The Three Keys

to Successful
Motor Maintenance
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 The Three Keys
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 Power
Power
Insulation
Air
Stator
Rotor
Quality
Gap
Circuit

Power Quality Power Circuit

Stator Insulation

Fault Zones
Air Gap PdMA Corporation Rotor
Case Study
Quality Assurance

PdMA Corporation
• Name Plate
-General Electric
-4000 Volt
-40.7 FLA
-300 HP
-5090Z Frame #
-1785 RPM

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PdMA Corporation
Case Study
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Name Plate Information
• Boiler Feed Pump
• 4160 V
• 309 FLA
• 2500 HP

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• 3580 RPM
• 46 Bars
• 54 Slots
 Trended MCSA Data

2008 2009

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2010 2011
Trended Demodulation Data
2008 2009

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2010 2011
 January 2012

We have a problem

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Demodulation Data

This demodulation capture

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represents nearly a 25 times
increase over baseline
 Rotor Problem Action List

• What speed is the motor?

• Rotor Design?
-Open bar or spun cast aluminum

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• Limit the starts and stops of the motor
• Increase testing frequency
• Minimize load fluctuations
Comparison Data

Data taken from Boiler Feed

Pump number 2 shows no

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rotor bar related anomalies
 Damaged Rotor

Rotor has multiple cracks

and shows visible signs of
rubbing damage

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Damaged Stator Tooth

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 Case Study
Insulation

Persistent Drive Failure on

400 HP Baghouse Fan

PdMA Corporation
 Problem Description
• Four (4) Variable Frequency Drive failures within a short life span
(all within 3 years)
• Electric Motor recently refurbished
• VFD’s always replaced with new components at a cost of $45,000
each
• Frequent trips of the motor causing additional process problems

PdMA Corporation
Name Plate Data

• AC Induction
• General Electric
• 400 Horsepower
• 1780 RPM
• 509LL Frame
• 460 Volt
• 442 Amps

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 Initial Standard Test
• Data collected from Test Date 07/28/2003

local disconnect Test Time

Frequency
09:17:08 AM

1200

• Quickly noticed the

Mohm Ph 1 to Gnd
Charge Time 60
Voltage 1000
Motor Temp 30
corrected Mohm value Measured Mohm
Corrected Mohm
289.3
145.0

was only 145

pF Ph 1 to Gnd 41750
ohm Ph 1 to 2 0.01951
ohm Ph 1 to 3 0.01956
ohm Ph 2 to 3 0.01952

• All other data mH Ph 1 to 2

mH Ph 1 to 3
2.775
2.575
mH Ph 2 to 3 2.790
appeared to be within Avg. Inductance
% Res. Imbalance
2.713
0.15
% Ind. Imbalance 5.10
acceptable limits $ Power Loss
Test Location
10.37
T-Leads
MCE # 030452HV
User
Notes Yes

PdMA Corporation
Polarization Index Test
Final value less than 400 Mohm

Erratic graph indicative of moisture

and/or contamination

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 Standard Test - At Motor Leads
Test Date 07/28/2003
Test Time 10:08:57 AM
• Data collected from Frequency
Baseline
1200
motor leads to isolate Mohm Ph 1 to Gnd
Charge Time 60

circuit from motor to Voltage

Motor Temp
1000
30
Measured Mohm 3400.0
disconnect Corrected Mohm
pF Ph 1 to Gnd
1700.0
40500

• Quickly noticed the ohm Ph 1 to 2

ohm Ph 1 to 3
0.01925
0.01913
ohm Ph 2 to 3 0.01918
corrected Mohm value mH Ph 1 to 2 2.830
mH Ph 1 to 3 2.780
increased from 145 to 1700 mH Ph 2 to 3
Avg. Inductance
2.615
2.742

• Began to suspect a % Res. Imbalance

% Ind. Imbalance
0.33
4.62
$ Power Loss 24.90
problem within the conduit Test Location
MCE #
Motor Leads
030452HV
between disconnect and User
Notes Yes

motor
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 Polarization Index - At Motor
Final value increased to over 12000 Mohm

Graph has more slope - less erratic

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 Remedial Actions
• Due to problem with low Mohm values apparently residing
between the local disconnect and motor junction box, we
suspected water in the conduit
• Conduit was removed
• NO water found
• Spirits were low

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 Remedial Actions (Continued)

• Due to some abrasions on lead-wire jacket, it was decided to have it

replaced
• Would allow further investigation of the conduit - still leaning on
water in conduit
• Would allow further investigation of the circuit for other possible
sources of our problem

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 Root Cause

Phase 1 Phase 2 Phase 3

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 Before/After Lead Change
Test Date 07/28/2003 07/28/2003
• Corrected Mohm Test Time 10:08:57 AM
Baseline
03:03:13 PM

value now very close Frequency

Mohm Ph 1 to Gnd
1200 1200

to when tested at Charge Time

Voltage
60
1000
60
1000

motor Motor Temp

Measured Mohm
30
3400.0
38
1745.0
Corrected Mohm 1700.0 1500.0
• Corrected Mohm pF Ph 1 to Gnd 40500 42250
ohm Ph 1 to 2 0.01925 0.02000
value increased from ohm Ph 1 to 3 0.01913 0.02000
ohm Ph 2 to 3 0.01918 0.02000
145 to 1500 mH Ph 1 to 2
mH Ph 1 to 3
2.830
2.780
2.780
2.860
• Resistive mH Ph 2 to 3
Avg. Inductance
2.615
2.742
2.620
2.753

Imbalance, although % Res. Imbalance

% Ind. Imbalance
0.33
4.62
0.00
4.84

low before now at $ Power Loss

Test Location
24.90
Motor Leads
0.00
Bot Fuses LD
MCE # 030452HV 030452HV
0.00 User
Notes Yes Yes

PdMA Corporation
 Problem Follow-Up

• Unit has operated flawlessly without as much as a

nuisance trip
• Process problems have as a result been
tremendously reduced
• Maintenance budget has experienced a much
needed rest from drive replacement costs

PdMA Corporation
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