COS-EP-038

LOW VOLTAGE MOTOR MAINTENANCE PROCEDURE

Status Date Prepared By Reviewed By Approved By

 Amendment Record
Revision Description Date Prepared By Reviewed By Approved By

00 First Issue 00/00/2018

Table of contents
Description Page
No
1.0 POLICY 4
2.0 PURPOSE 4
3.0 SCOPE 4

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 4.0 ABBREVIATIONS 4
5.0 RESPONSIBILITIES 4
5.1 Engineering Manager 4
5.2 Lead Electrical Engineer 4
5.3 Electrical Engineer 5
5.4 Electrical Technician 5
6.0 CMMS- COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM 5
7.0 PLANNED MAINTENANCE 5
7.1 Maintenance 5
7.2 Condition Monitoring 6
7.2.1 Vibration monitoring 6
7.2.2 Temperature monitoring 6
7.2.3 Current monitoring 6
7.3 Visual And Mechanical Inspection 6
7.4 Electrical Test 6
7.4.1 Insulation Resistance Test 6
7.4.2 Winding Resistance Test 7
8.0 APPENDIXES 8
8.1 Appendix-001E: Semi-Annual PM on LV Motors 9
8.2 Appendix-002E :Annual PM on LV Motor 9

1.0 POLICY

It shall be the policy at … plant to maintain all low voltage motors according to manufacturer’s
recommendation, or best industry practise for similar equipment in similar plants, in order to
achieve the maximum availability, maintainability and reliability of the equipment.

2.0 PURPOSE

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Low voltage motors are low-rated Kilowatts motors which are employed to drive relatively low and
medium load with supply voltage of 400V on the plant

These motors have fairly long life rating when properly maintained and serviced in accordance with
manufacturers OEM and industry best practices. The principal aim of this procedure is to ensure the
reliability and the efficiency of these Low voltage motors are maintained to standards for the
efficient running of the plant.

3.0 SCOPE

The scope for the Low voltage motors will cover all aspects of the motor needed to maintain its
efficiency and reliability in the course of operation. This will cover all Low Voltage motors installed
on the plant which include the GT’s ,ST, HRSG’s, Balance of plant low voltage motors,

4.0 ABBREVIATIONS

PTW Permit-To-Work
PPE Personal protective equipment
WI Work instruction

5.0 RESPONSIBILITIES

5.1 Engineering Manager

The Engineering Manager is responsible for the Electrical section’s adherence to guidelines
established for control of preventive maintenance program.

5.2 Lead Electrical Engineer

Lead Electrical Engineer is responsible for his crew’s performance of the maintenance task. The Lead
Electrical Engineer assists in continuous evaluation of the job to determine when/if adjustments to
the scheduled frequency of PMs are necessary, provide required resource, compliance with safety
and environmental procedure, the staff safety and determine if the job done properly.
The Lead Electrical Engineer is responsible for ensuring that the preventive maintenance work order
is completed as schedule and the completed work order is properly documented.

5.3 Electrical Engineer

The Electrical Engineer is responsible for identifying, establishing and allocating available resources
necessary to perform preventive maintenance work. He is also responsible for reviewing repeat
equipment failure for root cause and initiates corrective actions.

5.4 Electrical Technician

The Electrical technician is responsible for performing the job as specified in this procedure in safe
manner.

6.0 CMMS- COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM

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Any maintenance activity shall be carried out using MAXIMO generated Work Orders. Task
Instructions shall be prepared for creating preventive work orders in MAXIMO. Before carrying out
any maintenance work, a permit shall be obtained by the maintenance personnel, as per procedure
JAEPM0006.

7.0 PLANNED MAINTENANCE

The preventive maintenance program of motor is to employ the appropriate technical measures to
identify and address degraded conditions prior to impact on motor operation. Based on the results
of this program there will be occasions when corrective actions may be necessary. This program
should effectively address reliability, cost, and schedule considerations. The result of any tests or
inspections will be compared with established baseline data for each motor.

Low Voltage motors are mainly use to drive pumps, cranes, cooling fans, or any other machinery.
They are supplied from the 400V LV Bus.

7.1 Maintenance
 Semi-Annual PM
The Semi-Annual PM shall be a routine scheduled, which shall include visual, mechanical inspections
and trending of data acquired from the inspection.
For comprehensive Work instruction refer to Appendix 001E
 Annual PM
During the annual PM comprehensive Electrical test, cleaning and Mechanical inspections such as
bearing replacement if required, lube oil/ grease replacement, testing shall be done as per the OEM
recommendations.

For comprehensive Work instruction refer to Appendix 002E

7.2 Condition Monitoring

7.2.1 Vibration Monitoring

Vibration monitoring procedure of the motor include both local measurement where the vibration
of the motor is measured using a vibration meter in the X, Y and Z plane of the motor’s driving end
and non-driving end and the result compared to the motor data sheet for analysis; this test is done
together with the vibration measurement of the driven unit (pump, fan etc.).For some motors, there
are vibrations probes that will detect the vibration levels of the motors bearings in both the driving
end and non-driving end of the motor and send these signals via DCS to the operator HMI for remote
monitoring.

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7.2.2 Temperature Monitoring
The motor winding temperature and bearing temperature of both driving and non-driving end of the
motor is monitored and any abnormal conditions with reference to motor data sheet is analysed and
the requisite corrective measures implemented. This analysis is done taking into consideration the
ambient temperature, the load on the motor and the motor thermal curves. Aside this analysis the
motor thermal protection relay unit “49” will trip the motor with reference to the amount of current
being drawn by the motor

7.2.3 Current Monitoring

The current of the motor is measured and monitored continuously and compared to the motor
specification and other process parameters. The Current is measure by the use of panel ammeters or
clamp-on ammeters. These readings are also fed through EDCIS to DCIS HMI for remote monitoring
via fibre-optics communications to analyse trends. Protection relay incorporated in the LV Breaker
(TESYS) monitors the motor current and trips the unit should abnormal current values be registered.

7.3 Visual and Mechanical Inspection

When a motor start to experience some type of failure it shows off while is still running. It is
important to diagnose it and to determine what has taken place so that it can be repaired. This can
only be done by inspection and is scheduled for half yearly.

7.4 Electrical Test

7.4.1 Insulation Resistance Test

The insulation resistance test measures the resistance of the electrical insulation to ground to
determine the current condition of the insulation. This test is typically performed with a MEGGER or
other brand of mega-ohmmeters. Test voltage is commonly 500 volts. The insulation resistance is
typically in the thousand or tens of thousands of mega-ohms.

7.4.2 Winding Resistance Test

Winding resistance tests on direct current detect loose connections and open-circuited windings.
The winding resistance of motor windings, on both rotors and stators, can be measured with the use
of a digital low-resistance ohmmeter (DLRO) or a Kelvin Bridge. Typically these instruments are
intended to measure very low resistance ranges and are capable of measuring from 0.000001 Ohms
(1 micro Ohm) to 59.99 Ohms. It is important to compare the existing resistance to historical
measurements taken during previous outages. If the resistance has increased compared to previous
tests, it could indicate that a joint or connection has broken or begun to separate. If the resistance
has decreased, then there could be a short between layers of the winding.

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Page 7 of 9
 APPENDIXES

8.0 APPENDIXES
8.1 Appendix-001E: Semi-Annual PM on LV Motors
Task/Procedure
a. On running condition check the motor for any abnormal sound, noise or smell
b. On running condition measure and record the temperature of the motor
c. On running condition measure and record the voltage and ampere
d. On running condition measure and record the vibration
e. Check the crack or damage in casing or base.
f. Check for loose bolts or nuts.
g. Check Motor Grounding connections (Tightly fixed or loose).
h. General cleaning of dust by paint brush if possible when it is necessary
i. For any observation or findings, please initiate work request
j. Carry out housekeeping.
k. Return the unused parts.

8.2 Appendix-002E: Annual PM on LV Motor

Task/procedure
a. On running condition check the motor for any abnormal sound, noise or smell
b. On running condition measure and record the temperature of the motor
c. On running condition measure and record the voltage and ampere

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d. On running condition measure and record the vibration
e. Check for crack or damage in casing or base.
f. Check for Loose bolts or nuts.
g. Check if Rotor movement is free.
h. Retighten the power cable and grounding cable.
i. Carry out the IR test
j. Measure the resistance and insulation resistance of the space heater
k. General cleaning from dust and extra grease using service air, and non- flammable
cleaning solvents
l. Carry out housekeeping.
m. Return the unused parts.

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