Because 30% of motor failures are caused by overloading, it is important to understand how to measure for and identify motor overloading. Every robust PM program will includekeyperformance indicatorsso you can measure success and make improvements. Each harmonic has a different acceptable level of distortion, which is defined by standards such as IEEE 519-1992. Of that 48 percent, 12 percent can be attributed to rotor problems and 36 percent to winding problems. A root cause failure analysis can be relatively quick and informal. Reactive and preventive maintenance will always have a part in your operations. Document operating condition, machine specifications and performance tolerance ranges. Winding Failures. A newly installed valve or another component, An object striking, bending, or simply pressing on a pipe, Broken or lack-of pipe hangers or wall-mounting hardware. The most common example of this is in simple motor/pump combinations, where something applies force to the pipe works such as: Those forces can put an angular or offset force on the pump, which in turn causes the motor/pump shaft to be misaligned. We wrap it up by looking at the bigger picture, including how to perform a root cause failure analysis and prevent motor failures in the future. Know the breakpoints at which youre willing to repair vs. replace. c) moisture It treats the underlying condition that created the situation in the first place. Prescriptive maintenance is the next big step forward in the evolution of asset management, Read More Moving toward smart maintenance with prescriptive analyticsContinue, Read More As solar production rises, remote monitoring can improve efficiencyContinue, Dave OReilly, VP of Commercial, Fluke Corporation, offers a sneak peek of our upcoming webinar, Read More Why you should integrate your dataContinue. Vibration and alignment tools are the best technology for diagnosing mechanical faults in rotating machines. , as well as help you put together your motor purchase and repair policies. You remove the end bell, and the entire winding can be examined. Once the underlying causes are identified and understood, implementing preventive maintenance procedures through diagnostics testing is the best way to help remedy electric motor winding failures. From live engineering support to technical training and resources, EASA offers the solutions you need to elevate your business! Infrared imagers are the best technology for finding electrical hot spots in switchgear and motor controllers, for the screening process and mechanical assets. Yes, itll require some upfront work. Polarization index (PI) testing takes a ratio of the winding insulation resistance after 1 minute and 10 minutes to tell you how well the motor is functioning. With the motor running, you can perform dynamic testing to identify issues with temperature, balance and distortion. And fifth, use your motor shop to help you implement best practices for motor replacement, repair, storage and maintenance at your plant. Hot Surface Ignition System (HSI) controls lockout after how many unsuccessful attempts? It can also be a process that takes several months and proceeds systematically through all six steps, perhaps with external support from a consultant or experienced motor shop. Electrical failures disrupt the power supply to the motor. That way, action can be taken before its too late. (a) 1-Methylcyclohexene or 3-methylcyclohexene (b) Isopropenylcyclopentane or allylcyclopentane (c) Bicyclo[4.2.0]oct-7-ene or Bicyclo[4.2.0]oct-3-ene (d) (Z)-Cyclononene or (E)-cyclononene (e) (Z)-Cyclooctadecene or (E)-cyclooctadecene. Sounds simple. PM has been shown to reduce downtime by as much as 50%. Pipe strain refers to the condition in which new stresses, strains, and forces, acting on the rest of the equipment and infrastructure transfer backward onto the motor and drive to induce a misalignment condition. It can also detect the presence of dirt or moisture. When motor shaft voltages exceed the insulating capability of the bearing grease, flashover currents to the outer bearing will occur, thereby causing pitting and grooving to the bearing races. Performance & security by Cloudflare. Youll notice there are no solutions or implementation sections. And so on. A simple motor failure decision tree can form the foundation of a plants motor failure policy. Troubleshooting motor failure signs to look for, Storing motor in a location without adequate climate control, Corrosion of motor shaft, bearings and rotor, Leakage current from the armature windings (DC motors). Before diagnosing the problem as a failed compressor, always allow the motor protector time to reset, usually until the upper housing is within 5F of ambient temperature (this can vary by unit); Larger blower wheels are typically operated by ___________ motors. The most common types of single phase compressor motors are: Permanent split capacitor (PSC), capacitor start (CS), capacitor start/capacitor run (CSCR), and split phase, Motors with shunted field windings: This includes single-phased winding failures (wye- or delta-connected) caused by an opening from a blown fuse, open contactor, broken power line or bad connection. a. Its up to the maintenance or operations team to interpret it based on baseline information about the equipment and understanding of what a particular test can tell us (and what it cant). A simple way to do a root cause failure analysis is using the 5 Whys technique. The purpose of this section is to give information to those who might not be familiar with your particular equipment or processes, including management and the motor shop. Terms and ConditionsCopyright 2016-2021 Duke Electric. Instead, rely on the U.S. Department of Energy, whose, opens with this zinger: The most important thing a smart shopper can do is to carefully select a competent and reputable service center". Heinz Bloch, an international expert who has written 23 books on machinery maintenance and reliability, says that a failure report doesnt need to be rigidly formatted to help you understand what really happened. How many years of experience do they have? VIEW THE LISTLEARN MORE ABOUT THE PROGRAM, REGISTRATION OPTIONS & PRICINGSCHEDULE OF EVENTS. How long will it take to get the motor repaired? near the wall? When a motor goes down, someone has to be told. But it wont help you prevent it in the future. Reserve Your RoomSave your spot at EASA's official 2023 hotel - the Gaylord National Resport & Convention Center. This section is where you give the evidence for the cause of the failure. A method of measuring voltage across each component moving toward the malfunctioning load is called: The resistance of an AC magnetic device will have ________ resistance than Ohm's law predicts. famously compiled survey data and identified the five most common causes of electric motor failure, which can be linked to stresses related to normal operation as well as flukes. An open internal motor overload is distinguished by: The RPM of a belt driven blower can be determined by: Multiplying motor RPM and motor sheave diameter and then divide by the fan sheave diameter, When checking the resistance of a dual voltage wye motor, there should be ______ resistance readings. Which failure could cause nothing to happen when the thermostat is set to heat? c) 1/64th inch deflection per 1 inch span between drive shaft and driven shaft Instead of answering a bunch of questions from the motor shopwhich may require digging up information or recalling events from days or weeks agoyou hand the guys a report. Instead, rely on the U.S. Department of Energy, whose Service Center Evaluation Guide opens with this zinger: The most important thing a smart shopper can do is to carefully select a competent and reputable service center". Sales professionals need to keep their skills sharp in order to discover new leads, nurture promising prospects and close more deals. It adducts the humerus. Butdont screw it up. A. Bonnett and C. Yung famously compiled survey data and identified the five most common causes of electric motor failure, which can be linked to stresses related to normal operation as well as flukes. Whilevibration analysiscan be used to test critical motors for imbalance, misalignment, mechanical looseness, a bent shaft, critical speeds and more, its particularly helpful with identifying bearing problems. Maintenance teams can cost-effectively implement this technology platform to address their needs with ease. Other tests includeinsulation resistance testing(ensuring the insulation resistance of the motor decreases after it starts),DC step voltage testing(plotting the current that results from increasing the voltage applied to the insulation to look for a non-linear graph),HiPot testing(looking for leakage current as a way of establishing the effectiveness of insulation). D) After the draft switch closes to prove the draft. Shaft failure is the least common cause of motor failure. That doesnt mean humans are off the hook, however. But anyone in the biz knows that behind that question is a whole lot of hemming and hawing, made worse by pressure cooker environments and a lack of information. Should we repair the motor or replace it? These winding failures fall into four major categories related to what causes them: thermal stress, mechanical stress, electrical stress, and environmental stress. Fourth, move from reactive maintenance to preventive and predictive maintenance to catch problems early and extend the life of your assets. Create an archive reference of measurements to facilitate trend analysis and identify change of state conditions. But anyone in the biz knows that behind that question is a whole lot of hemming and hawing, made worse by pressure cooker environments and a lack of information. Potential relays measure the back ______ developed across the _______ winding to operate the relay. For example, your plant may decide to repair an off-the-shelf motor if the repair costs less than 60% of a new premium high efficiency motor. The sign to look for is a resistance reading that is different from the manufacturers stated resistance for the winding. Re-state what you felt caused the failure. Fluke Reliability helps you find the best solutions for your electric motor problems. Its important to remember that the causes of motor and drive issues are not confined to a single domain of expertiseboth mechanical and electrical issues can lead to motor failureand being armed with the right knowledge can mean the difference between costly downtime and improved asset uptime. Second, formalize your documentation and reporting so its easy to get all the information about a particular motor to the people that need it. An open winding falls into which general motor failure area? Improve Predictive Maintenance With Thermal Monitoring, Quick Start: Fluke Connect Handheld Tools, Quick Start: Fluke 1742/1746/1748 Three-Phase Power Quality Loggers, causes of electric motor winding failures, Computerized Maintenance Management System (CMMS). Many plants are taking preventive maintenance a step further using condition monitoring and other tools to look for signs of future motor failure. When you suspect an issue with your electric motor winding, there are three categories of measurements to help identify the likely source of failureselectrical, mechanical, and thermal. Special rates good through June 1. What term expresses the ability of the motor to work beyond its rated output? The suction pressure on a split AC system that is running with an excessive evaporator heat load: The manufacturer's data on a split AC system indicates that the normal temperature drop should be 15F at the current operating conditions. It can be helpful to put your motor management program together in partnership with a trusted motor repair shop. Consider the size, age, type and application of your motor. Open motor winding failures can be identified by: A) Zero resistance reading B) Infinite resistance reading C) Measurable resistance reading D) All of the above B) Infinite resistance reading Motor starting components can be made up of: A) Starting and running capacitors only B) Internal and external centrifugal switches only Any of these, if present in enough concentration on the windings, can lead to an early failure. To keep operations running smoothly, implementing preventive maintenance programs leads to a predictive and prescriptive maintenance future. The root cause methodology starts with the failed component, then follows a step-by-step process to understand the stresses that caused the component to fail. Mark your calendars for FM Ireland and stop by Stand D10 to learn about the Accelix ecosystem of maintenance and reliability solutions. Thermal deterioration of insulation in one phase of the stator winding. Having a motor failure policy will help your team make proactive decisions, including procuring services and equipment ahead of time. The motor and insulation tester assure safe operation, prolongs the life of electrical systems and motors. The benefits of detecting, identifying, and evaluating electric motor abnormalities are decreased motor failures and less unexpected downtime. 1 in 10 failures are mysterious. Your motor shop can help you. If they can't, lubricate them. Here are some of the more common motor tests to perform regularly as part of your early warning system. Fundamentals of DC Operation & Repair Tips, Mechanical Repair Fundamentals of Electric Motors, 2nd Edition, Pump Curves/Applications: Installation & Troubleshooting, Summary of Vertical Pump and Motor Mechanical Repair, Vibration Analysis & Balancing for Service Centers, Online Sales Training Program (Video Series), Request Letter of Invitation for U.S. Visa, Getting the Most from Your Electric Motors. Please include what you were doing when this page came up and the Cloudflare Ray ID found at the bottom of this page. Your IP: Note:A one-percent voltage unbalance may result in a six- to ten-percent current unbalance. Leveraging these tools offers facilities the greatest flexibility and power to manage the health of electric motor windings. The rotor is sometimes called an armature. Abnormally low resistance in the electric motor can be a sign of shorted to ground winding failure. This will help you identify patterns with a particular asset and make warranties easy to manage. How is the subcooling of an air-conditioning system affected by a low refrigerant charge? How static motor testing can support preventative maintenance programmes. The machines provide the data. Motor failure doesnt have to be a fact of life if you take this guides five key messages to heart. Variable frequency drives employ a pulse width modulation (PWM) technique to control the output voltage and frequency to a motor. Imbalance is a condition of a rotating part where the center of mass does not lie on the axis of rotation. Potential faults may be in the cabling to the motor, the terminations at the motor, and potentially the windings themselves. This guide is intended to help you identify the most common types of bearing failures and know how to prevent them from becoming an unnecessary maintenance expense. Your motor shop can help you identify critical assets,establish an online motor database, and store and maintain your spares, as well as help you put together your motor purchase and repair policies. How efficient is the motor that failed? A) Setting the thermostat below room temperature. This space between the rotor and stator is sized specifically to ensure proper interaction between magnetic fields and optimal performance of the motor. A common cause of an open winding is undersized lead lugs. The Effect of Repair/Rewinding on Premium Efficiency/IE3 Motors. When replacing fuses be sure to match which of these ratings? Whats the shops inventory of parts and materials for repairs? EASA's new streaming sales videos provide relevant and insightful training. Why. If the phase angle or current frequency responses are out of balance by more than 2 units from average, this may indicate winding shorts. Even if theres still some life left in the motor, youll want to ensure you have a good stator before rewinding. Connected tools and sensors offer all key stakeholders with access to the data they need. Normally, a split AC system that uses a fixed metering device can safely operate at temperatures: The first electrical checks of a system that is not operating generally involve: C) Checking the power circuit to the equipment. For this reason, it is important to check machine alignment more than just at the time of installationprecision alignment is a temporary condition that can change over time. This is another biggie. And those issues will have another cause. Electric motors serve as a critical component for any facility. Is it well suited for the application, or is it time to spec a new motor that can better accomplish what your process demands? Things to look for during an inspection of your motor include: Signs of corrosion, dirt or debris on components, including fins, windings, contacts and relay, A burning smell that may indicate overheating, Signs of wear on the commutator and brush assembly, Anything unusual with the motor mount, stator, rotor and belts, Dirt buildup, inadequate lubrication and signs of wear on bearings, A bearing housing thats hot to the touch, Loose connections, including in the starter switch and fuses\. Physical damage, corrosion, improper installation and excessive loads are often the root cause. Bearing failure is an expensive problem both in terms of motor repair and downtime, so helping to prevent this by measuring shaft voltage and bearing current is an important diagnostic step. To get there, you have to understand the underlying causes of motor failures. When the liquid line is restricted, the supply of refrigerant to the metering device is reduced. Winding shorted phase-to-phase This type of insulation failure is typically caused by contaminants, abrasion, vibration or voltage surge. Most rotors have conductors that carry currents and interact with the magnetic field created by the stator. Another common fault stems from mechanical rubs, which can be the result of looseness of the motor shaft and/or the motor bearings. an all-in-one tool for measuring volts, ohms and amps, an ohmmeter used to assess the insulation on wires and windings, measures the current in a circuit without having to de-energize the system, like a radar gun for taking a motors temperature, takes the digital multimeter to the next level (including price tag) by adding the ability to assess power quality. On the axis of rotation Stand D10 to learn ABOUT the program, REGISTRATION OPTIONS & PRICINGSCHEDULE EVENTS. Extend the life of electrical systems and motors theres still some life left in the future 48 percent, percent... 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Tree can form the foundation of a plants motor failure will always have a part in your.... Needs with ease different from the manufacturers stated resistance for the cause of failures... To work beyond its rated output Surface Ignition system ( HSI ) controls lockout after many. Finding electrical hot spots in switchgear and motor controllers, for the winding current unbalance motor be... Purchase and repair policies decision tree can form the foundation of a rotating part where the Center mass! Systems and motors fluke Reliability helps you find the best technology for finding electrical hot spots in switchgear and controllers. Goes down, someone has to be a fact of life if you take guides! One-Percent voltage unbalance may result in a six- to ten-percent current unbalance will help identify. And sensors offer all key stakeholders with access to the metering device is reduced evaluating electric motor abnormalities are motor. 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Programs leads to a motor failure decision tree can form the foundation of a rotating part the.
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