Industrial Motor Load Calculation Testing and Maintenance

INDUSTRIAL MOTOR
LOAD CALCULATION
TESTING AND
MAINTENANCE
E NG R . ME R VIN C. E D NI LAO
I I E E -SCC 2022 VP - T ECHNICAL
Industrial Motor Load Calculation
• Branch Circuit Conductors
• Motor and Branch Circuit Overload Protection
• Branch Short Circuit-Circuit and Ground Fault Protection
• Feeder Conductors
• Feeder Short Circuit Protection
• Motor Equipment Grounding Conductors
Industrial Motor Testing (Electrical)
• Winding Resistance Test
• Insulation Resistance Test
• Polarization Index Test
• Winding Surge Test
• No Load Test
Industrial Motor Testing (Mechanical)
• Total Run Out Check
• Rotational Speed and Rotation Facing Drive End
• Vibration Analysis
• Bearing and Motor Temperature
Industrial Motor Maintenance
• General Inspection
• Temperature Monitoring of bearing and windings
• Vibration
• Oil Analysis
• Running Current
• Insulation Resistance
• Polarization Index
• Winding Resistance
Advantages of AC Induction Motor
• Variety of Model
• Simple Design
• Low Cost
• Less Noise and Vibration
INDUSTRIAL • Efficiency and Productivity
MOTOR • Speed Control

AC Induction Motor/Asynchronous • High Power Factor
• Reverse Operation
Nikola Tesla in 1887 at his
workshop on 89 Liberty
Street, New York.
Who invented
the induction
motor?
AC Induction Motor
SQUIR R EL CAG E MOTO R S WO U ND R OTO R MOTO R S
Industrial Motor Load
Calculation
TA B L E VA L U E S NA ME P LAT E VA L U E S
Table 4.30.14.1 Full Load Current in
Amperes, DC motors (p. 370)
Table 4.30.14.2 Full Load Current in
Amperes, Single Phase Alternating
Current Motors(p. 370)
Table 4.30.14.1 Full Load Current ,Two
Phase Alternating Current Motor : 4
wire (p. 371)
Table Values Table 4.30.14.1 Full Load Current

,Three Phase Alternating-Current
Philippine Electrical Code 2017 Motors (p. 372)
Information:
• Manufacturers Name
• Rated Voltage & Full Load Ampere
• Rated Frequency and Number of Phases
• Rated Full Speed
• Rated Temperature Rise
• Rated Horsepower
Nameplate • Code Letter Locked Rotor Amperes
Values • Design Letter (A,B,C,D)
Motor Nameplate • Bearing Data
• Service Factor
• Others
Which values are used to calculate in sizing the branch circuit
conductors of the motor (other than for motors built for low
speed (less than 1200 RPM )or high torques and for multi speed
motors)?
TA B L E VA L U E S NA ME P LAT E VA L U E S
4.30.2.2. Single Motor. Conductors that
supply a single motor used in a
continuous duty application shall have
an ampacity of not less than 125% of
the motor full-load current rating
based on table values.
Branch Circuit Conductor:

Branch Circuit
Wire Ampacity = FLC x 125%
Conductors
• Result in smaller conductors.
Note: Table Values are typically higher
Why we will not than the nameplate rating.
use not the • The table values ensures that no

matter what motor installed, the
nameplate current conductor sized to safely operate the
rating of motors motor.
when sizing the
conductors?
Using the nameplate values:
Example: 75hp ,460V.,3 ph motor @ 0.86 PF and
0.95 Eff.
Why we will not
I = (75hp x 746)/(460V x 1.73 x0.86 PF x 0.95 Eff)
use not the
I = 85.95 A
nameplate current
rating of motors
when sizing the Using the assumed values:
conductors? Example: 75hp ,460V.,3 ph motor @ 0.85 PF and

0.85 Eff.
I = (75hp x 746)/(460V x 1.73 x0.85 PF x 0.85 Eff)
I = 97 A
Neglecting the PF and Efficiency:
Example: 75hp ,460V., 3 ph motor
Why we will not I = (75hp x 746)/(460V x 1.73)
use not the I = 70.2A
nameplate current
rating of motors Reference HP PF Eff I
when sizing the Nameplate 75 0.86 0.95 85.95 A
conductors? Table Values 75 - - 96 A
Assumption 75 0.85 0.85 97 A
w/o PF and 75 - - 70.2 A

Eff
Example: 75hp ,460V.,3 ph squirrel-
cage induction motor, ambient
temperature of 38deg. C
Table Values: 96 A
Branch Circuit Conductor:
125% of the Full Load Current
Branch Circuit 96 A x 125 %

Conductors 96 A x 125 % = 120 Ampere
Conductor = Allowable Ampacity x
Ambient Temperature x Adjustment
Factors
Table 3.10.2.6(B)(16) Allowable
Ampacities - Directly Buried (not
more than three current carrying
conductors) p 174
Table 3. 10.2.6(B)(2)(a) Ambient
Branch Circuit Temperature Correction Factors Based
Conductors on 30deg.C. p 170
Industrial Motor Load Calculation Table 3. 10.2.6(B)(3)(a) Adjustment
Factors for more than three current
carrying conductors 3. p 172
96 A x 125 % = 120 Ampere
For 50mm2 THW allowable ampacity = 140 A
(Table 3.10.2.6(B)(16)
Conductor Ampacity= Allowable Ampacity x
Ambient Temperature x Adjustment Factors
Conductor Ampacity = 140A x 0.88
Branch Circuit Conductor Ampacity = 123.2 A

Conductors Use three 50mm2 THW Wires
4.30.2.2. Several Motors(s) and other
Loads. Conductors that supplyng
several motor(s) and other loads, shall
have an ampacity of not less than the
sum of the ff:
1. 125 % x FLC rating of the highest
rated motor
2. Sum of FLC ratings of all the other
Feeder motors in the group
Conductors 3. 100% of the non-continuous non-
Industrial Motor Load Calculation motor load
4. 125 % of the continuous non -
motor load
Example:
1. One 75 hp ,460V.,3 ph motor = 96 A
2. One 40 hp ,460V.,3 ph motor = 52 A
3. One 10 hp ,460V.,3 ph motor = 14 A
4. One 3 hp ,460V.,3 ph motor = 4.8 A
Ambient Temp: 38 deg.C
Feeder
Conductors Total Computed Current = (96A x 125%) + (52 A
+ 14 A + 4.8 A)
Total Computed Current = 190.8 A
Total Computed Current = 190.8 A
For 100mm2 THW allowable ampacity = 220 A
(Table 3.10.2.6(B)(16)
Conductor Ampacity = Allowable Ampacity x
Ambient Temperature x Adjustment Factors
Conductor Ampacity = 220A x 0.88
Feeder Conductor Ampacity = 193.6 A

Conductors Use three 100mm2 THW Wires
Intended to protect the motors, motor-
control apparatus, and motor branch
circuit conductors against excessive
heating due to motor failure to start.
Motor Service Factor (SF):

The percentage of overloading the
Motor and Branch motor can handle for short period of
Circuit Overload times when operating normally within
the correct voltage tolerance.
Protection
Motor and Branch Circuit Overload
Protection
OVE R LOA D D E VI CE T HE R MA L P R OT E CTOR
temperature of 38deg. C. and service
factor of 1.25.
Motor and Branch Circuit Overload
Protection:
125% of the nameplate full load current
Motor and Branch (SF = 1.15 or greater)
Circuit Overload 84.1 A x 125 %
Protection
84.1 A x 125 % = 105. 125 Ampere (max)
Intended to protect the motor branch
circuit conductors, the motor control
apparatus and the motors against
overcurrent due to short circuits or
ground fault.
Table 4.30.4.2 Maximum Rating or

Branch Short Setting of Motor Branch-Circuit, Short-
Circuit-Circuit Circuit and Ground-Fault Protective
Devices. P356
and Ground
Fault Protection Table 2.40.1.6 (A) Standard Ampere
Ratings for Fuses and Inverse Time
Circuit Breakers p 86
Branch Short Circuit-Circuit and Ground
Fault Protection
Types of Motor Percentage of Full-Load Current
Type of Motor Nontime Dual Element (Time- Instantaneous Inverse Time
Delay Fuse Delay) Fuse Trip Breaker Breaker
Single-phase Motors 300 175 800 250
AC Polyphase motors other than 300 175 800 250
wound-rotor
Squirrel Cage – other than 300 175 800 250
Design B energy - efficient
Design B energy-efficient 300 175 1100 250

Synchronous 300 175 100 250
Wound-Rotor 150 150 800 150
DC (Constant Voltage) 150 150 250 150
temperature of 38deg. C.
Branch Short Circuit-Circuit and
Ground Fault Protection:
Using Inverse Time Circuit Breaker
Branch Short 250% of the Full Load Current
Circuit-Circuit 96 A x 250 % = 240 AT
and Ground Use 250 AT Inverse Time Circuit
Fault Protection Breaker
4.30.5.2 Rating or Setting - Motor
Load
(A) Specific Load
1. Not greater than the largest rating
or setting of the branch short-
circuit and ground fault protective
device for any motor supplied by
Motor Feeder Short the feeder plus
Circuit-Circuit and 2. Sum of the full load current of the
other motors of the group.
Ground Fault
Protection
Example:
1. One 75 hp ,460V.,3 ph motor = 96 A
250 AT Inverse Time Circuit Breaker
2. One 40 hp ,460V.,3 ph motor = 52 A
3. One 10 hp ,460V.,3 ph motor = 14 A
4. One 3 hp ,460V.,3 ph motor = 4.8 A
Motor Feeder Short
Circuit-Circuit and Total Computed Current = 250AT + (52A +
Ground Fault 14A + 4.8 A)
Protection Total Computed Current = 320 .8 A

Industrial Motor Load Calculation Use 300 AT Inverse Time Circuit Breaker
The conductive path (s) that provides a
ground-fault current path and connects
normally non-current carrying metal parts of
equipment together and to the system
grounded conductor or to the grounding
electrode conductor or both.
Table 2.50.6.13 Minimum Size Equipment
Grounding Conductors for Grounding
Raceway and Equipment. PEC 2017 p. 124
Motor Equipment
Grounding
Conductors
Example: 75hp ,460V.,3 ph squirrel-cage
induction motor, ambient temperature of
38deg. C.
Branch Short Circuit-Circuit and Ground Fault
Protection:
250% of the Full Load Current
96 A x 250 % = 240 AT
Use 250 AT Inverse Time Circuit Breaker
Motor Equipment
Grounding For 250 AT ITCB use 22mm2 copper equipment
grounding conductor.
Conductors Table 2.50.6.13 Minimum Size Equipment
Industrial Motor Load Calculation Grounding Conductors for Grounding Raceway
and Equipment. PEC 2017 p. 124
Industrial Motor Testing
(Electrical)
Purpose
The purpose of the winding resistance
Test is to determine whether or not an
motor winding is suitable for operation
or may proceed with the insulation
test.
To check the coil of the motor and
detect various faults:
Industrial Motor
1. Short Winding
Testing (Electrical)
Winding Resistance Test 2. Open Winding
3. Connection issues
Winding resistance
The resistance of a length of copper
wires or bars from one end to the
other, is a measure of DC voltage and
current
Ohm’s Law
R = V/I
Industrial Motor Instrument:
Winding Resistance Test
1. DLRO (Digital Resistance Low
Ohmeter)
2. Kelvin Bridge
Resistance Reading
The reading should be between 0.3 to 2
ohms.
1. If the reading is zero, there is a
short
2. If it is over 2 ohms or infinite, there
is an open
Industrial Motor 3. Resistance unbalance indicates
Testing (Electrical) connection issues.
Standard: Winding resistance for
random wound coils should be balance
within 2%
Example: 100HP, 3 ph, 440 induction
motor.
Winding Resistance Test:
Instrument Used: Baker DX Megger
Results:
L1-L2 = 58.604 milliohms
L1-L2 = 59.264 milliohms
Industrial Motor L1-L2 = 58.343 milliohms
Testing (Electrical) % Unbalance = (Maximum deviation
from average / Average Value) X 100
% Unbalance = 0.9 %
PASSED.
Purpose:
The purpose of the insulation
resistance and polarization index tests
is to determine whether or not an
insulation system is suitable for
operation or overvoltage testing.
Insulation resistance test data is useful
in evaluating the presence of some
Industrial Motor insulation problems such as
Testing (Electrical) contamination, absorbed moisture, or
Insulation Resistance Test
severe cracking.
3.4 insulation resistance (IRt ):
The capability of the electrical
insulation of a winding to resist direct
currrent. The quotient of applied direct
voltage of negative polarity divided by
current across machine insulation,
corrected to 40 °C, and taken at a
specified time (t) from start of voltage
application. The voltage application
time is usually 1 min (IR1) or 10 min
Industrial Motor (IR10), however, other values can be
Testing (Electrical) used.
Insulation Resistance Test and
Polarization Index Test
IEEE Std.43 Definition
Safety Consideration:
1. Before any testing is conducted,
Winding insulation must be
discharged
2. After completion of the test, the
winding should be discharged
3. For test voltages 5000 V and above,
Industrial Motor the lead between the test set and
the winding must be appropriately
Testing (Electrical) insulated and spaced from ground.
Polarization Index Test 4. Personnel must wear PPE
Components of the measured direct
current
The total resultant current:
1. Surface leakage (IL)
2. Geometric capacitance (IC),
3. Conductance (IG)
Industrial Motor 4. Absorption (IA)
Insulation Resistance Test
What happen if the test voltage is too
high ?
The applied test voltage may over

stress the insulation, leading to
insulation failure.
The measurement of insulation
resistance constitutes a direct-voltage
Industrial Motor test and must be restricted to a value
appropriate to the voltage rating of the
Testing (Electrical) winding and the basic insulation
Insulation Resistance Test and condition. This is particularly important
Polarization Index Test in the case of small, low-voltage
machines, or wet windings.
Guidelines for dc voltages to be applied
during insulation resistance test(IEEE 43)
3.6 polarization index (P.I.t2/t1):
Variation in the value of insulation
resistance with time. The quotient of
the insulation resistance at time (t2)
divided by the insulation resistance at
time (t1).
If times t2 and t1 are not specified,
they are assumed to be 10 min and 1
Industrial Motor min, respectively.
Testing (Electrical) PI = I1/I10
Polarization Index Test IEEE Std.43 Definition
Typical insulation resistance measurements
for three different machines
Factors affecting insulation resistance
1. Effect of surface condition
2. Effect of moisture
3. Effect of temperature
4. Effect of test voltage magnitude
5. Effect of existing charge on
Industrial Motor winding resistance measurements
Conditions for measuring insulation resistance
Record the following:
1.Ambient temperature
2.Relative humidity
3. Dew point
4.Winding temperature
5.Length of time out-of service
Industrial Motor 6.Test voltage
Testing (Electrical) 7. Connection arrangement at the time the test is
Insulation Resistance Test and performed.
It is also important to convert the measurement
to a 40 °C basis for future comparisons.
Winding connections for insulation resistance
tests
1. It is recommended, when feasible, that each
phase be isolated and tested separately.
When one phase is tested, the other two
phases should be grounded to the same
ground as the stator core or rotor body.
2. When testing all phases simultaneously, only
the insulation to ground is tested and no test
Industrial Motor is made of the phase-to-phase insulation
Testing (Electrical) 3. It is recommended that measurements of the
Insulation Resistance Test and insulation resistance be made with all
external equipment disconnected and
grounded.
Methods of measuring insulation resistance
1. Direct measurement
a) Direct-indicating megohmmeter with
self-contained hand or power-driven
generator
b) Direct-indicating megohmmeter with
self-contained battery
Industrial Motor c) Direct-indicating megohmmeter with
Testing (Electrical) self-contained rectifier, using a regulated
Insulation Resistance Test and line powered supply
d) Resistance bridge with self-contained
galvanometer and batteries
Methods of measuring insulation resistance
2. Calculated measurement
Insulation resistance may be calculated from
readings of a voltmeter and microammeter
using an external (well-regulated) direct-
voltage supply.
IR( t) = E(t )/ I(t )
Industrial Motor IR(t) is the insulation resistance in megohms,
Testing (Electrical) E(t) is the voltmeter reading in volts,
Insulation Resistance Test and I(t) is the ammeter reading in microamperes
(t) seconds after application of the test
voltage.
Interpretation of insulation resistance and
polarization index test results2. Calculated
measurement
1. The insulation resistance test history of a
given machine, measured at uniform
conditions so far as the controllable
variables are concerned, is recognized as
a useful way of trending some aspects of
Industrial Motor the insulation condition over years.
Testing (Electrical) 2. Estimation of the suitability of a machine

for the application of appropriate
Polarization Index Test overvoltage tests or for operation may be
based on a comparison of present and
previous P.I. and/or IR1 values.
Suitability for operation or continued testing
1. If the IR1 or P.I. is low because of dirt or
excessive moisture, it may be improved
to an acceptable value by cleaning and
drying.
2. When drying insulation, the P.I. can be
used to indicate when the drying process
may be terminated, i.e., the P.I. results
have exceeded the recommended
Industrial Motor minimum.
Testing (Electrical) 3. If the IR1 is low due to severe insulation
Insulation Resistance Test and deterioration or damage, operation and
Polarization Index Test overvoltage testing of the machine are
not recommended.
Recommended minimum insulation
resistance values at 40 °C (all values in MΩ) –
IEEE 43
Industrial Motor
Temperature Correction Factor for insulation
resistance tests taken at temperature other
that 40 deg. C – IEEE43
Industrial Motor
Recommended minimum values of polarization
index for all machine components insulation
classes per IEC 60085-01: 1984
Industrial Motor
NOTE—If the 1 min insulation resistance is above
5000 MΩ, the calculated P.I. may not be
meaningful. (IEEE 43)
Applicability of polarization index when IR1 is
greater than 5000 MΩ
When the insulation resistance reading
obtained after the voltage has been applied
for 1 min (IR1) is higher than 5000 MΩ, based
on the magnitude of applied direct voltage,
the total measured current (IT) can be in the
submicroampere range.
Industrial Motor Because of these phenomena, when the IR1 is
Testing (Electrical) higher than 5000 MΩ, the P.I. may or may not
be an indication of the insulation condition
Polarization Index Test and is therefore not recommended as an
assessment tool
Applicability of polarization index when IR1 is
greater than 5000 MΩ
Example: 100HP, 3 ph, 440 induction motor.
Polarization Index Test:
Instrument Used: Baker DX Megger
Applied Voltage: 500V
Industrial Motor Result in 1 minute: 5.12Gigaohms
Testing (Electrical) Result in 10 minutes: 5.18 Gigaohms
Polarization Index Test PI= 5.12/5.18
PI= 1.01 ????? Less than min. value of 2.0
High-potential tests are tests that
consist of the application of a voltage
higher than the rated voltage for a
specified time for the purpose of
determining the adequacy against
breakdown of insulating materials and
spacings under normal conditions
(IEEE 112)
Industrial Motor The test voltage should be applied

when, and only when, the machine is in
Testing (Electrical) good condition and the insulation
High-Potential Test (Over-potential resistance is not impaired due to dirt,
Test)/Dielectric Withstand Test moisture, or abrasion or other types of
damage.
Test Voltage
1. Factory testing of new stators is
1000 volts plus 2 times the rated
voltage of the machine.
2. New rotors of wound rotor
machines the test voltage is 1000
volts plus 2 times the maximum
voltage induced between collector
Industrial Motor rings.
Testing (Electrical) 3. In service motor ,1000 volts plus 2
High-Potential Test (Over-potential times the rated voltage of the
Test)/Dielectric Withstand Test
machine.
Test Voltage
1. New Motor
Vac = (2E + 1000)
Vdc = (2E + 1000)(1.7)
Where E = rated line to line voltage
2. Service-aged motor
Industrial Motor
Testing (Electrical) Vac = (2E + 1000) x 67%
High-Potential Test (Over-potential Vdc = (2E + 1000)(1.7) x 67%
Test)/Dielectric Withstand Test
Overvoltage tests are typically
conducted for 60 s
Test Voltage
Since high-potential testing is stressful
on winding dielectric components, it is
recommended that initial field high-
potential test voltages be limited to
85% of the levels used for factory
testing of new equipment. For any
further high potential testing, it is
recommended the test voltage level be
limited to a 75% level.
Industrial Motor
Testing (Electrical) Example: Reconditioned 100HP, 3 ph,
440V induction motor.
High-Potential Test (Over-potential
Test)/Dielectric Withstand Test Test Voltage = (1000 + (2 x 440V ))65%
= 1222V
Purpose
This test is recommended to detect
deteriorating windings.
Surge Test Level
Industrial Motor
Winding Surge Test
• Typical waveforms expected in the Surge
test
Industrial Motor
Winding Surge Test
If there is no separation between the two
wave forms indicates good winding.
• Current, applied voltages, and frequency (AC) are
recorded during no load testing
Example: 100HP, 3 ph, 440V induction motor.
No load test:
Instrument Use: Fluke Multitester
L1-L2 Voltage: 447 V, L1 Current=45.8A
Industrial Motor L1-L2 Voltage: 449 V, L3 Current=60.9A
Testing (Electrical) Voltage Unbalance: 1.77%
No Load Test Current Unbalance : 21.2% Failed
For 1-2% voltage unbalance we can expect about
5% current unbalance.
• Current, applied voltages, and frequency
(AC) are recorded during no load testing
Example: 100HP, 3 ph, 440V induction motor.
No load test:
Instrument Use: Fluke Multitester
Industrial Motor L2-L2 Voltage: 460 V, L2 Current=67.7A
Testing (Electrical) L1-L2 Voltage: 449 V, L3 Current=60.9A
No Load Test
Industrial Motor Testing
(Mechanical)
100HP, 3 ph, 440V induction motor.
Instrument Use: SKF Laser Tachometer Set
TMRT-1
Result
Speed Drawn: 1804 rpm
Rotation: Clockwise
Industrial Motor % slip = (1800-1804)/1800= 0.2% PASSED
Testing (Mechanical) Standard: +/- 20% of rated slip rpm as per
Rotational Speed and Rotation NEMA MGI
Facing Drive End
100HP, 3 ph, 440V induction motor
Instrument Use: IRD Vibration Analyzer and
Balance Kit 258
Result @ Non Drive End
Vertical : 0.50 mm/s - GOOD
Horizontal : 0.60 mm/s -GOOD
Industrial Motor Axial: 0.90 mm/s -GOOD
Testing (Mechanical) PASSED!
Vibration Analysis
Standard: 3.8 mm/s for motor 1200 rpm above
and resiliently mounted as per NEMA MG1
1. Bearing Housing Diametral Reading
a. Drive End Bearing Housing
b. Non Drive End Bearing Housing
2. Bearing Journal Diametral Reading
a. Drive End Bearing Housing
b. Non Drive End Bearing Housing
Industrial Motor 3. Total Indicator Run out Check
Testing (Mechanical) a. Drive End Bearing Housing

Total Indicator Run Out Check b. Non Drive End Bearing Housing
Standard Tolerance: 0.060 mm per IEC STD.60072-
1, C1.6
100HP, 3 ph, 440V induction motor
Instrument Use: IRD Vibration Analyzer and
Balance Kit 258
Result @ Non Drive End
Vertical : 0.50 mm/s - GOOD
Horizontal : 0.60 mm/s -GOOD
Industrial Motor Axial: 0.90 mm/s -GOOD
Vibration Analysis
Standard: 3.8 mm/s for motor 1200 rpm above
and resiliently mounted as per NEMA MG1
“Dynamic balancing is a way of balancing
machines by rotating parts quickly and
measuring the imbalance using electronic
equipment. The imbalance measured can then
be corrected by adding or subtracting weight
from the rotating parts until the vibration is
reduced.”
Ref:
Industrial Motor https://www.bellwoodrewinds.co.uk/dynamic-
balancing/
Testing (Mechanical)
Dynamic Balancing
Instrument Use:SKF Laser Infrared Thermometer
TKL10
Time: 5 min
Drive End Bearing : 35.6 deg C
Body: 36.8 deg C
Non Drive Bearing: 30.9 deg C
Industrial Motor
Bearing Motor Temperature
Bearing Temperature should be within the normal
operating temperature of 80deg C as per EASA
Technical Manual
Instrument Use:SKF Laser Infrared Thermometer
TKL10
Time: 30 min
Drive End Bearing : 48.9 deg C
Body: 50.0 deg C
Non Drive Bearing: 32.8 deg C
Industrial Motor
Bearing Motor Temperature
Bearing Temperature should be within the normal
operating temperature of 80deg C as per EASA
Technical Manual
Industrial Motor Maintenance
Electrical Preventive Maintenance (EPM).
A managed program of inspecting, testing,
analyzing, and servicing electrical systems
and equipment with the purpose of
maintaining safe operations and production by
reducing or eliminating system interruptions
and equipment breakdowns. (NFPA70B)
Industrial Motor
Maintenance A maintenance program for electric motors
should utilize proven and well understood
testing and inspecting methods performed by
qualified knowledgeable personnel to identify
and evaluate conditions.
1. The purpose of the maintenance is to
extend the useful life of the equipment.
2. All repairs, disassembly and assembly
related services must be carried out only by
qualified and well-trained personnel by
using proper tools and techniques.
3. Make sure that the machine has stopped
and it is disconnected from the power
Industrial Motor supply, including the accessory devices
Maintenance (space heater, brake, etc.), before any
servicing is undertaken.
1. Installed and running – Actions typically
performed with the motor installed and
coupled to the driven load.
2. Installed and offline – Actions which require
the motor to be electrically disconnected
but can be performed with the motor
installed and coupled.
3. Overhaul – Actions typically completed
Industrial Motor during a routine overhaul. Additional
Maintenance testing / activities may be required based
Recommended Maintenance
on the individual situation.
Practices and Frequencies
1. Visual Inspection every 6 months (Installed and
Running)
a. Evidence of damage caused by dirt, loose parts,
or foreign objects.
b. Verification that air inlets are not blocked.
c. Evidence of moisture and/or dirt build-up
d. Unusual noises, leaking oil seals, or high
vibration
Industrial Motor e. Oil level gages (if present) should be checked
Maintenance f. Evidence of degradation of foundation, bed
plates, anchor bolts
Practices and Frequencies g. Evidence of oil rings turning (if applicable)
h. Evidence of leaking oil and water piping and
connections
2. Temperature monitoring of bearings and
windings every 6 months (Installed and
Running)
a. If motor is not equipped with installed
sensors: record bearing temperatures and
stator temperature using thermographic
imaging.
This data should be trended. The monitoring
Industrial Motor should be completed at similar motor loading
Maintenance and ambient temperature to allow for accurate
trending.
3. Vibration every 6 months (Installed and
Running)
a. Record and trend vibration levels.
This should be done by a trained and
experienced technician, preferably a qualified
level II technician.
4. Oil analysis 12 months (Installed)
Industrial Motor a. Sample and analyze.
Maintenance Look at overall conditions and check for
foreign matter, additive depletion,
Practices and Frequencies varnish precursors and metallic elements.
Motor should be shut down when taking
sample.
5. Running current every 12 months (Installed
and Running)
a. Record and trend all three phase currents
and verify the currents are balanced and do
not exceed nameplate rating.
Each phase should be within +/- 5% of the
average of all three phases.
Industrial Motor 6. Insulation resistance(IR) every 12 months >
600 Volt motors (Installed and Offline)
Maintenance
Recommended Maintenance a. Perform IR check between motor leads and
Practices and Frequencies ground. This determines condition of the
ground insulation. Record, temperature
correct and trend.
6. 1 Insulation resistance(IR) every 12 months >
a. Perform IR check between motor leads and
ground. This determines condition of the
correct and trend.
Industrial Motor
Maintenance
6.2 Insulation resistance(IR) every 24 months <
a. Perform IR check between motor leads and
ground. This determines condition of the
correct and trend.
7.1 Polarization index (PI)) every 12 months >
Industrial Motor a. Ratio of the 10 minute IR to the 1 minute
IR.(10 min IR / 1 min IR)
Maintenance
Recommended Maintenance b. Determines condition of ground insulation.
Test voltages similar to the IR test voltages.
Acceptance criteria ratio > 2
7.2 Polarization index (PI)) every 24 months < 600
Volt motors (Installed and Offline)
a. Ratio of the 10 minute IR to the 1 minute IR.(10
min IR / 1 min IR)
b. Determines condition of ground insulation.
Test voltages similar to the IR test voltages.
Acceptance criteria ratio > 2
8.1 Winding resistance every 12 months > 600 Volt
motors (Installed and Offline)
Industrial Motor A comparison of the line to line resistances of the
Maintenance motor’s winding. This test should be done at the
motor terminals using a meter capable
Recommended Maintenance of measuring low resistance (milliohms). A typical
Practices and Frequencies ohm meter does not have adequate
accuracy. Record, temperate correct and trend.
Each phase should be within +/- (3% - 5%) of the
average of all three phase.
8.2 Winding resistance every 24 months < 600
Volt motors (Installed and Offline)
A comparison of the line to line resistances of
the motor’s winding. This test should be done
at the motor terminals using a meter capable
of measuring low resistance (milliohms). A
typical ohm meter does not have adequate
accuracy. Record, temperate correct and trend.
Industrial Motor Each phase should be within +/- (3% - 5%) of
the average of all three phase.
Maintenance
9. Shaft total indicated run out(TIR) every 60
months (Overhaul)
Measure the trueness of the shaft extension.
A high value can cause vibration issues.
Acceptance criteria:
3600 rpm max .001 in
Industrial Motor < 3600 rpm max .003 in
Maintenance
10. Inspection and measurements of bearing
journals and housing fits every 60 months
(Overhaul)
Diameters of the fits should be measured and co
mpared to bearing industry standards. Brg
journals and housing bores should be visually
inspected for finish, pitting, rubbing and
corrosion.
11. Stator visual Inspection every 60 months
(Overhaul)
Industrial Motor
Inspection should look for:
Maintenance
Recommended Maintenance coil movement, plugged vent holes, soft or
Practices and Frequencies degraded insulation, coil bracing adequate and
intact, lamination damage, partial discharge
activity and tightness of wedges
12. Rotor / Shaft visual Inspection every 60
months (Overhaul)
Inspection should look for:
a. cracks in rotor bars
b. balance weights properly secured
c. signs of bar movement
Industrial Motor d. signs of rotor/stator rub or lamination

damage
Maintenance e. cooling ducts clear
Practices and Frequencies f. rubbing marks on shaft
g. keyway distortion
13. Clean, bake dry and varnish(as needed)
every 60 months (Overhaul)
All parts should be cleaned and baked dry to
remove all dirt and contamination. The
windings should be reinsulated as
appropriate.
14. Insulation resistance every 60 months
(Overhaul and post overhaul)
Industrial Motor
Perform IR check between motor leads and
Maintenance ground. This determines condition of the
Recommended Maintenance ground insulation. Record, temperature
correct and trend.
15. Polarization index (PI) every 60 months
a. Ratio of the 10 minute IR to the 1 minute
IR.(10 min IR / 1 min IR)
b. Determines condition of ground insulation.
16. Winding resistance every 60 months
A comparison of the line to line resistances of the
Industrial Motor motor’s winding. This test should be done at the
motor terminals using a meter capable
Maintenance of measuring low resistance (milliohms). A
Recommended Maintenance typical ohm meter does not have adequate
Practices and Frequencies accuracy. Record, temperate correct and trend.
Each phase should be within +/- (3% - 5%) of the
average of all three phase.
17. Surge Test every 60 months (Overhaul)
The test verifies the insulation condition bet
ween the turns of a motor’s winding. It can
be a destructive test. This test should only be
done after the visual inspection ,the other
electrical checks and the clean and
drying process.
Test voltage(overhaul): 2 x rated voltage+
Industrial Motor 1000
Maintenance Acceptance criteria: steady and duplicate
Recommended Maintenance pattern
18 . Rotor balance every 60 months
(Overhaul)
Balance process minimizes the out of balanc
e of the rotor. Acceptable levels are based on
speed and application of the
machine.: steady and duplicate pattern
19. Core loss every 60 months (Overhaul)
Industrial Motor This test is completed on both the rotor and
stator. This test excites the core
Maintenance to determine overall core loss levels and
Recommended Maintenance locate any shorted laminations. Any
hotspots or high core loss found should be
investigated and corrected.
20 . Broken rotor bar checks every 60 months
(Overhaul)
Methods to check for cracked rotor bars inclu
de visual, audible, hot spot check, growler,
magnetic paper, single phase rotation.
21. No load run test with vibration
measurements every 60 months (Overhaul)
Industrial Motor This test is performed after all work has been
completed. Test should verify acceptable
Maintenance current balance, bearing temperatures,
Recommended Maintenance vibration levels and no unusual rubbing or
noises present.
References:
1. Philippine Electrical Code 2017
2. IEEE Std 1068 – 2015
3. National Electrical Manufacturers Association (NEMA) Standard MG1
4. IEEE STD 43, IEEE Recommended Practice for Testing Insulation Resistance of
Rotating Machinery
5. IEEE Std 112™-2004
6. National Fire Protection Association (NFPA) 70B, Recommended Practice for
Electrical Equipment Maintenance
7. IEEE STD 1415, IEEE Guide to Introduction Machinery Maintenance Testing and
Failure Analysis
8. Test Report (Mega MasterLink)
9. 420 HSB Recommended Practice for Electrical Preventive Maintenance
THANK YOU !!!!

Industrial Motor Load Calculation Testing and Maintenance

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Industrial Motor Load Calculation Testing and Maintenance

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INDUSTRIAL MOTOR

INDUSTRIAL • Efficiency and Productivity

MOTOR • Speed Control

Table Values Table 4.30.14.1 Full Load Current

Branch Circuit Conductor:

use not the • The table values ensures that no

conductors? Example: 75hp ,460V.,3 ph motor @ 0.85 PF and

conductors? Table Values 75 - - 96 A

Assumption 75 0.85 0.85 97 A

w/o PF and 75 - - 70.2 A

Branch Circuit 96 A x 125 %

Branch Circuit Conductor Ampacity = 123.2 A

Feeder Conductor Ampacity = 193.6 A

Motor Service Factor (SF):

Table 4.30.4.2 Maximum Rating or

Design B energy-efficient 300 175 1100 250

Protection Total Computed Current = 320 .8 A

The applied test voltage may over

Testing (Electrical) 2. Estimation of the suitability of a machine

Industrial Motor The test voltage should be applied

Industrial Motor 3. Total Indicator Run out Check

Testing (Mechanical) a. Drive End Bearing Housing

Industrial Motor d. signs of rotor/stator rub or lamination

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