a significant impact on the global energy crisis.
Motor Types:
Motors that operate through rotary motion by
receiving power when current flows within a magnetic field
are common. However, a wide range of motor types exist,
including ones that operate through linear motion.
Motors are broadly classified by the type of drive power used
(source): AC or DC.

What is a Motor & Types ?

CLASSIFICATION OF MOTOR
 INDUCTION MOTOR

Induction Motors are the most commonly used

motors in many applications. These are also called
as Asynchronous Motors, because an induction
motor always runs at a speed lower than synchronous speed.
Synchronous speed means the speed of the rotating magnetic
field in the stator.

There basically 2 types of induction

motor depending upon the type of input supply - (i) Single
phase induction motor and (ii) Three phase induction motor.
Or they can be divided according to type of rotor - (i)
Squirrel cage motor and (ii) Slip ring motor or wound type

Definition & Types

 BASIC WORKING PRINCIPLE OF AN
INDUCTION MOTOR

In an induction motor only the stator winding is fed with an AC supply.

Alternating flux is produced around the stator winding due to AC supply.
This alternating flux revolves with synchronous speed. The revolving flux
is called as "Rotating Magnetic Field" (RMF).
The relative speed between stator RMF and rotor conductors causes an
induced emf in the rotor conductors, according to the Faraday's law of
electromagnetic induction. The rotor conductors are short circuited, and
hence rotor current is produced due to induced emf. That is why such
motors are called as induction motors.
(This action is same as that occurs in transformers, hence induction
motors can be called as rotating transformers.)
Now, induced current in rotor will also produce alternating flux around it.
This rotor flux lags behind the stator flux. The direction of induced rotor
current, according to Lenz's law, is such that it will tend to oppose the
cause of its production.
As the cause of production of rotor current is the relative velocity between
rotating stator flux and the rotor, the rotor will try to catch up with the
stator RMF. Thus the rotor rotates in the same direction as that of stator
flux to minimize the relative velocity. However, the rotor never succeeds in
catching up the synchronous speed. This is the basic working principle of
induction motor of either type, single phase of 3 phase.
SOME SNAPS OF PPL MOTORS
PICTURE-2
PICTURE-3
 MOTOR MAINTENANCE

A well and carefully designed motor maintenance program, when

correctly used, can be sum med up as:
1.Preventive maintenance,
2.Predictive maintenance and
3.Reactive maintenance

Inspection cycles depend upon the type of motor and the conditions
under which it operates.

Motors need maintenance regularly in order to avoid failure and

prolong their lifespan. Generally speaking, motors and motor parts should
be maintained and tested at least every 6 months. Only then is it possible to
maintain a motor’s life and its efficiency.
 FACTORS FOR MOTOR FAILURE

These are the

basic cause of
Motor failure.
1.Poor Power quality
2. Heating
3. Vibration
4. Winding IR low Value
5.Blocked Ventilation
6. Misalignment of
Shaft
 PREVENTIVE MOTOR MAINTENANCE

The objective of this kind of maintenance is to prevent operating

problems and make sure that the motor continuously provides a reliable
operation Usually, preventive maintenance is a scheduled part of maintaining a
whole system. Following steps to be followed at the time of this type of
maintenance:
1. Motor Cleaning
2. Terminal Box cleaning and tightness checking.
3. Motor feeder checking.
4. Power contactor checking
5. IR / PI value checking of winding and cable
6. Greasing of both NDE & DE side
 CONTD.

Some of the important elements that preventive maintenance includes.

Motor ventilation:
If the motor is installed and operates in an area with limited ventilation, the
motor temperature may reach high temperatures that can damage the motor’s
insulation and bearing grease, and cause it to fail Dust and dirt often block the
ventilating passages.
Therefore, in order to prevent the motor from overheating, it is important
to blow away the dirt on a regular basis.
Even though motors are protected, it is important to install them in areas with
constant ventilation so that high temperatures do not damage insulation and
bearings. The cooler a motor operates, the longer lifetime it has. Therefore,
the fan cover and the cooling fin always have to be as clean as possible.
 CONTD.

Humidity and condensation:

In IP55 closed motors, water vapour may
condense and consequently reach the motor
windings and the bearings. Therefore, in this
kind of motor, the motor temperature must
always be warmer than the surrounding
temperature during stand still. This can be
done by using another solution is to remove
the drain plugs allowing condensed water to
escape.
Removing the drain plugs will change the motor
enclosure from IP55 to IP44.
Stator equiped with heating element to prevent
condensation problems

Induction Motor Stator

 CONTD.

Loose connections:

All electrical connections must be kept tight and

torqued according to the recommended values Cold or creep flow during load
cycles often cause joint failure. Fuses, cable connections, contactors and
circuit breakers are often subject to loose connections and should thus be
checked regularly as well.

All electrical connections must be kept tight and torqued

 CONTD.

Voltage and current imbalance:

Voltage and current imbalance is certainly an area of concern and the

values should be checked regularly in order to avoid problems with the
motor. Voltage imbalance occurs when the voltage of three phases differs
from one another. Voltage imbalance causes line currents to be unequal as
well.
This results in different kinds of problems // Vibrations, torque pulsations
and overheating of one or more of the phase windings. The voltage imbalance leads to
a decrease in the motor’s efficiency and shortens its life.
 CONTD.

Undervoltage and overvoltage:

Undervoltage and overvoltage wear out the motor’s stator
insulation. Undervoltage stresses the temperature in the insulation
At lower voltages, motors run at a reduced full-load efficiency, run hotter, have a
larger slip, produce less torque, and may have a shorter lifespan.
Usually, induction motors are capable of handling overvoltage situations. However,
severe overvoltage may cause turn-to- turn, phase-to-phase or phase-to-ground short
circuiting. That is a short-circuit between the phases or between the phases and the
frame.
Bearings:
Today, bearings are the components in the motor that are most exposed to wear.
The reason is that the insulation system is no longer subject to high temperatures
because the efficiency of motors has improved over the years. The most common
error is no longer short circuit but noise from the bearings and bearing damage.
Therefore, when carrying out preventive maintenance on the motor, replacement and
maintenance of bearings are indeed important factors!!
 CONTD.

Bearing lubrication:
Bearings in standard motors are always lubricated with grease either once
and for all(greased-for-life) or they may be relubricated via lubrication
nipples. Actually, only a small amount of bearings reach their optimum
lifespan. The explanation is linked to maintenance.
The major reasons for premature bearing failure are :
Wrong mounting
Contamination
Incorrect handling
Incorrect maintenance
Incorrect or no lubricant, (too old lubricant, wrong amount of lubricant, dirt
in lubrication etc )
 CONTD.

Cleanliness:

Motors should be kept clean, free of dust, debris and oil. Soft
brushes or clean cotton rags should be used for cleaning. A jet of compressed
air should be used to remove non-abrasive dust from the fan cover and any
accumulated grime from the fan and cooling fins.
Terminal boxes fitted to motors with IP-55 protection should be cleaned.
Their terminals should be free of oxidation, in perfect mechanical
condition, and all unused space dust-free.
Motors with IP(W) 55 protection are recommended for use under
unfavourable ambient conditions.
 PREDICTIVE MOTOR MAINTENANCE

The objective of this kind of motor maintenance is to ensure that

the right kind of maintenance is carried out at the right time. In order to
define these two parameters, it is necessary to monitor the motor
operation regularly and thereby detect problems before they actually occur.

By keeping a log-book it is possible to compare historical data on a

wide range of parameters and thereby anticipate potential problems.
Following steps to be followed:
1. Daily checklist fill up and verify.
2. Identify problem to be happen & planning accordingly
 REACTIVE MOTOR MAINTENANCE

The main objective of this kind of maintenance is to repair and

replace the motor when a failure occurs. Reactive maintenance or breakdown
maintenance as it is referred to as well, does not imply any regular service or
tests.
Unexpected downtimes are costly because they often imply that a
whole manufacturing process or parts of it is put to a stop. Preventive motor
maintenance on a regular basis can help prevent motors to fail and thus,
prevent unexpected production stops.
 MOTOR NAME PLATE DETAIL

These are the specifications found on the Name

plate about motor
 MOTORS USED IN PPL

As discussed later Induction motors were used

widely in Industrial sectors. So in PPL Premises
We use various types of Induction Motors range
starts from .5KW to 3800KW. On the basis of
input voltage range starts from 415V to 11KV
(Both slip ring & Squirrel cage type) . We are
using Motors of NGEF, Siemens, ABB,
Crompton Greave, Kirlosker, Bharat Bijlee make
. Before taking a motor into process we were
carried following testing procedures at site for
ensure that equipment was healthy or not.
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 SITE TESTING OF MOTORS

Measurement of Insulation Resistance (IR)

IR measurement is done for checking the strength of motor insulation.
Before test remove the star or delta connection and power cables.
Disconnect the HT cable from the motor terminal.
Remove the earthing connection of the neutral terminal.
Connect the Insulation Tester with any phase of motor winding as figured
below.
Record the value. It should not be less than (KV+1) M Ohm value.

After the above tests put back all connection properly.

Note: - Same procedure has to be followed for the test performed before no-
load and after no-load.
 Measurement of Polarization Index (PI)

•Connect the any phase of motor winding as in above

figure.
sasa
•Ensure that earthing connection of the neutral terminal
is open.
•Take IR measurement at different time intervals of 2
min. up to 10 min.
•Polarization index can be measured by dividing 10 min.
IR value to 1 min. IR value.
 No Load Test

This test is carried out at rated frequency and balanced

poly phase voltages. Readings are taken at the rated
voltages after the motor has run for a considerable
amount of time necessary for bearing to be properly
lubricated. At no-load machine slip and rotor current are
very small there by resulting to negligible no-load rotor
loss. During the test the bearing temperature, body
temperature and noise levels are checked. Current, voltage
and power are measured at the motor input. In this test a
healthy motor should take narly 40% current of its full
load rating.
 Tan Delta and Capacitance
measurement of windings
Insulation power factor or dissipation factor (Tan δ) and
capacitance measurement of bushing provide an indication
of the quality and soundness of the insulation in the bushing.
It is one of the most powerful tests to monitor the health of
the transformer.
For getting results of Tan δ and capacitance without
removing the bushing from the transformer, a suitable test
set capable of taking measurement by ungrounded specimen
test (UST) method shall be used.
Portable C and Tan δ Bridge test set are used. Portable test
set include measuring bridge such as Schering Bridge or
Transformer Ratio Arm Bridge, power and standard
capacitor in one enclosure.
 Winding resistance
measurement
Motor winding resistances are measured at site in order to
check for any abnormalities due to loose connections
during transit.
Ensure the isolation of Motor from power supply before
test.
Remove the star point of neutral terminal.
Connect Micro ohm meter between two different end of
the same winding of the motor as figured below
Repeat the same for other two winding.
 High Voltage test:

In H.V test for motor high voltage is supplied between

one of the phase winding of the motor and earth (with
the remaining winding being short circuited) and measure
the leakage current (indicated in the H.V kit). The test
voltage shall be commenced at half of the full test voltage
and increased steadily at the increment of 5% of full test
value in 10 Seconds. The Full test voltage shall be
maintained for one minute.

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 Vibration Measurement:

Vibration measurement is done to ensure that motor and

its pump and fan is aligned perfectly.
Vibration is measured with the help of a portable digital
vibrometer.
Connect vibration measuring probe on the bearing body
and record the amplitude of vibrations.
Displacement should not be more than 50 micron pk –pk.
 MOTOR PROTECTION RELAY

We are using various types of Motor Protection relays for

indentify fault of motor and its circuit. MM30, C&S MPR,
O/L relay, Thermal O/L relay etc. . For Overload we set a
limit of 110% of FLC and for Earth fault setting was
20% of FLC. For under voltage this setting was 80% of
supply voltage. Except this we were using single phasing
and phase imbalance protection.
Usage of Relay simplify maintenance activity by identify
particular fault that was happened in equipment.
 COMPONENTS USED IN
MOTOR FEEDER

Following components were

we used in a motor feeder.
1. HRC Fuse. 6
2. Isolator
4 7
3. Main Contactor
4. Overload Relay
5. Motor Protection relay
6. Current Transfermor
(CT) 3
7. Thermal Overload relay
8. Indication Lamp (RGA)

1 2
Inside View
INSULATION CLASS
 Duty cycle
A duty cycle or power cycle is
the fraction of one period in which
a signal or system is active. Duty
cycle is commonly expressed as
a percentage or a ratio. A period
is the time it takes for a signal to
complete an on-and-off cycle.
 TYPES OF DUTY CYCLE

Continuous running duty (type S1)

Short-time duty (type S2)
Periodic duty (type S3-S8)
Intermittent periodic duty (Type S3)
Intermittent periodic duty with starting (Type S4)
Intermittent periodic duty with electric braking (Type S5)
Continuous-operation periodic duty (Type S6)
Continuous-operation periodic duty with electric braking (Type S7)
Continuous-operation periodic duty with related load / speed (Type S8)
Non-periodic duty (type S9)
Duty with discrete constant loads (and speeds) – type
S10
 THANK YOU

“ To STAY ALIVE, you have to STAY ALERT ”