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8/18/2019 EASA Motor Repair Slides
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Motor Management Truths
and Consequences:Understanding Electric Motor
Rewinds and Efficiency
MDM Webcast
May 25, 20112 - 3 p.m. Eastern
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Housekeeping
Web Portion
Ensure that your pop-up blocker is turnedoff and Java is enabled
Minimize the numberof applications running
Use the chat featureduring presentation
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Today’s Web cast
• MDM and motor management strategies
• Overview of motor repair and rewinds
• Mechanical rebuilding and rewinding
• Effects of repair and rewind on efficiency
• Resources and considerations
• Questions and Answers
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MDM Sponsors
Manufacturers – Motor & Drive• ABB• Danfoss• GE Energy Motors• TECO-Westinghouse Motor
Company
Other Organizations• Advanced Energy
• Copper Development Association,Inc. (CDA)• Electrical Apparatus Service
Association (EASA)
Efficiency Programs• Alliant Energy
• BC Hydro• Efficiency Vermont
• Long Island Power Authority (LIPA)• MidAmerican Energy Company• National Grid USA • New Jersey Office of Clean Energy• New York Power Authority (NYPA)• NYSERDA• Northwest Energy Efficiency Alliance• Pacific Gas & Electric (PG&E)• Southern California Edison (SCE)
• Tennessee Valley Authority (TVA)• Xcel Energy
For more information, visit: http://www.motorsmatter.org/sponsors/
http://www.motorsmatter.org/sponsors/http://www.motorsmatter.org/sponsors/
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Motor Decisions Matter SM
Managed by CEE, a national awareness campaign to:
• Encourage sound motor management, including – Demonstrate financial benefits of life cycle cost analysis – Inform motor repair-replace decisions
– Promote premium efficiency motors and
best practice motor repair
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Effective Motor Management
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Tom Bishop, P.E.Electrical Apparatus
Service Association, Inc.
St. Louis, MO
Motor Management
Truths and Consequences: Understanding
Electric Motor Rewinds and Efficiency
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Background: What is EASA• Electrical Apparatus Service Association
• Trade association serving the electrical andmechanical apparatus sales, service and repairindustry
• Founded in 1933• More than 1,900 member firm locations worldwide;
approximately 1,400 in the U.S.
• Supports its members with industry research,engineering services, and education
• Establishes industry standards and practices
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Motor Repair and Rewind
Overview
• All repairs include mechanical rebuilding
Some repairs require rewinding
• Repair truths and consequences
• Key resources• Key factors that influence the repair
decision
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Rewind versus All Repairs
Source: A Survey of Faults ..., IEEE Petroleum and Chemical Industry Paper No. PCIC-94-01.
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Mechanical Rebuilding• Consists of
Test and inspectDisassemble
Cleaning/overhaul
Measurement of mechanical fitsBearing replacement
Restore mechanical fits and components
Assemble and test
• Most repairs are mechanical rebuildingwithout rewinding
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Mechanical Rebuilding
• Test and inspect
• Disassemble
• Cleaning/overhaul
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Mechanical Rebuilding
• Measurement of fits
• Bearing replacement
• Restore mechanical fits
and components
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Mechanical Rebuilding
• Assemble and test
• Final step after
mechanical repair withor without rewind
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Rewinding
• A sub-process to
mechanical rebuilding• Random (round wire)
windings• Form coil windings
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Rewinding
• Resin treatment
and curing
• Electrical testing
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Effect of Repair and Rewind on
Efficiency
• Truths
• and Consequences
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Truths• Rewinding using
best practicesMaintains efficiency
May improve
efficiency
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Truths• Maintain efficiency by
Copy-rewind or windingpattern improvement
Using same windingcoil wire area
Using same average
length of turns
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Truths• Opportunity to improve
efficiency byUsing larger winding
coil wire area
Reducing average
length of turns
Average length of turn
= (2 x Ls) + (4 x Lc)
Wire Size: AWG 16
Bare Diameter = .0508
Wire Size: AWG 17
Bare Diameter = .0453
Wire Size: AWG 17
Bare Diameter = .0453
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Truths• Efficiency does not change with
subsequent rewindsCore losses do not increase
Winding data rarely changes
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Truths• Repairing can restore:
Reduction in efficiencydue to prior repairs
• Restoration associated
with a rewind
• Restoration associatedwith mechanical repair
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Truths• Repairing can restore:
Reduction in efficiencydue to damage from
motor failure(s)
• Associated with
winding failure(s)
• Associated withmechanical failure(s)
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Truths• Repairing can restore:
Motors to like-newcondition
Sometimes even better
than new
• Repairs can enhancesuitability of motor forits application and
environment
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Consequences• Consequences of poor
practice repairs:Reduced efficiency
Reduced reliability
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Consequences• Reduction in efficiency
can occur Core damage due to
winding removal
Not the only reason for
reduction in efficiencyduring repair…
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Consequences• Consequences of best practice repairs:
Efficiency maintained
• Efficiency may be improved
Reliability maintained
• Reliability may be improved
Motor description
Efficiency
before rewind
Efficiency
after rewind Efficiency change Comments
7.5hp 4 pole 83.2% 84.0% +0.8%concentric to lap5 burnouts 1 rewind
100hp 4 pole 93.0% 93.6% +0.6% full to half slot lap
100hp 4 pole 93.0% 93.7% +0.7% 3rd rewind
150hp 2 pole 95.9% 95.9% 0.0% full to half slot lap1st and 2nd rewinds
Source: EASA/AEMT Motor Rewind Study, 2003
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Key Resource Documents• ANSI/EASA AR100 2010
Recommended Practice for the Repair ofRotating Electrical Apparatus
•EASA/AEMT Rewind StudyThe Effect of Repair/Rewinding on Motor
Efficiency
• EASA Tech Note 16
Guidelines for Maintaining Motor Efficiency
During Rebuilding
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ANSI/EASA AR100• The American National
Standard for repair ofrotating electrical apparatus
• Purpose: establishguidelines in each step ofelectrical apparatus
rewinding and rebuilding• Concisely (22 pages)
describes best practice
repairs
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ANSI/EASA AR100 Benefits• Provides guidance for service centers to
perform best practice repairs• End users are assured that compliant
repairs follow a national standard
• Results:
Quality repairs
Reliable repairs
Efficiency maintained
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ANSI/EASA AR100 Content• GeneralIdentification, inspection, condition assessment,failure analysis, cleaning, transport
• Mechanical repair Shafts, bearings, lubrication14 fit and tolerance tables
• Rewinding
Core inspection, winding removal, windingspecification
• Testing
Insulation resistance, high-potential, surge,core laminations, no-load
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EASA/AEMT Rewind Study
Key content: Good Practice Guide
• Inspection and dismantling
• Testing
• Winding removal and rewind
• Mechanical repairs
• Reassembling
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EASA/AEMT Rewind Study
Key content: Good Practice Guide
• Lessons learned
Guide good practices AR100 best practices
• Provides source details forgood/best practices
Repair reference document
for service centers
Specification reference
document for end users
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EASA Tech Note 16*
Key content
• Do’s include
Core test before and afterwinding removal
Repair or replace defectivelaminations
Evaluate impact on efficiency ifwinding design changes
• Don’ts includeOverheat stator core/use openflame
Short laminations when
grinding/filing Increase winding resistance
* Guidelines for Maintaining
Motor Efficiency During
Rebuilding
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Key factors in repair or rewind
decision• Horsepower rating
Economic evaluation
• Motor type/features
Availability of new• Maintenance history
Evaluate reliability
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Questions?
Thank You!
www.easa.com
http://www.easa.com/http://www.easa.com/
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Contact Information
• Motor Decisions Matter Campaign
– www.motorsmatter.org
– Email: [email protected]
– Sign up for E-Newsletter
• MDM Events Calendar
– www.motorsmatter.org/events/calendar.asp – Will include slides from today’s webcast
http://www.motorsmatter.org/mailto:[email protected]://www.motorsmatter.org/events/calendar.asphttp://www.motorsmatter.org/events/calendar.aspmailto:[email protected]://www.motorsmatter.org/