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Developed for electricians, mechanics, students and reliability managers, Electrical Motor Diagnostics is an essential working tool for the new and experienced Electrical Motor Diagnostics professional. The Second Edition provides the information, case studies, and materials necessary to interpret motor circuit analysis, motor current signature analysis, electrical signature analysis, and other standard testing technologies for AC/DC electric motors, transformers, machine tool motors, synchronous motors, and generators including pass/fail values. Information on the development of a motor management program and the SUCCESS by DESIGN Time to Failure Estimation methodology for any technology are covered in detail.

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Publié par	Success By Design
Date de parution	09 décembre 2014
Nombre de lectures	1
EAN13	9780986347726
Langue	English
Poids de l'ouvrage	7 Mo

Informations légales : prix de location à la page 0,1700€. Cette information est donnée uniquement à titre indicatif conformément à la législation en vigueur.

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Electrical Motor Diagnostics
2nd Edition
©2008 SUCCESS by DESIGN Publishing
All Rights Reserved. No part of this book may be reproduced in any form or by any electronic or mechanical means including information storage and retrieval systems – except in the case of brief quotations embodied in critical articles or reviews – without permission in writing from its publisher, SUCCESS by DESIGN Publishing.
Published By: SUCCESS by DESIGN Publishing
Old Saybrook, CT 06475
Email: info@motordoc.com
http://www.motordoc.com
This publication is designed to provide accurate and authoritative information in regard to the subject matter covered. It is sold with the understanding that the use of the information contained within this book does not imply or infer warranty or guaranties in any form.
ISBN: 0-9712450-7-X
ISBN-13: 978-0-9712450-7-5
Table of Contents
Table of Figures
Table of Tables
Table of Equations
Introduction
Chapter 1: The Motor Diagnostics and Motor Health Study
Electric Motor Repair Study, 1995
In Service Motor Testing, 1999
Success by Design Best Practice Survey
Dealing with the State of the Motor Testing Industry
Chapter 2: Basic Electricity and Electro-Magnetism
Current, Voltage and Resistance
Electro-Magnetic Fields
Alternating Current Electricity (Hz)
Chapter 2 Questions
Chapter 3: Electric Motor Theory
AC Induction Motor Theory
Wound Rotor Motors
Synchronous Motors
Direct Current Electric Motors
Machine Tool Motors
Traction Motors
Transformers
Chapter 3 Questions
Chapter 4: Electrical Insulation Systems and Theory
The Motor Circuit
Insulation and Magnetic Field Effects
Winding Faults
Traditional Test Methods
Insulation to Ground Testing (Meg-Ohm Meters)
Polarization Index
Resistance Testing
Surge Comparison Testing
Modern Low-Voltage Testing: Motor Circuit Analysis
Detection of Winding Contamination
Overheated Windings
Winding Shorts
Additional Tests
Rotor Testing and Back Iron Effects on MCA
Armature and Commutator Contamination Detection
Summary of MCA Theory
Development of Experiments
Test Tolerances
MCA Tolerances
Surge Testing Tolerances
Experiment Test Results
Experiment 1
Experiment 2a
Experiment 2b
Experiment 2c
Experiment 3
Experiment Conclusions
Experiment 1 Conclusions
Experiment 2a Conclusions
Experiment 2b Conclusions
Experiment 2c Conclusions
Experiment 3 Conclusions
Summary
Chapter 4 Questions
Chapter 5: Common Electric Motor Testing
Electrical Motor Diagnostics Defined
Condition-Based Technologies
Voltmeter Troubleshooting of an AC Motor
The Power of a Volt Meter
Checking Contacts with a Volt Meter
Checking Fuses with a Volt Meter
Ammeter Testing of an AC Motor
Analog Ammeters
Digital Ammeters
Load Measurements
Current Unbalance Conditions
Other Current Conditions
DC Resistance Testing of AC Machines
Selecting the Right Measurement Tool
Considerations When Using an Ohm Meter
Troubleshooting Motors with Ohm Meters
Classical Insulation Resistance Testing
The Basic Insulation Resistance Test
Utilizing Hi-Pot Testing for Insulation to Ground Stress Testing
Evaluating Motor Condition with Low Voltage Advanced Diagnostics
Motor Circuit Analysis
Surge Comparison Testing
Comparison of the ‘Big Three’
Introduction to Electrical Signature Analysis
Multi-Technology Approach to CBM
Major Components and Failure Modes
Common Approaches to Multi-Technology
Application Opportunities
Chapter 5 Questions
Chapter 6: Time to Failure Estimation
The Tools for TTFE
The Severity Modifier
Understanding Series and Parallel Availability
Time To Failure Estimation with MCA
Electric Motor Winding Failure
Insulation Breakdown
Stages of Winding Failure
Introduction to Motor Circuit Analysis (MCA)
Trending Fault Descriptions
AC Rotating Machine Testing
Time to Failure Estimation
Nuisance Tripping Situations
Winding Contamination
Winding Shorts
Test Cases
Chapter 6 Questions
Chapter 7: Motor Circuit Analysis Testing AC Machines
Fault Detected Procedure
Data Collection and Test Result Issues
Rotor Test Procedure
Synchronous Machine Testing with MCA
Most Common Synchronous Motor Faults
Basic Steps for the Analysis of Synchronous Machines with MCA
Generator Analysis with MCA
Evaluating Generators with MCA
MCA Instrumentation: The ALL-TEST PRO 31
Analysis of Pin-Hole Shorts (VFD-Related Motor Failure)
AC Machine Case Studies
Case 1: New Motor Phase Unbalance
Case 2: Casting Void 200 HP Motor
Case 3: ID Fan Motor Rebuild Defect
Case 4: Cable Faults
Case 5: Evaluation of an 8000 HP Synchronous Motor
Case 6: AC Traction Motor – Good
Case 7: Spindle Motor – Good
Case 8: Brushless DC Servo – Coil-to-Coil Short
Case 9: 100 Horsepower, 1800 RPM with Dirty Windings
Case 10: Servo Motor – Turn-to-Turn Fault
Case 11: Rotor Position Related Unbalance
Case 12: Motor Tested from MCC – Shorted Windings
Case 13: Brand New 300 Horsepower Motor with Shorted Phase
Case 14: 3000 Horsepower with Fractured Rotor Bar
Case 15: New 50 Horsepower, 2-pole Motor Combined Faults
Case 16: 300 HP, 2300 Volt, 3600 RPM Broken Rotor Bars
Case 17: 1000 HP, 3600 RPM – Special Signature on Good Motor
Case 18: 700 HP, 3600 RPM, Broken Rotor Bars and Cracked Shaft
Chapter 7 Questions
Chapter 8: Motor Circuit Analysis Testing DC Motors
The Commutator
Brush and Commutator Operation
Seating, Tensioning and Cleaning
Basics of DC Machines for MCA Testing
Common DC Motor Electrical Faults
Armature Testing
Series Motor Testing
Shunt Motor Testing
Compound Motor Testing
General DC MCA Testing Notes
Chapter 8 Questions
Chapter 9: Electrical Signature Analysis Theory
Alternating Current Induction Motors
Induction Motor Troubleshooting Procedure
Induction Motor Troubleshooting Analysis Overview
Power Quality and Electrical Analysis
Rotor Analysis
AC Motor and Stator Analysis
Driven Equipment Evaluation
Belts
Gear Mesh
Driven Equipment – Blade Pass Frequencies
Generator Analysis with ESA
DC Electric Motors
DC Motor Testing Procedure
Basic DC Motor Analysis
Chapter 9 Questions
Chapter 10: Electrical Signature Analysis Pattern Recognition AC Machines
The Elusive Stator Slots and Rotor Bars
Stator Slots
Rotor Bars
Use of Databases
Alarm Levels
Evaluating Data: Basic Steps for Pattern Recognition
Common AC Induction Motor Signatures
Unbalance and Misalignment
Gearbox Fault
Classical Rotor Bar Fault
Punch Press: Driven Equipment Effects
Fan and Belt Faults
Coil Movement
Static Eccentricity
Variable Frequency Drives
Chapter 10 Questions
Chapter 11: Electrical Signature Analysis Pattern Recognition DC Machines
DC Troubleshooting Patterns
Considerations in DC Analysis
Chapter 11 Questions
Chapter 12: Developing an EMD Program
Concepts of the Program
Key Performance Indicators
RCMM Team
Considerations in Selecting Equipment
Defining Motor Management Programs
Company Mission
The RCM-Based Approach for Motor Management
Selecting CBM Equipment
Appendix 1: Advanced Transformer Analysis with the ALL-TEST IV PRO 2000
Single Phase Transformer Testing
Procedure
Test Results
Three Phase Transformer Testing
Procedure
Testing Notes and Limits
Appendix 2: Evaluation of Capacitance in Motor Circuit Analysis Findings
Appendix 3: MCA Tables for TTFE Baselines
Appendix 4: Determining Testing Frequency
Appendix 5: Stator Slot and Rotor Bar Tables
Table of Figures
Figure 1: Cost Impact of Maintenance Programs $/HP/YR
Figure 2: Modifications to Windings Through Rewind Process
Figure 3: Testing Through the Repair Process
Figure 4: Reasons for Motor Testing
Figure 5: Technologies Used
Figure 6: $/Hour Downtime
Figure 7: Shifts and Operation
Figure 8: Primary Driver for Motor Testing Program
Figure 9: Bohr’s Model of the Atom
Figure 10: Basic Motor Circuit
Figure 11: Three Phase Stator and Windings
Figure 12: Three Phase Rotor
Figure 13: Rotating Field and Rotor Cage
Figure 14: Series Motor
Figure 15: Shunt Wound Motor
Figure 16: Compound Wound Motor
Figure 17: Power Transformer
Figure 18: Delta-Delta Transformer
Figure 19: Delta-Wye Transformer
Figure 20: Wye-Delta Transformer
Figure 21: Wye-Wye Transformer
Figure 22: Delta-Wye Transformer Connection
Figure 23: Delta-Delta Transformer Connection
Figure 24: Single-Phase Transformer Connection
Figure 25: Single-Phase Equivalent Circuit
Figure 26: Insulation Model of Motor Winding System
Figure 27: Generation of a Dipole
Figure 28: Dipolar Effect of Insulation
Figure 29: Magnetic Dipoles
Figure 30: Balanced Wye System
Figure 31: Surge Results T1-T2
Figure 32: Surge Results T1-T3
Figure 33: Surge Results T2-T3
Figure 34: Fault Detection (Night Vision Video)
Figure 35: Arc Damage (Night Vision Video)
Figure 36: Effect of Surge Comparison Testing on Winding Contamination
Figure 37: Virtual Motor with Spacers to Hold Airgap
Figure 38: Surge Values on Each Test
Figure 39: Arc Damage to Winding and Insulation
Figure 40: Impact of Voltage Deviation
Figure 41: Voltage Unbalance Multiplier
Figure 42: Wheatstone bridge
Figure 43: Double Kelvin Bridge
Figure 44: Basic 4-Wire Kelvin Bridge
Figure 45: 4-Wire Kelvin Bridge
Figure 46: Insulation Resistance Temperature Correction
Figure 47: Dielectric Absorption
Figure 48: Polarization Index
Figure 49: Good Impedance and Inductance Pattern
Figure 50: Bad Impedance and Inductance Pattern
Figure 51: PI Curve and Capacitive Discharges
Figure 52: Broken Rotor Bar Signature
Figure 53: Coil Movement Signature
Figure 54: Louis Allis 800 HP Stator
Figure 55: Copper from Louis Allis Coil Failure
Figure 56: Inherent Availability of Parallel Pump Components
Figure 57: Failure Curve of Primary A for Bear