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Motor Maintenance Course
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Reduce the costs of selecting, installing, maintaining, and
replacing industrial motors. This course show you how to maintain motors
effectively, efficiently, and safely. This self-paced course requires no textbook or instructor. This is is our most popular course. Our harmonics mitigation course is a close second. Now you can understand how to maintain industrial motors cost-effectively. |
This
motor maintenance course teaches you:
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| This course provides you with the
information you need to reduce the costs of selecting, installing,
maintaining, and replacing industrial motors. You’ll see how to
maintain motors effectively, efficiently, and safely. Of course, you
can’t do maintenance without the proper resources; this course will
help you work within the larger organization to get those resources when
you need them.
This course presents principles of motor maintenance in an easy-to-read format. It includes real-life examples of real-life applications. If you maintain motors and would like a searchable reference source that helps you do the job right, this course is for you. This course teaches you:
Click here for pricing and more information |
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| Here's the table of contents of this motor maintenance course: Table of Contents PREFACE.......................................................................................................... 10 W HY SHOULD WE MAINTAIN MOTORS?................................................................. 12E DITOR’S NOTE ................................................................................................. 13CHAPTER 1: WHY MOTORS (AND DRIVES) FAIL ......................................... 14 P ARETO PRINCIPLE ........................................................................................... 16G ETTING GOOD INFORMATION ON FAILURE CAUSES .............................................. 18V OLTAGE IMBALANCE......................................................................................... 25S INGLE-PHASING............................................................................................... 28S URGE VOLTAGES............................................................................................. 30B EARING FAILURES............................................................................................ 32O VERLOAD ....................................................................................................... 33R ESTRICTED VENTILATION.................................................................................. 34S HORT CYCLING................................................................................................ 35M OISTURE........................................................................................................ 39V IBRATION........................................................................................................ 42G ROUNDING PROBLEMS..................................................................................... 43S IDEBAR 1: THE COMPLEXITY OF MOTORS ........................................................... 47S IDEBAR 2: A CAUSE WITHOUT A REBEL .............................................................. 48S IDEBAR 3:WATSON, COME QUICKLY.................................................................. 49S IDEBAR 4: VOLTAGE IMBALANCE AMONG THE PHASES—THE DETAILS ................... 50S IDEBAR 5: SINGLE-PHASING—THE DETAILS........................................................ 53E ND OF CHAPTER QUESTIONS............................................................................ 56CHAPTER 2: FORENSICS................................................................................ 57 B EARING ANALYSIS............................................................................................ 61W INDING ANALYSIS............................................................................................ 63F AILURE FREQUENCY ANALYSIS.......................................................................... 66F AILURE MODE ANALYSIS ................................................................................... 70P OST-FAILURE PROCEDURES............................................................................. 76S IDEBAR 2.0:WHAT A CMMS SHOULD DO .......................................................... 80E ND OF CHAPTER QUESTIONS............................................................................ 81CHAPTER 3: MAKING RELIABILITY, NOT FAILURE, INHERENT................. 82 M OTOR SELECTION............................................................................................ 83Load considerations.......................................................................................................................86 Duty cycle......................................................................................................................................87 Inertia level ...................................................................................................................................89 Expected running load ...................................................................................................................93 P ROTECTING AGAINST EXCESSIVE LOAD .............................................................. 95S ELECTING A VARIABLE DRIVE ............................................................................ 97P OWER QUALITY ............................................................................................. 101Size feeders for the motor system.................................................................................................. 102 Voltage drop................................................................................................................................ 103 Phase balance/voltage balance .................................................................................................... 105 Power factor correction ............................................................................................................... 107 Harmonics................................................................................................................................... 108 Build in reliability and reparability .............................................................................................. 109 Drives and power quality ............................................................................................................. 110 G ROUNDING ................................................................................................... 111C IRCUIT PROTECTION ...................................................................................... 113The special considerations of IEC protection devices.................................................................... 115 Fuses........................................................................................................................................... 116 High efficiency motors and circuit protection ............................................................................... 117 M OISTURE...................................................................................................... 119Motor heaters .............................................................................................................................. 121 Heating the windings ................................................................................................................... 121 M ECHANICAL PROTECTION ............................................................................... 122I NSTALLATION AND ALIGNMENT ......................................................................... 126M AKING CONNECTIONS .................................................................................... 131DC Motors................................................................................................................................... 133 AC Motors................................................................................................................................... 135 Physical connections.................................................................................................................... 137 Aluminum conductors .................................................................................................................. 140 R OTATION TESTING ......................................................................................... 141S TARTUP........................................................................................................ 145E ND OF CHAPTER QUESTIONS.......................................................................... 148S IDEBAR 3.1: TOP TIPS FOR PROPER MOTOR SELECTION .................................... 149S IDEBAR 3.2: VFD SELECTION TIPS .................................................................. 150S IDEBAR 3.3: SOME KEY VFD APPLICATION CONSIDERATIONS ............................ 151S IDEBAR 3.4: CONDUCTOR/CONNECTION TIPS ................................................... 152S IDEBAR 3.5 THE PRIME DIRECTIVE .................................................................. 154CHAPTER 4: PREDICTIVE MAINTENANCE.................................................. 155 W HY IS PREDICTIVE MAINTENANCE USEFUL?...................................................... 156H OW SHOULD I APPLY PREDICTIVE MAINTENANCE?............................................. 158A UTOMATIC TESTS .......................................................................................... 165Vibration monitoring.................................................................................................................... 166 Insulation resistance testing......................................................................................................... 169 Overspeed, underspeed, and torque monitors ............................................................................... 171 Current signature analysis ........................................................................................................... 173 Coil group short........................................................................................................................... 174 Turn to turn short......................................................................................................................... 174 Field winding ground................................................................................................................... 175 Brush ground............................................................................................................................... 175 Brush position.............................................................................................................................. 175 Differential current ...................................................................................................................... 176 M ANUAL TESTS ............................................................................................... 177Insulation resistance testing......................................................................................................... 178 High-potential testing .................................................................................................................. 183 Core loss testing .......................................................................................................................... 185 Surge comparison testing............................................................................................................. 186 Current and voltage measurements .............................................................................................. 187 Vibration analysis........................................................................................................................ 190 Visual, auditory, and olfactory inspection..................................................................................... 195 H IGH-END TESTS............................................................................................. 197Lube oil tests................................................................................................................................ 198 Ferrography ................................................................................................................................ 199 Motor current analysis................................................................................................................. 203 Partial Discharge Testing ............................................................................................................ 204 Thermography ............................................................................................................................. 205 E ND OF CHAPTER QUESTIONS.......................................................................... 207S IDEBAR 4.1. SOME BENEFITS OF PREDICTIVE MAINTENANCE.............................. 208S IDEBAR 4.2. FITTING PREDICTIVE MAINTENANCE INTO YOUR ORGANIZATION........ 209S IDEBAR 4.3. PM/PDM THE TYPICAL ELECTRICIAN CAN DO WITH STANDARD“ TRADITIONAL” EQUIPMENT............................................................................... 210S IDEBAR 4.4. PARAMETERS YOU CAN MONITOR AUTOMATICALLY......................... 211S IDEBAR 4.5. SAFETY TIPS FOR INSULATION TESTING ......................................... 214S IDEBAR 4.6.WHY WOULD YOU NEED AN RMS METER?..................................... 215S IDEBAR 4.7. HOW MUCH DID THE SHAKING MOTOR COST?................................. 216S IDEBAR 4.8 COMMON CAUSES OF VIBRATION ................................................... 219S IDEBAR 4.9.WHEN YOU MAY NEED HIGH-END TESTS ........................................ 221S IDEBAR 4.10. TIPS ON LUBE OIL TESTING......................................................... 222S IDEBAR 4.11. THERMOGRAPHIC MEASUREMENT METHODS................................ 223 CHAPTER 5: PREVENTIVE MAINTENANCE AND REPAIR .................. 224P ROCEDURES ................................................................................................. 225M OTOR CONTROLS.......................................................................................... 228Prevention ................................................................................................................................... 229 Inspections................................................................................................................................... 231 Troubleshooting........................................................................................................................... 233 M OTOR INSPECTIONS (ROUTINE) ...................................................................... 237Air filters, air supply.................................................................................................................... 238 Bearings ...................................................................................................................................... 239 Belts ............................................................................................................................................ 240 Brush/commutator ....................................................................................................................... 241 Motor mounts .............................................................................................................................. 242 Temperature ................................................................................................................................ 243 Vibration ..................................................................................................................................... 244 M ECHANICAL MAINTENANCE TASKS................................................................... 245Air filters..................................................................................................................................... 246 Cleaning...................................................................................................................................... 248 In-place cleaning......................................................................................................................... 249 Lubrication.................................................................................................................................. 250 M OTOR NOISE................................................................................................. 252Isolation and identification........................................................................................................... 253 Solutions...................................................................................................................................... 254 C ONDENSATION PREVENTION AND REPAIR......................................................... 255Open motors ................................................................................................................................ 256 Totally Enclosed Fan Cooled (TEFC) motors ............................................................................... 257 W HEN TO SEND OUT FOR REPAIR ...................................................................... 260E ND OF CHAPTER QUESTIONS.......................................................................... 268S IDEBAR 5.1 TOP TIPS FOR WRITING A GOOD PROCEDURE.................................. 269S IDEBAR 5.2. HOW TO GREASE A MOTOR .......................................................... 272S IDEBAR 5.3. SAFETY TIPS............................................................................... 273S IDEBAR 5.4.WHAT A MOTOR REPAIR SHOP DOES ............................................. 274CHAPTER 6: COST JUSTIFICATION............................................................. 275 C ASH FLOW .................................................................................................... 279H OW TO BUY THE LESS EXPENSIVE MOTOR, EVEN IF IT COSTS MORE .................... 282H OW TO GET GOOD BIDS ON PREDICTIVE MAINTENANCE SERVICES....................... 284H OW TO JUSTIFY AND OBTAIN PM DOWNTIME .................................................... 288E ND OF CHAPTER QUESTIONS.......................................................................... 291S IDEBAR 6.1 RULES FOR DRAWING CASH FLOW SCHEDULES ............................... 292CHAPTER 7: SHORTENING MOTOR MAINTENANCE DOWNTIME ............ 293 P ARTS AND ASSEMBLIES .................................................................................. 299W ORKING CLEARANCES................................................................................... 304T ROUBLESHOOTING GUIDES............................................................................. 307S PECIAL TOOLS............................................................................................... 309T RAINING........................................................................................................ 312How to train ................................................................................................................................ 313 Which skills?................................................................................................................................ 315 W ORKING WITHIN THE ORGANIZATION ............................................................... 316Finance ....................................................................................................................................... 317 Safety director ............................................................................................................................. 318 Security people ............................................................................................................................ 319 Maintenance people interaction with production .......................................................................... 320 Production management .............................................................................................................. 325 Higher management..................................................................................................................... 326 Field paperwork .......................................................................................................................... 327 E ND OF CHAPTER QUESTIONS.......................................................................... 331CHAPTER 8: SAFETY..................................................................................... 332 K NOW THE PROCESS ....................................................................................... 333K NOW THE AREA ............................................................................................. 334T HE SIX-STEP SAFETY METHOD......................................................................... 335Think—be aware.......................................................................................................................... 336 Understand your procedures ........................................................................................................ 337 Follow your procedures ............................................................................................................... 338 Use appropriate safety equipment ................................................................................................ 338 Ask, if you are unsure................................................................................................................... 339 Do not answer what you do not know ........................................................................................... 340 P ERSONAL PROTECTIVE EQUIPMENT (PPE)...................................................... 341R OTATING EQUIPMENT..................................................................................... 341M ECHANICAL CONSIDERATIONS ........................................................................ 342O PERATING A DISCONNECT SWITCH .................................................................. 343L OCKOUT/TAGOUT........................................................................................... 346T EST EQUIPMENT ............................................................................................ 350T ESTING FOR PRESENCE OF VOLTAGE............................................................... 354G ROUNDING ................................................................................................... 354G ET FIRST AID AND CPR TRAINING .................................................................. 355S IDEBAR 8.1. COMMON CAUSES OF INDUSTRIAL INJURIES ................................... 356S IDEBAR 8.2. THE FIVE-STEP SEQUENCE FOR EQUIPMENT DE-ENERGIZATION ....... 358E ND OF CHAPTER QUESTIONS.......................................................................... 359
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