Professional Documents
Culture Documents
The Three Keys To Successful Motor Maintenance
The Three Keys To Successful Motor Maintenance
to Successful
Motor Maintenance
Trifecta ?
The Three Keys
• Quality Control
• Trending
• Troubleshooting
• Quality Control
• Trending
• Troubleshooting
• Quality Control
• Trending
• Troubleshooting
Power
Power
Insulation
Air
Stator
Rotor
Quality
Gap
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
PdMA Corporation
PdMA Corporation
Case Study
Trending
PdMA Corporation
Name Plate Information
• Boiler Feed Pump
• 4160 V
• 309 FLA
• 2500 HP
PdMA Corporation
• 3580 RPM
• 46 Bars
• 54 Slots
Trended MCSA Data
2008 2009
PdMA Corporation
2010 2011
Trended Demodulation Data
2008 2009
PdMA Corporation
2010 2011
January 2012
We have a problem
PdMA Corporation
Demodulation Data
PdMA Corporation
represents nearly a 25 times
increase over baseline
Rotor Problem Action List
PdMA Corporation
• Limit the starts and stops of the motor
• Increase testing frequency
• Minimize load fluctuations
Comparison Data
PdMA Corporation
rotor bar related anomalies
Damaged Rotor
PdMA Corporation
Damaged Stator Tooth
PdMA Corporation
Case Study
Insulation
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
PdMA Corporation
Initial Standard Test
• Data collected from Test Date 07/28/2003
Frequency
09:17:08 AM
1200
PdMA Corporation
Polarization Index Test
Final value less than 400 Mohm
PdMA Corporation
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
motor
PdMA Corporation
Polarization Index - At Motor
Final value increased to over 12000 Mohm
PdMA Corporation
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
PdMA Corporation
Remedial Actions (Continued)
PdMA Corporation
Root Cause
PdMA Corporation
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
PdMA Corporation
Problem Follow-Up
PdMA Corporation
Trending
Trifecta…
Questions