Care and Maintenance of

Electric Motors

Define Electric Motor

A

device that converts

electrical energy into
rotational or linear motion
The electric motor is one
type of prime mover in a
mechanical system

Common Motor
Applications Include

Pumps
Fans
Conveyors
Extruders
Agitators
Crushers
Mills
Grinders
Elevators
Many, many more.

Electric Motors

Some Energy approximate facts:

Electric motors make up the largest end use of
electricity in the United States
60 % of electrical consumption in Industrial Plants
70 % of electrical consumption in Process
Industries
Motor Systems 60-70% of total electricity used in
any Industrial Facility
25 % of total electricity sales in the U.S.

Electric Motors

The

annual energy cost to

run a 100 HP Electric Motor
continuously for 1 year is
approximately - $ 30,000 at .
05 KWH.

Electric Motors
Care and Maintenance

Why and when invest resources to

maintain Electric Motors ?
What strategies can be
implemented?
What have other motor users done to
maintain their motors
What support resources and tools
are available ?

Types of Electric Motors

AC Induction Motors
DC Motors and Generators
Synchronous
Wound Rotor
Single Phase
Permanent Magnet AC - New

AC Induction Nema
Frame

Large AC Induction Motor

5500 HP 6600 volt

AC Induction Nema
Frame
Nema Frames 145T 449T
Low voltage, 3 Phase/ up to 600 volts
1-250 Hp
900, 1200,1800, and 3600 rpm
ODP, TEFC, TENV, TEBC
Ball or roller bearings
All mounting positions

Synchronous Motor

Synchronous

A synchronous motor is an ac motor in which the

rotor revolves in step or in synchronism with the
rotating magnetic field produced by the stator
winding. . This action means that if the magnetic
field of a 60-cycle, four-pole motor revolves at the
rate of 1,800 rpm, the rotor will also turn at that
speed.

Synchronous

Larger Ratings 500 10,000 Hp

Usually Medium Voltage 2300/ 4160 volt
Often slower speeds 164 3600 rpm
Often sleeve bearing
Typically open frame designs

Wound Rotor

Wound Rotor

THREE-PHASE WOUND-ROTOR
The three-phase wound-rotor motor ranges in size
from fractional to hundreds of horsepower. They
are designed for variable speed operation, and
accelerating large inertia loads. Typical use for this
type of motor would be pumps, cranes, conveyors,
and large air compressors.

Single Phase

AC Permanent Magnet

Electric Motor
Nomenclature
Motor Frame
Induction Rotor
Motor End Bracket
Motor Bearings
Stator Winding
Fan Cover
Conduit Box

2
2

AC Motor Nameplate
Phas
e

Fram
e
Temperat
ure

Frequen
cy
Horse
Power
RPM
Volta
ge
Amp
s

Motor Enemies

Heat
Time
Power Supply Issues
Humidity
Improper Lubrication
Unusual Mechanical Loads

Leading causes of
Motor Failures
Bearings
Stator Winding
External
Unknown
Rotor Bar
Shaft/Coupling

51%
16%
16%
10%
5%
2%

Common Causes For Motor

Failures

Failure distribution statistics, like these

from IEEE Petro-Chemical Paper PCIC94-01, are helpful, but still necessary to
conduct a thorough root cause analysis
when determining modes of failure.

Focus on greatest
opportunity to Improve

Bearings 51% of motor failures

The largest percentage of these
failures will be in Nema Frame
Motors
The largest percentage of motors in
most plants will be Nema Frame
Motors

Factory Lubed

Factory lubed ball bearing

Factory Lube in housing

Typical lube after time

Contaminated Lube

Lack of lube

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Bearing Failures in
Motors

Practical Maintenance
Practice ?

Develop predictive and preventative

plans to maximize motor reliability
and to minimize major motor repairs
Thats easily said, however defining
what that is will differ based on type
of plant, operating philosophy,
applications, environment, etc.

Practical Maintenance
Practice ?

There are volumes of information,

technical papers, publications, guidelines,
and typical plans available
EPRI Electric Motor Tiered Maintenance Program
EASA- Recommended Practice for Repair of
Rotating Apparatus
Electric Motors- Care and Maintenance Exxon
Mobil Corp.
IEEE Electric Motor Predictive and Maintenance
Guide

So what is practical ?

The ideal plan would cost nothing,

and motors would never fail

Mobile Recommendation

4 Part Improvement Plan to include:

Implement a Rebuild and New Motor
Specification Guide
Implement a Motor Acceptance test for
all new and rebuilt motors
Implement a Motor storage program
Implement a Tiered Maintenance
Strategy for your motor population

Motor Specification
Guide

New Motors
Rebuilt Motors

Electric Motor
Specifications - New

Inpro/seal on Drive end Only 25 HP & Above.

Oversized J-Box per specifications.
Blue Chip Quality. 100% cast iron construction for rigidity and reduced
vibration.
Internal and external epoxy paint.
MAX GUARD insulation system
1.15 Service Factor.
Extended grease tubes, regreasable in service.
Brass drain and breather
Meets IEEE45 USCG Marine Duty IP54 Construction.
Actual test and vibration data supplied with each motor
CSA Certified
Division 2 CSA certification nameplate, for hazardous locations, Class I
Groups A, B, C, and D.
Temperature code T2B
Three Year warranty.

Electric Motor
Acceptance Test
All motors for a plant should go
through an acceptance test prior to
be put into service or storage
The purpose would be to insure:
1. Not damaged during shipping and
handling
2. No obvious manufacturing defects
3. Motor has been repaired properly

Acceptance test may

include:
Incoming
Electrical

visual inspection
Megger PDMA

Mechanical

Vibration Test

Required to perform
acceptance tests

An appropriate test area:

Power supply to run motors at
rated voltage 460 volt. 2300/4160
volt, 500 volts DC
Test bed isolated from ambient
vibration to mount horizontal and
vertical motors
Qualified personnel

Required to perform
acceptance test
A

complete testing facility is

typically not practical in
most industrial plants and
environments

So

what can you do ?

Back to Specifications

Adopt a specification for the

purchase of new electric motors
Only allow purchases from
Manufactures that meet or exceed
your specification
Require a final test document for
each motor that includes actual
vibration data and electrical test
results

Back to Specifications

Develop a specification for the repair of electric

motors
Closely evaluate and only utilize Motor Repair
Service Centers that meet your requirements
Require repair and test reports indicating scope of
repair, failure analysis, recommendations, and
complete test data
Electrical final tests
No load vibration and rotor balance data
Mechanical fits and shaft run out
Sleeve bearing clearance and end play

Evaluate Repair Providers

Make a point to spend time evaluating each

potential providers service center
Look for indicators of a quality control
program, such as evidence of participation in
an ISO 9000 program, membership in EASA, &
participation in EASAQ program.
Inquire about staff morale, training, turnover,
etc.
Determine whether the service center has
sufficient facilities & materials to handle the
size & type of motors you send them.

Evaluate Repair Providers

Note what test equipment the service center owns and

routinely uses to verify successful repair. Examples:
Core loss tester
Surge comparison tester
Voltage regulated power supply for
running at rated voltage
Vibration testing equipment
Ask to see record-keeping system that the service center
maintains for repaired motors
Inquire about method of insulation removal, burnoff,
mechanical pulling, etc.
For burn off, ask about methods for preventing flames
or hotspots & ensuring uniform temperature when
roasting multiple motors
Take note of the overall cleanliness of the service center

Evaluate Repair
Providers

Become better informed about motor repair and

maintenance
Prequalify and select a quality electric motor repair
facility before you need it
Aquire or write a set of motor rebuilding standards
Establish a spare motor inventory system
Request a completed motor repair report of each
repaired motor
Test new and rebuilt motor when they are received at
your plant
Maintain communication system and relationship with
your repair shop

Repair Warranty Rate

Electric Motor Storage

Guidelines
Pick

a location:

Clean and dry area indoors if possible

Avoid heat, humidity, and vibration
Store in position for the intended usehorizontal horizontal and vertical vertical

Electric Motor Storage

Guidelines
Outdoor

motors:

storage of large

Cover allow for breathing at the

bottom
Energize space heaters if they
exist 1020 degrees F > ambient
Prevent rodents, snakes, birds, and
small animals from nesting inside

Electric Motor Storage

Guidelines

Apply rust preventative coating to

shaft and other exposed machine
surfaces
Bearing damage is possible in
storage avoid humidity and
vibration
False brinelling of ball and race
Fretting from corrosion

Electric Motor Storage

Guidelines
Recommend

to rotate shafts
at regular intervals
Monthly
Redistributes lubrication to
prevent corrosion
Minimize brinelling by relocating
the balls within the races

Electric Motor Storage

Guidelines
Tip

Leave all keyways the same, and in a

different position each time
This provides an easy visual indication

Electric Motor Storage

Guidelines
Periodic shaft rotation is more
critical on:
Larger 2 pole (3600 rpm) machines
Machines with long shafts and
heavy rotors
Critical to avoid shaft distortion
due to rotor sag

Electric Motor Storage

Guidelines
Oil

Lubed Bearings

These motors are always shipped without oil

Fill to capacity as soon as set into

storage

Do not move motor with oil in the reservoirs

Drain it Move it Refill it

Tiered Maintenance

Define motor population

Apply appropriate maintenance and
predictive tools according to
criticality, safety significance , and
economic significance of each motor

Categorize level of
Maintence
Minimum

Maintenance
Moderate Maintenance
Trendable Maintenance
Extensive Maintenance

Minimum Maintenance
Category

Non-critical motors less than 50 HP

Motors having low safety and
economic significance
Motors not of special design and
normally readily available
Unexpected failures are tolerable
Typically not repaired, but replaced
with new

Moderate Maintenance
Category

Motors that may run to electrical

failure, but not mechanical failure
Maintenance may focus on the
mechanical health of the motor

Trendable Maintenance
Category
Mid

sized low and medium

voltage motors
50 -200 Hp 460 volt
200 1000 Hp 2300/4160
volt
Larger DC motors - > 50 hp

Extensive Maintenance
Category

Mission Critical Motors

Require comprehensive electrical
and mechanical monitoring
Usually the larger and medium
voltage motors
Motors that have highest safety and
economic significance

Testing Motor Windings

Motor Winding Failures

Grounded winding
Turn to turn short
Single phased condition
Roasted winding due to overload
Locked rotor condition
Shorted connection
Winding damaged by voltage surge
23

Tests for Winding

Condition

Insulation Resistance megger test

Spot Check and Trendable
Indicates condition between the
conductors and ground
Low readings indicate moisture, dirt, or
damaged insulation
Minimum 1 meg ohm/1000 volts
23

Tests for Winding

Condition
Polarization

Index

Further indicates condition between the

conductors and ground
Its the ratio of 10 min/1 min reading
A PI > 2 or 1 min reading > 5 giga ohms
indicates motor is suitable for service
PI > 7 could indicate brittle or aged insulation
PI can also help determine if a winding is wet or
contaminated

23

Tests for Winding

Condition
DC

Hipot

DC test voltage is applied to entire winding to

verify the insulation to ground
[ (2 x nameplate volts + 1000) x 1.7 x .60
Common on motors rated 4000 volts and higher
Done on low voltage motors to verify that its
safe to perform a surge comparison test

23

Tests for Winding

Condition
Surge

Comparison Test

Normally not performed in the

field
Indicates presence of phase to
phase and turn to turn shorts
within a winding
23

Tests for Winding

Condition
Rotor

Current Analysis

Indicates the presence of

cracked and broken rotor bars
or voids in cast rotors
These could be the cause for
vibration especially under load
23

Electric Motor
Lubrication

According to EASA the motor

component with the highest failure
rate is the bearing.
51% of all motor failures are due a
bearing failure.
Bearing lubrication is one of the
many aspects of motor care and one
of major importance to the life of a
motor.

Preventive/Predictive
Maintenance

The establishment of an effective

predictive maintenance system will
significantly affect the life of a motor.
Lubricating bearings at arbitrary
intervals can result in bearings that
are under lubricated or over lubricated.
Either of these conditions can reduce
the expected life of a bearing.

Is this enough grease ?

Unique Lubrication Coating

Moisture in Lubricant

Moisture in Grease

Bearing Protection

Shaft slinger
Inpro/Seal Bearing Isolator

Bearing Types

Motor bearings are manufactured in

various types of configurations.
Shielded (2Z), shielded bearings have
a metallic shield on both sides of the
bearing that is open on the ID or
inner race side.
Single Shield (1Z), same as above
except one side of the bearing is
open.

Bearing Types

Sealed (2RS) sealed bearings have a

seal arrangement on both sides of
the bearing that will not allow any
contaminants to enter the bearing.
These bearings are lubricated at the
factory and do not require any
additional grease.
Single Seal (RS) same as above, but
sealed on one side only.

Determining Frequency
of Lubrication

1.
2.
3.
4.
5.
6.

Determining what frequency at which a

particular bearing needs to be
lubricated requires consideration of
many criteria.
Type of grease
Type of bearing
Motor operating temperature
Motor speed
Environmental conditions
Duty Cycle

Lubricant Compatibility

If two lubricants that are

incompatible are mixed they will lose
their lubrication ability.
If in doubt check with your motor
manufacturer or lubrication supplier.
The majority of motor manufacturers
use a polyurea based grease that
meets EP-2 standards such as Mobil
Polyrex-EM

Motor Operating
Temperature

Motors that operate in elevated

ambient temperatures need to be
lubricated more frequently.
Motors operating in a temperature
controlled environment can be
lubricated less frequently.

Motor Speed

Motors operating at 3600 RPM need

to be lubricated more frequently.
Motors operating at 900 RPM need to
be lubricated less frequently.
Roller bearings require more
frequent lubrication than ball
bearings.

Environmental
Conditions

Motors operating in a cement plant

need to be lubricated more
frequently.
Motors operating in a clean room
need to be lubricated less frequently.

Duty Cycle

Motors operating 24/7 need to be

lubricated more frequently.
Motors operating 8 hours/day 5
days/week need to be lubricated less
frequently.

Bearing Size

The size of a particular bearing will

determine the amount of lubricant
the bearing needs.
Most motor manufacturers provide
instruction manuals detailing the
correct procedures and the amount
of lubricant required to re-lubricate a
bearing.

Amount of Lubricant
6200 Series
Bearing

Deep Groove
Ball Bearings
6200 Series

Size

Ounces

Strokes

6204

0.10

6205

0.12

6206

0.15

6207

0.19

6208

0.23

6209

0.25

6210

0.28

6211

0.33

11

6212

0.38

13

6213

0.43

14

6214

0.47

16

6215

0.50

17

6216

0.55

18

6217

0.65

21

6218

0.74

24

6219

0.84

28

6220

0.95

31

Amount of Lubricant
6300 Series
Bearing

Deep Groove
Ball Bearings
6300 Series

Size

Ounces

Strokes

6304

0.12

6305

0.16

6306

0.21

6307

0.26

6308

0.32

11

6309

0.39

13

6310

0.46

15

6311

0.54

18

6312

0.63

21

6313

0.72

24

6314

0.81

27

6315

0.92

30

6316

1.03

34

6317

1.14

38

6318

1.26

42

6319

1.40

46

6320

1.57

52

Amount of Lubricant
200 Series
Bearing

Cylindrical Roller
Bearings
200 Series

Size

Ounces

Strokes

204

0.10

205

0.12

206

0.15

207

0.19

208

0.23

209

0.25

210

0.28

211

0.33

11

212

0.38

13

213

0.43

14

214

0.47

16

215

0.50

17

216

0.55

18

217

0.65

21

218

0.74

24

219

0.84

28

220

0.95

31

Amount of Lubricant
300 Series
Bearing

Cylindrical Roller
Bearings
300 Series

Size

Ounces

Strokes

304

0.12

305

0.16

306

0.21

307

0.26

308

0.32

11

309

0.39

13

310

0.46

15

311

0.54

18

312

0.63

21

313

0.72

24

314

0.81

27

315

0.92

30

316

1.03

34

317

1.14

38

318

1.26

42

319

1.40

46

320

1.57

52

Lubricant Storage

Lubricants need to be stored

properly to avoid contamination.
Keep lubricants stored in a storage
locker if possible.
Keep lids on oil drums, grease
containers etc. to avoid
contamination.

Priority Equipment

Some equipment is vital to the

operation of your facility.
Some equipment can be replaced for
a minimal amount of cost.
It is not economical to spend
$100/month lubricating a $300 motor.

Vibration Analysis

Vibration analysis can be used as a tool

to determine when a particular bearing
requires lubrication.
A baseline vibration reading should be
taken shortly after a motor is put into
service.
Subsequent vibration readings can be
compared to the base line to determine
the need for additional lubrication.

Conclusion

Proper care and maintenance of the

motor and its bearings, can
significantly increase the life of the
motor,increase productivity, reduce
costs and improve profits.

Take care of your bearings

and theyll take care of you!

Thats all
folks

Questions ?

Thank you !!