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ELECTRIC MOTORS “ TEFC “ IN PARTICULAR ARE
LENGTHEN THE LIFE OF THE MOTOR IN NO SMALL WAY
Do not remove plastic cover Clean, Dry, Covered storage with levelled surface
Prevention of rain water accumulation Avoidance of corrosion due to moisture / dust combination
Vibration free environment - protect bearings against induced standstill vibrations
Do not remove rotor locators provided on motors with roller bearing till final commissioning stage
CHECKS IN STORES
• • • • • • • • Choose correct motor Visual inspection - Physical soundness Change of grease - Prolonged storage Insulation resistance
Perfectly levelled (Shims if necessary) Rigid Isolated from induced vibrations
DRIVE / TRANSMISSION ELEMENT
Dimensions - Check • Dynamic balancing • Mount carefully (use appropriate tools) - Heavy blows to be strictly avoided to protect bearings • Lock the drive element suitably
Connection of Motor to supply system
BEFORE CONNECTING ENSURE • Free unobstructed air supply for cooling • Free passage of hot air • Terminal box interior is clean (no cable remnants etc.) • Tight and firm cable connections with proper air clearances Minimum 10 mm for 415 V • Sealing of unused conduit entry holes and proper assembly of gaskets and covers BEFORE STARTING ENSURE • Shaft free to rotate • Supply system OK • Motor protection system OK • Earthing provided (Both inside terminal box and on motor body)
RUNNING ON NO-LOAD Check direction of rotation Check terminal voltage Check no load current Check mechanical noise, if any Check vibration level Check bearing noise, if any
LOAD MOTOR GRADUALLY, IF POSSIBLE ON LOAD CHECK Full load current Motor speed Noise level Vibration level Motor / Bearing temperature (if possible)
SIMILAR MONITORING OF DRIVEN EQUIPMENT, WITH RESPECT TO ITS CHARACTERISTICS, SHOULD ALSO BE DONE IN THE INITIAL PERIOD
Planned Low down time cost Carried out at ease and in line with production schedules Best available methods adopted Achieving best results Economical in the long run -
Forced type High down time cost Carried out under pressure and tension Emergency method adopted Quality of work short of best possible, many a time
PREVENTIVE MAINTENANCE CAN BE DIVIDED INTO TWO PARTS :
Periodic check-up of motors while running Periodic servicing of motors
HOW TO GO ABOUT THESE TASKS
Classify the motors depending upon their IMPORTANCE and CRITICALITY to the running of plant Depending upon criticality fix up “ Monitoring - Cycles “ for motors Full load current Voltage and frequency variations Vibration level (both motor and equipment Bearing health Recording of these readings helps in identifying the DEVIATIONS from the normal trend Feb‘01
WHAT TO BE OBSERVED
Periodic cleaning of cooling air paths Observance of motor regreasing cycles Occasionally checking “ fasteners “ tightness
Preventive Maintenance STAND - BY SPARES
Cage Motors Slipring Motors : : Set of Bearings Set of Bearings Carbon Brushes Advisable if there are a no. of identical motors at same site.
Spare rewinding kit
DRYING OF WINDINGS
Normal Moisture Ingress • • For motors provided with space heaters, switch on heaters for 8 - 10 hours. Check IR improvement after every 2 hours. For smaller motors where space heaters are not available, supply windings with 24 V, 1 ∅ supply.
If it is noticed that motor is submerged in water OR large ingress of water has taken place, dismantle motor and heat in oven and revarnish. Thoroughly clean and dry other parts also. While dismantling and assembling motors, use proper tools.
Rotor components normally are “ Interference Fit”. Use correct pullers - Mechanical or Hydraulic Avoid Hammering
Always support the rotor with crane or Hydraulic Jack.
Protect open windings from moisture and Dust.
OVERHAULING OF MOTORS
Windings and bearings to be serviced properly for good and long service from the motor. Remove bearing carefully Look for Feb‘01
any grease contamination before cleaning with thinner blackening, overheating damaged or cracked cages dent marks, scratches on rolling elements or races markings indicating eccentric loading sufficient grease quantity inside bearing
Replace bearings if any defects noticed. Replacing a doubtful bearing is always economical in the long run. Always procure the bearings from a genuine / authorised source. Adhere to the correct radial clearance as per original bearing. Mount the bearing by heating it to approx. 80°C. NEVER HAMMER THE BEARING Thin coat of grease on shaft and bearing housing helps to a great extent in easy assembly.
Use correct type of grease. Unirex N3 Grease should be clean - free from impurities. DO NOT MIX GREASES OF DIFFERENT BASES Fill up grease in the bearing, as also the inner bearing cover - to about one-third of the available volume. Clean the grease nipples and grease pipes thoroughly. Fill up grease pipes before assembly with grease.
While assembling the components apply a thin coat of graphite grease on spigots to maintain the quality of motor enclosure.
Check soundness of brazed joints in brazed rotors. Look out for looseness of end lamination teeth - particularly in rotor (hammer them in position, if necessary and retain with the help of caulking rotor bars. If cores are segmented - clean them. Clean all cooling air paths and perforated screen. Check tightness of mounting feet fixing bolts. Clean cooling fans (particularly blades). Check condition of gaskets (cracks, hardness etc.) - replace if necessary.
Clean all mating surfaces with thinner - apply thin coat of black graphite grease for sealing. Always mark the various components of the motor to avoid mix-up of parts of other motors. Apply a fresh coat of paint particularly for motors in corrosive atmosphere.
WINDINGS Check condition of connecting cables and braxed joints. Look out for dis-colouring of overhangs : (black spots indicate overheating). Clean windings with dry compressed air.
FOR SLIPRING MOTORS Check rotor windings similarly. Clean sliprings (check surface finish). Replace carbon brushes if worn-out. Check spring pressure.