EXECUTIVE SHIP MANAGEMENT

To: Master of all ESM fleet vessels

From: Executive Ship Management Pte Ltd
Date of issue: 29th August 2014 Category: Electric Motors

MT 09-14: Preventive Measures to avoid Electric Motors from burning

Applicable to all vessels

The trend of machinery related incidents have shown across the vessels shows a steady number
of cases of burnt electric motors. So far this year in 2014, we have had around 12 cases of motor
failures. (The motors were of equipment such as Sea water pump, Feed pump, waste oil pump,
windlass, etc.). See some pictures below for the damage to motors:

We believe most cases are avoidable, as warning signs are present, such as unusual vibration,
heat, etc. which can be easily identified by the duty engineers during their normal routine rounds,
inspections and checks.

We would like to introduce you some good practices to properly manage and maintain electric
motors. We hope this information will be of help and reduce the number of cases of burnt out
electric motors.

Main Causes of Electric Motor Burnout

Damage to the motors can occur because of one or more of the below

MT 09-14 Page 1 of 4

EXECUTIVE SHIP MANAGEMENT

1) Contact with Stator and Rotor due to damaged Ball Bearing

- Due to Misalignment of Coupling Centering.
- Poor mounting of Ball Bearing.
- Poor Management.
2) Contact with Stator and Rotor due to Abnormal wear down of Bearing Housing (Motor end
cover)
3) Single phasing
4) Overload

In both the above items (cause 1 and 2), there is contact with the stator and rotor. Therefore, to
reduce the number of electric motor burnouts, we need to take countermeasures such as correct
alignment of motor when installing, Proper procedure of bearing installation and proper inspection
and maintenance of the motors.

Inspection and Maintenance of Motor

1) During Operation :

a) Vibration - To be measured daily by feeling or by vibration meter if provided

Cause of vibration is basically for following
- Miss alignment, unbalance of equipment
- Induced Hull vibration
- Failure of bearing

b) Noise - To be monitored daily by listening or by using listening rod, if not distinct.

Cause of noise is for following
Damaged bearing ( rattling noise )
Single phasing ( humming noise )

c) Temperature- To be measured and monitored daily by either means of infrared thermometer

normally available on board, by feeling, by attaching a thermometer on motor body with
putty .Maintain a record of weekly measurement of important motors body temperature and
ambient temperature. Normally the temp should be 5 to 7 deg C higher than ambient
temperature. If a motor is run 10 deg C above its rating, its life span reduces by 50%.

Cause for high temperature can be any of the following:

Overload
Ambient temperature high
Damage to cooling fan
Thick paint coat on motor
Single phasing

d) Current - Check from ammeter. Each phase current can be checked by using clamp-meter
across each phase. Normal running amps to be marked on the specific amp meter. This
normal value can be obtained from shop trial data.
Cause for over current is due to overload

2) During Overhaul :

a) Bearings Confirm that bearing is not loose in the housing. Check if any discoloration on
the outer surface of bearing. In case bearing is loose, outer surface will turn black. Ensure
the bearing is put in right direction as mentioned in manual as one specific side is designed
to take thrust.

MT 09-14 Page 2 of 4

EXECUTIVE SHIP MANAGEMENT

b) Stator and Rotor Inspect for any signs of damage etc.

c) Cables check for any damage to cable, particularly the hidden section under gland for the
terminal box. Check that connecting lugs are secured tightly.

d) Cooling fans inspect that there is no damage to blades and the key-way is not damaged.

e) Varnish condition inspect condition of varnish. If varnishing is carried out on board, carry
out proper baking by use of lamps. In case motor is overhauled during docking, baking is
carried out inside special oven.

f) Fitting of Bearing there has been several cases of motor damage after overhaul due to
improper fitting procedure of bearing. Attached information on guidance for fitting bearing.

g) End cover judgment in case bearing is found loose in the housing, it can be restored by
two methods before it is renewed. Following two methods are normally applied by workshop
or during docking.

Fitting sleeve when wear down is higher than 0.12, bearing housing is machined
and then snug fit sleeve is fitted.
Metal spraying if the wear is below 0.12mm, metal spray is applied before fitting
bearing.

In case bearing housing is found worn down during maintenance on board, above methods
cannot be done .In that case please report to office and superintendent to seek advice and
raise requisition for spare end cover .

h) Coupling removal - During dismantling of the coupling flange (especially for large motors,
generally constructed of Cast Iron) please use a strong back behind the coupling flange
whilst extracting the same using a puller. Avoid hammering of the rotor shaft as this may
lead to deformation of the shaft. If the trueness of the shaft is lost, it can cause damage due
to vibration.

i) Adjusting alignment coupling alignment must be checked before assembly. All dowel pins
should be replaced in place and height is to be adjusted by adding or removal of shims in
foundation.
For motor couplings with flexible/rubber coupling bushes, the coupling bushes to be checked
for wear and renewed if required.
For Motors with Pulley/Belt drive, proper alignment and tensioning of belt is imperative.
The alignment value is basically applied according to the instruction book, but ideally it is less
than 3/100mm.

j) No load running - the motor is to be tested without load to confirm current drawn and
direction of rotation. Check each phase current of the motor and confirm balance (deviation
max within 5 %).

3) Greasing of Bearing :
Carry out greasing of open end bearing every three months or as recommended by the
maker and in principle while the motor is in stop condition. Please note excess greasing is
not recommended. Ensure the grease breather line on other end is clear and the old grease
is replaced with new grease. Otherwise excess grease will be scattered on stator / rotor and
consequently damage the motor.

Further please refer to following attachments for your guidance:

MT 09-14 Page 3 of 4

EXECUTIVE SHIP MANAGEMENT

Attachment 1- Trouble shooting Guide for motor Failure

Attachment 2- Guidance for Bearings removal, heating, fitting and greasing

Please discuss this alert with all concerned ship staff. Record this discussion in the next monthly
HSE meeting report.

Thanking you with best regards.

QA Manager

MT 09-14 Page 4 of 4

 Attachment1
GuideforTroubleShootingforMotorFailure

TROUBLE SYMPTOMS PROBABLECAUSE PREVENTION/ACTION
Followmaker'sdrawingandinstructiontofitthebearingsinright
Bearingdirectionnotcorrecttotakethrust
direction.
BearingThrustspring(whereapplicable)
Takecaretofitthethrustspring.
missing
Avoidhammeringatoneside;usealwaysasleevesothat
forceisuniformlyappliedalongcircumference.
Bearingfittingprocedurenotcorrect, Avoidexcessheating(maxheatingtempinoilbathis120deg
Rattlingnoise C)foropentypebearing.
Rotorhardtobeturned Enclosedbearingstobeheatedbykeepingonhotsurface
Wobblingmovementof
BEARINGFAILURE
rotor Greasethreemonthly.Avoidovergreasing.Usecorrecttypeof
Vibration Lackofgreasing grease.Whilegreasing,ensurethebreatherdrainisclearon
otherendtoreplacetheoldgrease.

Usecorrectpartcodee.g.N3C3forhighspeedandhightorque,
Incorrectbearing
ZZforenclosetypeetc.
Renewalofhousingrenewal.Incaseweardownislessthan0.12
Bearinghousingworn mm,metalspraycanbeapplied,otherwisesnugfitsleevetobe
fittedaftermachiningthehousingastemporarymeasure.
Notedonotputanypunchmarkonshaft.
Motortrip Contactortrouble.Onesetmaybestuck Periodicallyinspecttightnessofcables,OCRrelays.
SINGLEPHASING Motorwindingburnt closeoronesetdidnotopen.Contactchip ChecktheOCRsetting105%ofmaximumloadcurrentfor
Hummingnoise damage,unequalweardownduesparking. eachmotor.
Contactorcontactsburnt Oneofthephasesofoverloadprotection Checkthereisnodamagetomotorcablesinterminalbox.
andfused relaygotburnt. InstallationofSinglephasingprotectiondevice
Loosecableorrelayterminals
DamagetoinsulationofoneoftheMotor
cables
 ShortCircuitofcontactorcables
Donotoverload
Hummingnoise Attachedpumpmechanicaltrouble
Takecaretoensurepumpsideisfreemovingandclearofany
OVERLOAD Motorhightemp Externalobstructiononmotorrotation.
obstruction
Missalignmentwithpump
Carryoutalignmentbeforeconnectingcoupling
Monitortemperatureondailyround.
Overload,
Avoidoverload.
Overheating Ambiencetemperaturehigh,
Properaircirculationforcooling.
Thickpaintcoatingonmotorbody
Donotapplythickcoatofpaint.
OTHERS Oldageandbreakdownofwindingvarnish
Varnishingandbakingofwindingaddslongerlifetomotor
coatingduetovibration.
Suddenfailure
Ingressofforeignsubstancelikepaint
Ensurenoforeignsubstancecanbedrawninsidemotorwinding.
spray,water,dirtetc.

Attachment 2: Guidelines for bearings removal, heating, fitting and greasing

Dismounting
Check the lubricant for impurities by rubbing a little between fingers.
The types of impurities are indicative of seal or bearing damage for future preventive
measures.
Inspect carefully the raceways, cage and rolling elements for damage, scoring, pitting or
discoloration.
This inspection is necessary to understand cause of failure if any.

Bearing removal

Mark position to show its relative mounted position, so the new bearing should be reinstalled
in the same position.

Interference fit on the shaft

a. If the bearing has an interference fit on the shaft, use puller or press.(press is preferred)
b. Load should be applied only to the inner race.
Fitting of Bearing

AA) Shaft Inspection

Clean, and then check the shaft for any damage or burrs.
Check the size of shaft and bearing, using micrometer to ensure correct fit.
Check shaft imbalance, using dial test indicator andV blocks.
Check the shaft shoulder for correct seating.
The shoulder fillet should not prevent bearing from fully contacting shoulder.

BB) Housing inspection

Clean the housing and check for any damage or burrs.
Check housing for correct size or ovality.
Take three readings in different positions, using inside micrometer.

CC) Basic rules for installing bearings

Never directly strike the rings, cage or rolling elements while installing.
Never apply pressure to one ring in order to install the other; During mounting of the
ball bearing, avoid hitting the outer ring hit the inner ring.
During mounting of the ball bearing, get the ball bearing warmed up using heated
Lube Oil or by putting the ball bearing in a heated location, (M/E cylinder cover, etc.)

DD) Cold installation

Bearing rings that rotate should have a tight (interference) fit to prevent creeping and
turning.
Bearing rings that are stationary may be mounted with a loose (transition) fit.
Make sure the bearing is mounted at right angle to the shaft/housing.
a) Always use a sleeve to the size of the fitting ring (Inner or outer).
b) Lubricate the shaft journal before fitting.
c) The sleeve should have parallel faces and must be burr free.
EE) Illustration for correct mounting of bearing
FF) HOT INSTALLATION

Force needed to mount a bearing increase rapidly with bearing size.

Larger bearings cannot easily be pressed on to a shaft because of the high mounting
force requiredtherefore; the bearingis heated before mounting.
Normal mounting temperature of bearings varies from 80 to 90C
Never heat a bearing to a temperature greater than 125C
Never heat a bearing using open flange.

as heating will not be even. No naked flame

When you apply heat to the ball bearing, be aware of the following factors:

For Shielded Types

Shielded Ball Bearings have grease inside, so if you soak the shielded ball bearing into
heated L.O., the grease inside the bearing will liquefy. One suggestion to thermally
expand the ball bearing is to put it on the M/E cylinder cover or using heated L.O.
indirectly. (Kindly refer to below diagram) You can easily heat Lube Oil over 100C
because L.O. has a low specific heat.

As shown in the above figure, put the ball bearing into an empty can and fill the can with
heated Lube Oil.
For Open Types
 Open types are different from shielded types as they do not have grease inside the
bearing. So the opened type bearing can be put into heated L.O. directly. Point to
remember is that you can use L.O. for heating, but do not heat up to the flash point.It is
sufficient to heat up to approximately 110C.

GG) Bearing handling and care

a) Always keep bearings in their protective packages till installation time.
b) Cover equipment with plastic, waxed paper or a clean dry lint-free cloth to
protect exposed components and un-mounted bearings.
c) Never install a bearing close to Chip-forming or dust producing machinery.
d) Never apply direct blows to a bearing.
e) Use a length of tubing when mounting.

HH) Angular type bearings Mounting Direction.

The angular type ball bearing is used in some machinery such as the vertical shaft of
the Purifier, Steering Gear motor, Boiler water Circ. Pump, etc. Also, in the steering
gear motor, etc. a double type bearing is used.
By correctly following the CODE, you cannot make a mistake when mounting the ball
bearing:
DB: Back-to-Back arrangement
DF: Face-to-Face arrangement
DT: Tandem arrangement

Also, some bearing makers use markings engraved in the outer ring.

Note
When you insert a Single Type Angular bearing, please follow the instruction book regarding
the insertion direction (especially for the Purifier vertical shaft, etc.).

GREASING ROUTINES OF BALL & ROLLER BEARINGS

In a bearing balls act as tiny viscosity pumps, and the grease is less viscous when hot, a
bearing should be re-greased while the motor is running. If this is not practical, then perform
re-greasing immediately after the motor is removed from service while the grease is still hot.
Although no program eliminates over greasing an already filled grease cavity, the steps
listed below will help minimize over greasing-related failures.

The following steps should be performed in the sequence listed:

1. Ensure the grease gun contains the appropriate lubricant for the bearings to be re-
greased.
2. Clean the areas around the fill and drain fittings.
3. Grease the bearing with the proper amount of grease. Add grease slowly to minimize
excessive pressure buildup in the grease cavity.
4. If re-greasing is performed with the motor out of service, operate the motor until
bearing temperature stabilizes to allow thermal expansion of the grease. Ensure the
drain plug is left out during this run unless the plunger-type is used.
5. After excessive grease has been purged, reinstall the drain plug and clean excessive
grease from the drain area.

How often should bearings be re-greased?

Report is based on the following information about the motor design and operation:

1. Continuous operation
2. Intermittent operation
3. Standby or lay-up
4. Open face, single-shielded or double-shielded bearing (inboard and outboard).
Different types can be used for the inboard and outboard bearings. Note: Sealed
bearings cannot be re-greased.
5. RPM of the motor
6. Horsepower of the motor
7. Load configuration side-loaded verses direct-loaded
8. Ambient temperature - less than 60C and greater than 60C

Table 1 below was designed for a relatively clean environment. A dirty or contaminated
environment may require adjustments to the recommended intervals.

a) Motors with these design characteristics have less time between greasing intervals. The number of characteristics designated by (a) for which each
motorismarkedwithanX(1,2,3,4or5),wasusedtodeterminethegreasinginterval
b) Thegreasingintervalsformotorsinthestandbyorlayupmodeshouldbe1.5timesthatofmotorsoperatingcontinuously.
c) Onceper3operatingcycles,nottoexceed58months.
d) Onceper2operatingcycles,nottoexceed40months.
e) Onceperoperatingcycle,nottoexceed22months.
f) Twiceperoperatingcycle,nottoexceed11months.
Note:Operatingcyclesarebasedonan18monthcycle

Table1Regreasingintervalsforopenfaceandsingleshieldedbearings.