Beruflich Dokumente
Kultur Dokumente
Housekeeping
Audio Portion
Web Portion
Dial *0 to speak to a
RollCall operator
Dial *6 to
Mute/UnMute
Be sure that hold
music is turned off
MDM Sponsors
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
Motor Management
Truths and Consequences: Understanding
Electric Motor Rewinds and Efficiency
10
Source: A Survey of Faults ..., IEEE Petroleum and Chemical Industry Paper No. PCIC-94-01.
Mechanical Rebuilding
Consists of
Test and inspect
Disassemble
Cleaning/overhaul
Measurement of mechanical fits
Bearing replacement
Restore mechanical fits and components
Assemble and test
11
Mechanical Rebuilding
Test and inspect
Disassemble
Cleaning/overhaul
12
Mechanical Rebuilding
Measurement of fits
Bearing replacement
Restore mechanical fits
and components
13
Mechanical Rebuilding
Assemble and test
Final step after
mechanical repair with
or without rewind
14
Rewinding
A sub-process to
mechanical rebuilding
Random (round wire)
windings
Form coil windings
15
Rewinding
Resin treatment
and curing
Electrical testing
16
and Consequences
17
Truths
Rewinding using
best practices
Maintains efficiency
May improve
efficiency
18
Truths
Maintain efficiency by
Copy-rewind or winding
pattern improvement
Using same winding
coil wire area
Using same average
length of turns
19
Truths
Opportunity to improve
efficiency by
Wire
Wire Size:
Size:
AWG 17
Bare
BareDiameter
Diameter == .0453
.0453
Wire Size:
AWG 16
Truths
Efficiency does not change with
subsequent rewinds
Core losses do not increase
Winding data rarely changes
21
Truths
Repairing can restore:
Reduction in efficiency
due to prior repairs
Restoration associated
with a rewind
Restoration associated
with mechanical repair
22
Truths
Repairing can restore:
Reduction in efficiency
due to damage from
motor failure(s)
Associated with
winding failure(s)
Associated with
mechanical failure(s)
23
Truths
Repairing can restore:
Motors to like-new
condition
Sometimes even better
than new
Consequences
Consequences of poor
practice repairs:
Reduced efficiency
Reduced reliability
25
Consequences
Reduction in efficiency
can occur
Core damage due to
winding removal
Not the only reason for
reduction in efficiency
during repair
26
Consequences
Reduction in efficiency
-- other factors
Winding copper
losses increased due to
incorrect winding data or
method
Bearing friction losses
increased due to
incorrect bearings, fits,
improper lubrication
(I2R)
Wire Size:
AWG 16
Wire Size:
AWG 17
27
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 lap
5 burnouts 1 rewind
100hp 4 pole
93.0%
93.6%
+0.6%
100hp 4 pole
93.0%
93.7%
+0.7%
3rd rewind
0.0%
150hp 2 pole
95.9%
95.9%
28
ANSI/EASA AR100
The American National
Standard for repair of
rotating electrical apparatus
Purpose: establish
guidelines in each step of
electrical apparatus
rewinding and rebuilding
Concisely (22 pages)
describes best practice
repairs
30
Results:
Quality repairs
Reliable repairs
Efficiency maintained
31
Mechanical repair
Shafts, bearings, lubrication
14 fit and tolerance tables
Rewinding
Core inspection, winding removal, winding
specification
Testing
Insulation resistance, high-potential, surge,
core laminations, no-load
32
33
Lessons learned
Guide good practices
AR100 best practices
Provides source details for
good/best practices
Repair reference document
for service centers
Specification reference
document for end users
34
Dos include
Core test before and after
winding removal
Repair or replace defective
laminations
Evaluate impact on efficiency if
winding design changes
Donts include
Overheat stator core/use open
flame
Short laminations when
grinding/filing
Increase winding resistance
Motor type/features
Availability of new
Maintenance history
Evaluate reliability
36
Questions?
Thank You!
www.easa.com
37
Contact Information
Motor Decisions Matter Campaign
www.motorsmatter.org
Email: mdminfo@cee1.org
Sign up for E-Newsletter
38