Electric Motor Control, Maintenance and Testing Training 12th – 16th August 2024 (Weekdays)

Overview

This customized 5-day training course will certify that your electrical workers are qualified to work on motor control circuits safely and effectively and VFD installations. This course is built around High Voltage, Medium Voltage and Low Voltage Electric Motors. The participants will gain the knowledge and abilities to troubleshoot motors, motor control systems, troubleshoot and program a range of VFDs from this 90% hands-on course. Using IR, DW, WR, impedance, and surge testers, the participants will test and diagnose several three-phase motors with internal defects. They will also troubleshoot a range of malfunctioning panels and MCC systems.

Learning Objectives

Upon completing this course, participants will be able to:

• Motor nomenclature & definitions
• DC motors.
• AC motors (1-Ph & 3-Ph).
• Induction Motors.
• Synchronous motors.
• Understand AC motor operation and construction.
• Overview of different types of motor duties.
• Read & explain the motor NP data.
• Motor de-rating factors.
• Motor enclosures
• Suitability of various designs
• Frame repair methods
• Fans and air deflectors

• Motor Mounting/Assemby
• Horizontal motors
• Vertical motors
• Typical motor applications
• Safety & handling considerations
• Basic motor theory
• Motor standards
• Stators
• Rotors
• Squirrel cage rotors
• Aluminum vs. copper
• Material/construction
• Performance characteristics
• Shafts
• Step-by-step replacement procedures
• Materials and design features
• Fits, clearances and importance of finish

• Bearings & lubrication
• Types: ball, roller, sleeve, hydrodynamic
• Installation and handling
• Special modifications:
• Roller-to-ball conversion
• Vertical mounting of horizontal motors
• Severe duty applications
• Lubrication systems
• Sleeve bearing repair
• Seals
• Labyrinth seal design
• Repair methods
• Aftermarket seal modifications: lip seals, non-contact bearing isolators
• Motor accessories & terminal boxes
• Test & inspection procedures
• Disassembly tips & procedures
• Time- and labor-saving ideas

• Motor Dynamics, alignment, vibration & noise
• Alignment (internal and external)
• Importance of air gap
• Dynamic balancing (emphasis on 2-poles)
• Storage procedures
• Synchronous machines
• Specify, select, and install motors.
• Specify speed control requirements for motors.
• Interpret motor performance curves
• Electrical motors in the Hazardous area.
• Install and commission motors
• Specify protection requirements for HV motors.

• Maintenance & testing of motors (Condition Monitoring and Diagnostics)
• Partial Discharge
• Insulation Resistance Monitoring
• Correction for Winding Temperature
• Insulation Contamination
• IR Test Connections
• Typical IR Testing Program
• DC HI-POT TEST
• Maximum Allowable Test Voltage
• Measuring Insulation Degradation
• Capacitive Charging Current
• Resistive Leakage Current
• Insulation Power Factor
• Insulation Power Factor Standards
• Power Factor Test Sets
• Outage for Scheduled Maintenance
• On-Line Measuring Partial Discharge Activity (PDA) For Insulation
• Motor Current Signature Analysis (MCSA)
• Shaft currents and corrective measures
• Explosion-proof motor repair
• Fix faults on motors.
• Failure Modes of Motors

• Fundamentals & basic concepts of control methods
• Starting methods of the motors
• Soft starters
• VFDs
• The protection system of motors
• Basics of VCB
• Incoming and post-disassembly tests
• In-process tests
• Pre- and post-assembly tests
• Explanations of the applied tests and how to interpret the results

Who Should Attend?
This training course is recommended for the following personnel:

• Electrical Engineers
• Maintenance Engineers and Technicians
• Operations Managers
• Plant Supervisors and Technicians
• Automation Engineers

Course outline

Day 1
Module 1: Introduction to Electric Motors

–  Basic construction and physical configuration, windings.

–  Principles of operation and performance.

–  How the motor produces torque.

–  Theory of operation.

–  Basic principles of rotating electric machines.

–  Fundamental principles of speed control.

–  Efficiency, torque, inertia, horsepower/power factor.

–  Torque-speed curves.

–  Motor Losses & Efficiency.

–  Induction motor design.

–  Duty cycles.

–  Insulation and Cooling requirements.

–  Selecting motors.

Types of Electric Motors:

–  Basic construction and physical configuration, windings.

–  Principles of operation and performance.

–  How the motor produces torque.

–  Theory of operation.

Module 2: Electrical Safety and Standards

Electrical Safety Procedures:]

Course Evaluation

–  AC motors (synchronous and asynchronous)
–  DC motors
–  Applications:
–  Industrial, commercial, and residential uses
–  Principles of Operation:
–  Electromagnetic induction
–  Motor torque and speed characteristics
–  Motor Components:
–  Stator, rotor, bearings, windings
–  Classified Ex motors.
–  De-rating Factors (Temperature, altitude, …etc.)
–  Voltage unbalance.
–  Power Factor Improvement
–  Motor Shaft Currents