Motor Maintenance

Mentors:- Ashwani Kumar Mishra

Mr. Vipul Modi G.E.T (Electrical)
Mr. Vishal Kumar Petronet LNG Ltd
90170
 Objectives Of This Presentation

 What is Motor and its basic concept?

 Identifying and studying important parts of any LT and HT
motor which need regular maintenance.
 Get to know different stages in motor maintenance.
 Studying the activities which are performed under motor
PM in our plant.
 Major job carried out as part of motor PM in our plant.

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 What is Motor?
 An electric motor is an electrical machine having both moving (rotor) and stationary parts
(stator) and which converts electrical energy into mechanical energy.

 It works on the principle of Electromagnetic Induction.

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How does a 3-ph Induction Motor starts?

Fleming’s
Right Hand
Rule

 When a 3-ph balanced voltage is applied on the stator of a 3-ph Induction Motor, Rotating Magnetic Field is setup in the stator
windings.
 The stationary rotor cuts this revolving magnetic field of the applied voltage and due to electromagnetic induction, an emf is
induced in the rotor conductor.
 As the rotor conductors are short-circuited through end rings (form closed circuit), current is induced in the rotor conductors.
 Now the rotor becomes a current carrying conductor placed in a magnetic field. So, a force is developed on the rotor.
 Since the magnetic field force is tangential to the rotor surface, an Electromagnetic Torque (Rotating force) is developed.
 Any mechanical load connected to the rotor has its own Load Torque due to its inertia.
 The rotor will start rotating when the developed electromagnetic torque overcomes the load torque in a particular direction.

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Squirrel-Cage
Induction Rotor
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 Ratings of HT & LT motors (major loads) of Ph-I & Ph-II
Sr.No. Motors Rating

1 HP Pumps P-104A/B/C/D/E, P-105A/B/C/D/E 1500kW, Y-6.6kV, 2985rpm, 0.9pf, ɳ=87%

2 BOG Compressor C-101A/B/C 1270kW, Y-6.6kV, 495rpm, 0.79pf

3 Fire Water Pump P1001-A/B 600kW, Y-6.6kV, 1483rpm, 0.86pf, ɳ=95%

4 SCV Blower E-106A/B, E-107A/B 295kW, Y-6.6kV, 2980rpm, 0.9pf, ɳ=95.8%

5 LP Pumps P-101A/B/C, P-102A/B/C, P-103A/B/C, P-106A/B/C 220kW, Y-6.6kV, 2985rpm, 0.86pf, ɳ=86%
Glycol Water Pump P-301A/B/C/D/E/F/G 150kW, ∆-415V, 985rpm, ɳ=94.5%
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P-302A/B/C/D/E/F/G 160kW, ∆-415V, 1485rpm, ɳ=95%

7 Air Compressor U-703A/B 145kW, ∆-415V, 2985rpm, 0.9pf

8 Hot Water Pump P-303A/B 132kW, ∆-415V, 2975rpm

9 Jockey Pump P-1003A/B 90kW, ∆-415V, 2970rpm, ɳ=94%

10 Ph-2 GW E-109 Loop P-306A/B, P-307A/B 45kW, ∆-415V, 2965rpm, 0.8pf, ɳ=92.5%

11 Air Heater Fans E-301 to 316 & E-321 to E-336 (A, B, C, D, E, F, G) 22kW, ∆-415V, 980rpm, ɳ=92%

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 Ratings of HT & LT motors (major loads) of Ph-IIlA

Sr.No. Motors Rating

1 HP Pumps P-110A/B/C/D/E 1615kW, Y-6.6kV, 0.89pf, ɳ=95.2%

2 BOG Compressor C-101D/E/F 1150kW, Y-6.6kV, 372rpm, 0.75pf, ɳ=95%

3 SCV Blower E-111A 600kW, Y-6.6kV, 2965rpm, 0.92pf, ɳ=95%

4 Glycol Water Pump P-332A/B/C/D 350kW, Y-6.6kV, 740rpm, 0.78pf, ɳ=93.6%

5 LP Pumps P-108A/B/C, P-109A/B/C 250kW, Y-6.6kV, 3000rpm

6 Air Compressor U-703C/D 102kW, ∆-415V, 2842rpm

7 Air Heater Fans E-341 to 368 (A, B, C, D) 22kW, ∆-415V, 975rpm, 0.83pf, ɳ=91.7%

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Motor Nameplate Details
 Manufacturer’s Name & Address
 Frame Size
 Rated Voltage (V) (Y or ∆)
 Rated full-load current (FLC)
 Full Load Efficiency (EFF(FL))
 Power Factor (cosø)
 Frequency (Hz)
 Phase (3~ or 1~)
 Rated full-load speed (RPM)
 Insulation Class (INS. CL)
 Ingress Protection (IP)
 Temperature Class (T)
 Rated Ambient Temperature (AMB)
 Rated Horsepower (kW(HP))
 Time Rating (Duty)
 Bearing Number (DE & NDE)

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 Auto-Ignition Temperature

Ex
Description Location Use
Code

Equipment construction is such that it can withstand an internal explosion and provide
relief of the external pressure via flamegaps. The escaping gases (hot) must sufficiently Motors & Lighting JBs,
d Zone 1
cool down along the escape path that by the time they reach the outside of the Electronics
enclosure not to be a source of ignition of the outside.

e Equipment is very robust and components are made to a high quality Zone 2 or 1 Motors & Lighting JBs,

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IP Rating
 These standards are used to define the level of sealing
effectiveness of electrical enclosures against intrusion from
foreign bodies such as dirt and water.
 Rating consist of letters IP followed by two digits, first digit
stands for level of protection against solid bodies, second
digit describes the degree of protection of equipment inside
the enclosure against water.

Time Rating

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PM is done of :-
 Motor Canopy
 Motor Body Earthing
 Greasing Nipple
 Bearing Cover Plate (both DE & NDE side)
 Motor Terminal Box
 Motor Winding Condition (IR & winding resistance is taken)
 TB Gasket condition
 Space Heater Terminal Box
 Cooling Fan Cover
 Cooling Fan
 (IJB) Intermediate Junction Box (if present)
 (LCS) Local Control Station
 Respective Feeder (both Power & Control chamber).
 Respective Circuit Breaker at s/s bldg.

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 Steps In Motor Maintenance
 PM Request
Lockout requested by the concerned Dept. Officer and issue of work permit.
 Lock-Out Tag-Out
CB/SFU lockout and tagout at respective MCC/PMCC or 6.6kV panel at s/s building.
 Approval/Signatures
Signature of maintenance officer, maintenance technician, electrical shift-incharge, safety
officer, plant shift-incharge and field-operator on the permit.
 Cross-check
Cross-checking of motor tag number. and permit number by the concerned electrical
officer/technician at the s/s as well as on the field.
 Earthing
Discharging of power cables with electrical discharging rod from the feeder end.

 Initial megger reading from the feeder end.

 PM activity on the respective motor at the field.
 PM activity on the respective circuit breaker at s/s building.
 Final megger reading and other measurements at the feeder end.

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 Basic Precautions To Be Taken Before
Doing Motor PM:-

 Before carrying out the job, work permit must be obtained.

 Ensure that the respective LT/HT circuit breaker or SFU (in MCC for AHFs)
are under electrical lockout.
 To ensure safety during maintenance work, all parts of main circuit, where
access is required, must be switched off and earthed.
 Before executing the job, first discharge the power cable terminals at the
feeder end with the help of electric discharge rod.
 All PPEs and required tools must be available to the maintenance
personnel before the job is carried out.

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Checklist
for LT/HT
Motor PM

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Checklist for
LT Motor
Feeder PM

Checklist for
HT Motor
Feeder PM

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Checklist for LT
Motor Breaker
(ACB) PM

Checklist for HT
Motor Breaker
(SF6) PM

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 Bearing Replacement Job In E-303 AHF motor

I. Installation of two inverted V-shaped clamps with a pulley and a vertical support.
II. Removing of supply terminals from motor TB & covering the terminal leads with PVC insulation
tape. R, Y, B is also marked with a marker on the lug of each phase.
III. Motor removed from casing after disconnecting it from fan belt.
IV. All the bolts, checknuts and all four Greasing Tubes are removed.

Checknut is used so that main nut does not come out from the screw due to vibration.
V. Fan was not coming out due to rusted circlip. So broke the circlip & then removed it.
VI. After removing the cooling fan, Key on both DE & NDE side shaft was also removed.
Key is used to make the relative motion between shaft and pulley zero.
VII. Now Bearing pin and cover is removed. Bearing puller is used for this purpose.
VIII. The to-be-installed bearing is heated by Induction Heater till approx. 110˚C

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 Order Of Re-installing Material Specifications
Motor Parts After The Job
 Grease Specifications
Lithium Base Grease of Grade-3
I. Bearing
II. Seal
 Motor Nameplate Ratings
III. Bearing Cover V=∆-415±10%, ɳ=92%, 22kW
IV. Key FLC=41A, 980rpm, 50Hz,
V. Cooling fan Insulation Class-F, 750kg
Temp.Class- T1-T3
VI. Circlip
VII. Fan Cover
 Bearing Specifications
SKF, Ball Bearings
DE-6313C3, NDE-6313C3.

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