Guidelines for

Repair/Replace Decisions
and Performance Optimization

Electrical Apparatus
Service Association, Inc.
1331 Baur Blvd.
St. Louis, Missouri 63132 USA
314-993-2220 FAX 314-993-1269
www.easa.com

This paper was presented by Austin H. Bonnett, EASA Education and Technology Consultant
at EASA's Convention in Chicago, Illinois, June 25, 2001

ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com 16

 Reliable Solutions Today!

GUIDELINES FOR REPAIR/REPLACE DECISIONS

AND PERFORMANCE OPTIMIZATION
By Austin M. Bonnett
Education and Technology Consultant
Electrical Apparatus Service Association, Inc.
St. Louis, Missouri
Chuck Yung
Technical Support Specialist
Electrical Apparatus Service Association, Inc.
St. Louis, Missouri
ABSTRACT
MOTOR REPAIR BEST PRACTICE GUIDES
For general-purpose motors, there are many cases where
The Electrical Apparatus Service Association (EASA)
replacing a failed motor with a new one of EPACT effi-
has available the following repair guidelines to assist
ciency levels or better is the best choice. However, in
in providing quality motor repairs.
some cases, the motor will fail again unless the root cause
of failure is addressed through some modification to the
ANSI/EASA AR100-1998, Recommended
motor or the system.
Practice for the Repair of Rotating Electrical Ap-
paratus, Copyright 1998.
There are also many cases where repairing the existing
motor is the best choice. This is especially true if an up- Association of Electrical and Mechanical Trades
grade is required to address the cause of failure, or in (AEMT) Good Practice Guide: The Repair of
some cases, where cost, availability or unique perfor- Induction Motors, Best Practices to Maintain En-
mance is an issue. The motor service center is in an ergy Efficiency, Crown Copyright 1998.
excellent position to make these assessments. The pur-
pose of this paper is to explore both choices and present EASA A Guide to AC Motor Repair and Re-
some of the many options available. placement, Copyright 1999.
Quite often when a motor fails, the procedure is to re- These documents can be obtained from EASA head-
move the damaged motor from service and replace it quarters in St. Louis to be used as reference
without a thorough evaluation of the root cause of the documents when selecting or working with a motor
failure. Depending on the motor size and the amount of repair facility.
damage, the old motor may be repaired and placed into
spares inventory or even scrapped. Appendix D includes several sample pages from these
documents.
The problem with this approach is that the replacement
motor, whether new or rebuilt, may fail again for the same able for the application, the service center is able to make
reason. If a root cause failure analysis is conducted, it is the required modification faster than the motor manu-
often possible to identify and correct the underlying facturer can produce a unique model.
cause. All that may be required is to modify the motor,
driven equipment or system to extend the mean time The application checklist in Appendix A can be used to
between failures (MTBF) significantly. assist in this analysis.

In most cases, where a standard motor is no longer suit- INTRODUCTION

The Electrical Apparatus Service Association (EASA) has
This paper was presented at EASA's Convention in established Recommended Practices for its 2500 mem-
Chicago, Illinois, June 25, 2001. bers around the world to assure that the repair process
does not degrade the motor performance characteris-

ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com 1

 Guidelines for Repair/Replace Decisions and Performance Optimization

tics. This paper provides the reader with a repair guide- for the study. The Dowding and Mills facility in Birming-
line to implement these procedures with their local repair ham, UK will facilitate all motor modifications and repairs
organizations. that are part of the study. The University of Nottingham
will perform the basic load testing on their dynamom-
Criteria are presented to determine when the repair of eters in Nottingham. There may be additional tests
the motor is not practical and may lead to reduced effi- performed at Dowding and Mills.
ciency levels. In some cases, it is possible to improve
ROUND ROBIN TESTING AND TEST PROTOCOL
the level of operating efficiency during the repair pro-
cess. One motor will be selected for round robin testing to en-
sure the accuracy of the Nottingham University facility.
EASA members rebuild electrical equipment, primarily These tests will be conducted at the U.S. Electrical Mo-
motors and generators. Many EASA service centers also tors Motor Technology Center in St. Louis, Mo. and the
rebuild peripheral equipment such as pumps and Invensys Brook Crompton UK plant. Both IEEE and IEC
switchgear. methods of efficiency testing will be conducted. All test-
ing will include (at no load and full load) a loss segregation
EASA is in the process of conducting a major test pro- method that allows for detailed analysis.
gram to verify the results of these Recommended
Practices. This paper will include an update on this work OTHER DELIVERABLES
in progress. It is expected that due to the large size of the sample
and the data collected additional deliverable might be
EASA/AEMT MOTOR REWIND STUDY developed as part of a supplementary document. It may
be possible to update an EASA tutorial on other aspects
INTRODUCTION of motor repair that affect overall motor performance and
efficiency. Winding configuration, span, slot fill, flux den-
Previous studies were conducted on motors in the 10 hp sity and mechanical factors will be considered.
range at four-pole speeds, which do not reflect the true
degree of difficulty associated with rewinding the typical SCHEDULE
failed motor. The EASA/AEMT Motor Rewind Study is
The motors are all now at the University of Nottingham
focusing on motors that are more typically rewound for
both the NEMA and IEC designs.
FIGURE 1: REPAIR OR REPLACE OPTIONS
OBJECTIVE OF STUDY
The major objectives of the study include:
Issue a best practice guide for motor rewinds.
Determine whether low- and medium-voltage ma- Failed motor
chines respond similarly. Repair Replace
Investigate the impact of repeated rewinds of the Options
same motor.
Establish the correlation between the static core
loss test and the running core loss test. Restore EPACT
Repair to original
Evaluate the impact of physical damage to the sta- condition
Level Efficient
tor core.
SCOPE OF PRODUCT EVALUATED Redesign/Upgrade
Optimize horsepower Premium
There will be at least 27 motors used in the study, most to load Efficient
of which will be in the 50 to 200 hp range. Both 50 and Optimize voltage
Change speed
60 Hertz will be included, as well as low- and medium- Inverter-duty winding
voltage, IEC and NEMA frames, ODP and TEFC Increase insulation
class
enclosures and two- and four-pole speeds.
PARTICIPATING MANUFACTURERS Modify Customized
AND INSTITUTIONS Improve enclosure motor
Add seals
At least seven different motor manufacturers have com- Make bearing
modifications
mitted to provide motors, technical data and assistance

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 Guidelines for Repair/Replace Decisions and Performance Optimization

FIGURE 2: REPAIR OR REPLACE DECISION PROCESS

Failed motor

Is the motor suitable for the Investigate replacement with suitable motor (size/enclosure).
No
application?
Yes

What is the condition of the

Significant damage or high losses
stator core?

OK
Special cases
(e.g., very expensive
motors)
Has catastrophic failure occurred,
or is there evidence of prior Yes
catastrophic failure?

No
Is the cost of repair greater than Yes
Is the rotor damaged, or is there the cost to replace the motor?
severe damage to other Yes
mechanical parts? No
No Are replacement funds available?
No Yes

Is it an EPACT motor? Yes No Is replacement motor available?

No Yes

Is return on investment of EPACT Is lead time of replacement motor

Yes No
motor acceptable? acceptable?
No Yes

Repair motor Replace motor

Additional considerations include increased reliability, life expectancy and benefits of additional features, upgrades
or modifications.

and testing is under way. lt is expected that this evalua-
tion will be complete by the end of 2001. The co-chairmen
are David Walters and Austin Bonnett. The technical
group will review progress monthly and have already held
one meeting in Birmingham.
REPAIR-REPLACE DECISION MODEL
In the past, the decision whether to repair or replace an
electric motor has been one of economics. Replacement
of an older electric motor with a more efficient model
often makes sense for a motor operating continuously.
However, in most cases the decision is more complex
(Figures 1 and 2). A motor operating infrequently, a mo-
tor with special mounting or design features, an EPACT
motor or a motor larger than those covered by EPACT
are all examples where the repair option may be the bet-
ter choice.
When comparing the cost to replace or repair an electric
motor, the equation should include not only operating
cost and payback period, but also downtime and associ-
ated factors such as capital depreciation, lost
opportunities and customer good will. A replacement
EPACT motor that fails within a year or two may have a
significantly higher cost than a repair that optimizes the
motor for its unique application.

ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com 3

 Guidelines for Repair/Replace Decisions and Performance Optimization

Annual energy savings of several hundred dollars are TABLE 1: LEVELS OF REPAIR
quickly wiped out by unscheduled downtime when a
motor fails unexpectedly. Level 1 Basic reconditioning. Includes replacing
bearings, cleaning all parts and replacing
Much of todays literature emphasizes efficiency and the lubricant. Also adds seals and other acces-
cost of energy as stand-alone factors in the repair-re- sories as agreed with customer.
place decision matrix. Frequently, the cost of the motor Level 2 Includes Level 1 with the addition of varnish
or its repair is a small fraction of the total cost of down- treatment of stator windings, repair of worn
time when lost production is factored in. bearing fits and straightening of bent shafts.
Level 3 Includes Level 1 as well as rewinding the sta-
Considerations (other than efficiency and simple pay- tor (replacing windings and insulation).
back) include reliability, performance and anticipated Level 4 Includes rewinding of the stator plus major
motor life as well as availability of a replacement. Of these, lamination repair or rotor rebar. May include
the most critical may be reliability. A motor customized replacement of the stator laminations or
to its application will offer the greatest chance of long restacking of laminations. Shaft replacement
life. (See Appendix C for a list of repair options.) Zero would normally fall into this category. In short,
downtime is a noble goal, one that requires commitment Level 4 involves major repairs that are costly
and planning. enough to justify examining the option of re-
placement.
NEMA MG 1-1998 defines Unusual Service Conditions Level 5 Motors that would normally be replaced ex-
(Appendix B). Most readers will recognize many of these cept for special circumstances faced by the
as the norm for real-life motor applications. By itself, this customer (i.e., no spare or unacceptable lead
fact may be justification for repair and customization of time for a replacement). Level 5 includes
a failed electric motor. misapplied motors, inadequate enclosures
and pre U-frame motors. A motor that should
be replaced, if not for the owners inability to
s
ing

operate without it.

ind

Dr

ge
W

volta n
ive

Be tio
Line ica
n

ar As these five levels imply, the damage resulting from

ing r
lo

En b
ad

s v ir
on Lu a motor failure varies widely as do the associated re-
me
nt pair costs. An evaluation process that fails to consider
the various levels of repair is too simplistic to yield
an accurate assessment.
It makes economic sense to identify the weak link in any
process, and to detect imminent failure before it occurs.
When the weak link is strengthened, the entire process FIGURE 3: FAILURES BY COMPONENTS
becomes stronger. A motor subject to accidental wash-
Rotor bar 5% Shaft/coupling 2%
down should be of a suitable enclosure, and can be
modified to further protect the motor from this hazard. Unknown 10%*
(No root cause
Likewise, since more than 50% of electric motor failures failure analysis
performed)
start as bearing failures, bearing temperature detectors
or vibration probes are logical options in many cases, as
shown in Figure 3. External 16%*
(Environment, voltage
and load will likely
occur again)
With todays rapidly changing technology, the motor
manufacturer is hard-pressed to incorporate emerging
technology within a 2- to 3-year period. One advantage
the service center has is its ability to deal with each Stator winding 16%*
(May have been voltage,
unique motor and apply new technology as it develops water, overload, etc.) Bearing 51%*
to address specific concerns about that particular motors
* For each component shown, appropriate measures
application and environment. to either prevent or predict the failure could greatly
reduce three-quarters of motor failures.
This means the end user can take advantage of unique
Reference: IEEE Petro-Chemical paper PCIC-94-01
technology that meets their unique needs.

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 Guidelines for Repair/Replace Decisions and Performance Optimization

Whether the concern is winding temperature, vibration
or bearing temperature, specific accessories can be in-
corporated into the repair process to enhance motor
life and permit the end-user to monitor the critical fea-
ture.
Consider winding temperature alone: There are 4 dif-
ferent RTD resistances, 14 different thermocouples and
numerous thermistors and bimetallic switches in com-
mon use. Clearly, a stock motor cannot cover all these
options. These features are a special order from motor
manufacturers and usually require long lead times. The
service center is able to tailor the motor repair to match
the monitoring equipment used by the user, incorporat-
ing special features without impacting the repair
turnaround.
Vibration monitoring is available as a continuous, on-
line system. Accelerometers are but one item that can
be retrofitted to improve the users ability to predict
equipment failure. Non-contact shaft probes, acceler-
ometers intended for continuous monitoring and periodic
data collection, accelerometers integral to a sophisti-
cated continuous monitoring system; all are available

FIGURE 4 : POSSIBLE MOTOR UPGRADES AND MODIFICATIONS

Windings
Core damaged? Repair/restack core
Rewind? Optimize voltage? Replace core
Special coatings?
Inverter duty?
Optimize slot fill
Winding RTDs?

Bearings
Replace bearings* Mechanical damage
Add seals* to shaft and housing
Install automatic Is is repairable?
lubrication device If replacing shaft, is
Special grease there a better material?
Change bearing type* Is stainless steel
warranted?
Are shaft modifications
warranted?

Other options
Upgrade enclosure Change starting method to
Improve sealing of reduce in-rush current
the enclosure Add space heaters
Upgrade paint for corrosion Precision balance rotor
resistance Increase air flow

Special considerations
Corrosion Inverters
Special paints Spike-resistant wire
Varnish treatment Higher corona-inception voltage
Stainless steel shaft Upgrade winding bracing
Abrasion
Special energy-absorbing coatings
Improve wedging
Upgrade enclosure and add filters

Moisture Heat Severe starts

Special coatings Add RTDs Better shaft material
Shaft seals Improve fan design Stronger shaft design
Seal leads Heat exchanger Additional winding bracing
Gaskets Upgrade insulation class Change starting method
Seal brackets
Space heaters * Adding seals or changing bearing types may affect efficiency.

Illustration courtesy of Siemens AG

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 Guidelines for Repair/Replace Decisions and Performance Optimization
technology today. Once a user makes the financial com-
mitment to a particular system, it is rarely practical to
abandon it in favor of another emerging technology. That
makes the service center a partner in maintaining the
system(s) selected by each end user.
With most companies returning to their core business,
and outsourcing maintenance, the competent service
center is best qualified to assess the cause of each mo-
tor failure and develop a plan to reduce the possibility of
a repeat failure. The service center warranty ensures
the repairer has a vested interest in identifying the root
cause of the motor failure, and performing a quality re-
pair.
EXAMPLES OF UPGRADES
AND MODIFICATIONS
Once a cause of failure is determined, the service cen-
ter can work with the equipment owner to identify specific
remedies to extend MTBF. The following are but a few
examples of frequent problems and solutions ser-
vice centers encounter.
VOLTAGE OPTIMIZATION
A municipal pump station is located at the end of the
power transmission line. Motor failures are common, and
winding temperatures are higher than identical motors
operating at the water treatment plant in town. Repeated
measurements have confirmed chronic low voltage.
When a winding failure is the result of low applied volt-
age, the replacement motor regardless of efficiency
will be subject to the same low line voltage. The solu-
tion, then, is to redesign the motor to optimize
performance at the actual applied voltage. It is common
to apply a 230 volt motor to a 200 or 208 volt application.
Compounding the problem, the utility supplying 208 volts
is allowed to deviate and may supply even lower voltage.
TABLE 2: EFFICIENCY AND WINDING
TEMPERATURE
Volts 208 230
Efficiency (%) 80.6 84.4
Power factor (%) 85.0 82.7
Full load current (amps) 30.5 26.9
Inrush current (amps) 129 148
Temperature rise ( C) 91 72
Slip (%) 5.9 4.1
Design B, 4-pole, tri-voltage motor (208-230/460)
ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com
Table 2 illustrates the effect on efficiency and winding
temperature.
Low voltages are especially common in rural areas,
where the motor may be operating at a considerable dis-
tance from the nearest substation. Irrigation pumps and
municipal pump stations are two examples.
While many manufacturers can deliver a motor to opti-
mize non-standard line voltage, typical manufacturer lead
times of five to eight weeks may be prohibitive. The ser-
vice center can accomplish the same voltage optimization
during a motor repair.
An added benefit: It is common practice for manufactur-
ers to produce motors with up to 12 leads, so that the
motor may be used on multiple voltages, often as a part-
winding start or wye-start, delta-run. This means the
electrician may deal with 9 to 12 leads in the junction
box, increasing the chances of a ground failure from
abraded leads. When an electric motor is repaired, the
service center has the option of installing only the num-
ber of leads required. With only 3 or 6 leads, there is
more room in the junction box and less chance of lead
damage or misconnection during installation.
Note: Tri-voltage motors represent a compromise be-
tween the possible applied voltages. This improves
potential availability, to the detriment of efficiency at cer-
tain applied voltages.
VIBRATION MONITORING AND IMPROVEMENT
A Blanchard grinder begins to vibrate, and pieces of valu-
able precision plate are scrapped before the cause is
identified.
FIGURE 5: ROTOR BALANCING
Rotor being dynamically balanced in a service center.
6
 Guidelines for Repair/Replace Decisions and Performance Optimization

Vibration sensors are vital when the application is a pre- BEARING TEMPERATURE PROTECTION
cision grinder or similar vibration-sensitive equipment.
Installation of vibration probes can be accomplished by
The cause of a plant fire is tracked back to a bearing
the service center with minimal intrusion into the motor.
failure. The bearing, unmonitored, failed catastrophically.
Accelerometers can be installed on the frame or in the
Vibration damaged the pump seal and the pump leaked,
junction box, while non-contact shaft probes may be pre-
by which time the bearing temperature was high enough
ferred for sleeve bearing machines. A finishing grinder in
to ignite the spewing liquid.
a machine shop must hold close tolerances to minimize
Bearing temperature protective devices (Figure 6) can
scrap. Vibration from a defective bearing can be expen-
be installed during routine repairs to provide early warn-
sive.
ing of increased temperature. Excessive lubrication
Another good candidate for vibration sensors is a pump
intervals, high ambient temperature, imminent bearing
motor operating in a remote location. Continuous moni-
failure and other general machinery faults may cause
toring by instrument is infinitely better than a weekly visit
an increase in bearing temperature before damage oc-
by a plant operator.
curs. A bearing RTD is not intended to just protect the
bearing, but rather to protect the machinery by alerting
The service center can install the appropriate vibration
personnel when an equipment fault results in an increase
sensing accessories on eligible motors in the course of
in bearing temperature. Depending on the critical nature
each repair.
of the machine, feedback can take the form of a light in
the control room, or automatic shutdown of the equip-
Manufacturers standard motors are balanced to NEMA
ment.
MG 1-1998, Part 7 specifications while the service cen-
ter can routinely balance to one-quarter of NEMA or
The service center can install the appropriate tempera-
better. While precision manufacturing has a legitimate
ture detectors to interface with instrumentation already
need for this, many end-users request special balance
in use at the plant.
tolerances because they recognize that there is a reli-
ability factor associated with vibration.
The cost to fit an electric motor with bearing thermals
may be only a few hundred dollars. That cost should be
FIGURE 6: BEARING TEMPERATURE weighed against the possible consequences of failure,
DETECTORS not against the cost of the motor.
Weatherproof terminal head CORROSION RESISTANCE
Spring-loaded, fluid-seal holder Bearing A chemical plant removed a 600 hp motor for routine
repairs. The corrosive environment had rusted through
the motor frame in numerous places, even the mounting

FIGURE 7: TYPICAL MOTOR ENCLOSURE

Probe element UPGRADES
Customer's
conduit
entrance Bracket outer wall

Courtesy of Minco Courtesy of Siemens AG

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 Guidelines for Repair/Replace Decisions and Performance Optimization
FIGURE 8: STRESS RAISERS
A B
The lines indicate the path of stresses in the shaft. Where stresses converge, the chance of failure is much higher. The sharp
inside corner of shaft C is 40% weaker than it would be with an appropriate radius.
feet. Although running when removed from service, the
motor was beyond repair and had to be replaced.
When a motor (new or rebuilt) is placed into a known
corrosive atmosphere, the service center can take pre-
cautions to greatly improve motor life. At the simplest,
corrosion-resistant paint can be used to protect the frame.
In extreme cases, the shaft can be chrome plated, or
replaced with a stainless steel shaft to better resist cor-
rosive materials. When caustic solutions are evident,
aluminum parts may be quickly eroded. Preventive mea-
sures may be as simple as dipping the rotor with varnish
to protect it. The rotor might even be rebarred using
bronze alloy of similar resistivity to avoid changing the
torque characteristics (rotor cage resistance should be
maintained to avoid changing motor performance). The
rotor should also be balanced after work is done to the
rotor. A precision balance requires only slightly more time
than a standard balance.
The exploded view of an open motor (Figure 7) illus-
trates the ease with which various degrees of weather
protection can be accomplished by the addition of cov-
ers, filters or guards. While an open motor is ill-suited to
outdoor operation, the upgraded WPII enclosure was de-
signed for outdoor service.
HIGH-TORQUE APPLICATIONS
An electric motor driving a hammer mill application fre-
quently experiences a broken shaft.
There are several ways to approach this problem de-
pending on the application. One would be to replace the
shaft using material with higher tensile strength than the
original shafting. The corners should all be radiused to
minimize potential stress raisers (Figures 8 and 9). The
keyway can be machined in a manner to reduce the stress
raisers at the end of the keyway (a sled-type keyway as
opposed to a milled keyway.) In extreme cases, the key-
way can be milled with a radius bottom and fitted with a
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C
FIGURE 9: STRESS RAISERS
VENT FAN
ROTOR CORE COUPLING/
PULLEY
BEARING
BEARING
A B C D E F G H I J
All of the highlighted areas create stress raisers. Points F,
H, I and J are usually the most vulnerable because of shaft
load at these points. It is hard for a shaft to fracture at
points A, B, C, D or E.
custom key. It is not necessary to modify the keyway in
the coupling.
Most service centers can machine custom shafts and
keyways to address concerns about fatigue-related fail-
ures.
WASH DOWN AND FLOODING
When a power outage occurs, the sump pumps stop and
the pit floods. Electric motors must be removed, cleaned
and dried before production can be restored.
Accidental wash down and flooding cause many electric
motor failures. To increase reliability, special seals are
installed on the shaft openings to exclude water from
the bearings (Figure 10). Special water-resistant grease
can be used to pack the bearings, to further resist wash-
ing of lubricants. Sealed bearings may be preferred when
the installation precludes regular maintenance.
The service center can seal T-leads using special pot-
ting compounds to prevent water from entering through
the lead opening. End brackets can be sealed with sili-
cone during the assembly process. These are
inexpensive steps, but are very effective for a motor sub-
ject to flooding or inadvertent wash down. Examples of
8
 Guidelines for Repair/Replace Decisions and Performance Optimization
FIGURE 10: NON-CONTACT BEARING ISOLATOR
The standard-design non-contact bearing isolator consists
of two parts: The stator, which is press-fitted into a bearing
housing and is designed to retain lubricant in the housing,
and the rotor, which in combination with the stator, is
designed to keep contamination out of the bearing housing.
Courtesy of Inpro/Seals Company
candidates for this sort of modification include motors
operating below grade in pump rooms, as well as cool-
ing tower motors.
PROTECTION FROM ABRASIVE DUST
An electric motor operates downwind of a rock quarry
and abrasive dust sandblasts the windings.
Unprotected windings do not last very long in this type
of environment. The service center can topcoat the wind-
ings with a special material that absorbs impact energy,
thus protecting the windings. Filters can be added to
exclude the dust from the motor enclosure, or additional
covers can be installed to upgrade the enclosure.
Motors operating in rock quarries, cement mills or power
plants benefit from this treatment. Motors operating near
agricultural fields may also benefit. These treatments can
also be applied to new motors before they are placed
into service.
RECONNECTION
To reduce starting torque, a wye-start/delta-run connec-
tion can be used. In some cases a motor can be
reconnected, while in other cases a rewind is required.
Other starting options include a VFD or a solid-state soft-
starter.
There will always be applications where reduced start-
ing current will be required. In most cases a Design A
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FIGURE 11: ALTERNATIVE METHODS
OF CONNECTION
wye start - delta run
part winding
double delta
motor will still be justified, when coupled with an appro-
priate starter sized for the current. Typical paybacks when
comparing energy savings against capital investment
range between 1 and 3 years, based on the cost of en-
ergy and hours of running time. Wye-delta starting
reduces inrush current to 37% and provides one-third
the torque. Part-winding start methods reduce inrush cur-
rent to one-half to two-thirds while supplying one-half
the starting torque.
The service center can often reconnect an existing wind-
ing to reduce starting current and torque. (See Figure 11.)
ENERGY EFFICIENCY IMPROVEMENT
There are occasions when rewinding a motor where the
opportunity may exist to enhance the motor performance
and reliability by modifying the winding configuration and
copper content. For many designs, the copper loss (I2R)
is the largest loss component (Figure 12). In some cases,
this loss can be reduced by converting from a concen-
tric, machine-wound configuration to a traditional,
hand-inserted lap winding. In many cases, the copper
9
 Guidelines for Repair/Replace Decisions and Performance Optimization

FIGURE 12: TYPICAL DISTRIBUTION OF LOSSES TABLE 4: ENERGY EFFICIENCY IMPROVEMENT

Stray load losses Friction and windage losses

Full-load efficiency (%)

10-15% 5-10%

Nameplate NNE (%)

Space factor (%)*
Winding type
Horsepower
Stator core losses
15-20%

Original pre-EPACT 25 Machine 43.0 88.5 88.7

Rotor losses Rewound pre-EPACT 25 Lap 62.0 90.2 90.8

15-20%
EPACT reference 25 91.7

Stator winding losses Original pre-EPACT 50 Machine 46.0 91.7 91.6

35-40%
Rewound pre-EPACT 50 Lap 60.0 92.4 92.6
The laminated core, stator windings and rotor account for EPACT reference 50 93.0
as much as 80% of the total losses for the typical electric
Typical 4-pole, open dripproof, general purpose, T-frame motors of pre-
motor. While losses are generally associated with lost energy efficient design.
efficiency, they represent energy converted to heat.
3.14 D 2
Total number of wires per slot of wire
4
*Percent space factor = 100
NEMA Standards MG 10-1994, Table 2-2 (National Elec- Total slot area - area of insulation
trical Manufacturers Association, Rosslyn, VA, 1994). D = wire diameter

content (slot fill) can also be increased. Figure 13 shows

the contrast between a relatively low slot fill (40 to 50% FIGURE 13: EXAMPLES OF SLOT FILL
where the wire is PD2/4) and one of a much higher per-
cent slot fill (60 to 64%).

This modification will improve heat transfer, reduce the

copper loss and winding temperature and improve mo-
tor efficiency. There will be less coil movement, and
increased resistance to moisture, due to better varnish
retention. Even though these improvements are difficult
for the service shop to quantify, they are none the less
real and will usually improve motor performance and re-
liability. With this modification, the motors service factor
will be improved and it will be able to withstand wider Low slot fill Improved slot fill
variations in voltage, ambient and starting conditions.
improve processes, and the competent service center is
Table 4 shows the possible efficiency improvements that able to assist in this task.
can be made for a generation of T frame motors pro-
duced during the 1970s and 80s. Not all motors offer When evaluating the operating cost of an electric motor,
this opportunity, but for those that do this option should the cost of energy is only one variable (and often not the
be considered as a possible product improvement. biggest one) in the equation. The key to maximizing pro-
ductivity is to eliminate downtime. While zero downtime
CONCLUSION
is not always possible, any significant reduction in down-
By incorporating effective technology as it becomes avail- time improves profitability. When downtime is measured
able, it is possible to reduce downtime, improve in thousands of dollars per hour, the payback reaped
productivity and operate more efficiently. Reduced costs from extending motor life can be enormous.
make an organization more profitable. Savings can be The economics of the repair or replace decision process
redirected to improve other weak links. The savvy main- are complex. All variables must be considered in order
tenance professional is always looking for ways to to select the best option.

ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com 10

 Guidelines for Repair/Replace Decisions and Performance Optimization

REFERENCES
Principles of Large AC Motors. Electrical Apparatus
Service Association, Inc., St. Louis, MO, 2000.

Intelligent Motors Take the Lead in Predictive Main-

tenance. Matt OKane, U.S. Electrical Motors, St.
Louis, MO. Presented at EASA Convention 2000,
Anaheim, CA, April 5, 2000.

Ongoing Issues With AC Electric Motors. Austin

Bonnett, Education and Technology Consultant, Elec-
trical Apparatus Service Association, Inc., St. Louis,
MO, and Cynthia Nyberg, Technical Support Special-
ist, Electrical Apparatus Service Association, Inc., St.
Louis, MO. Presented to the EPRI-sponsored National
Motors & Drives Steering Committee, Montreal, Que-
bec, Canada, June 29, 2000.

A Survey of Faults on Induction Motors in Offshore

Oil Industry, Petrochemical Industry, Gas Terminals
and Oil Refineries. Olav Vaag Thorsen, Senior Mem-
ber IEEE and Magnus Dalva, Member IEEE. IEEE
Transactions on Industry Applications, Vol. 31, No. 5,
Sept./Oct. 1995.

Root Cause Failure Analysis for Large AC Induction

Motors. Austin Bonnett, Education and Technology
Consultant, Electrical Apparatus Service Association,
Inc., St. Louis, MO. Presented at EASA Convention
1999, Toronto, Ontario, Canada.

ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com 11

 Guidelines for Repair/Replace Decisions and Performance Optimization
APPENDIX A Application Checklist
Voltage
What is the nominal voltage?
How much voltage variation is present?
Is there voltage drop when starting under load?
Is there nuisance tripping?
Are there transient peaks?
Environmental factors
What is the frequency of moisture ingression?
What is the frequency of condensation?
What is the ambient temperature range?
What other contaminants are present?
Load conditions
Are there load swings? If so, how wide?
What is the hp required versus rated hp?
What is the load pump, fan, compressor, conveyor?
How is the motor mounted / coupled?
Direct coupled What are the thrust conditions?
Overhung load Describe the motors mounting.
Starting method
Across-the-line Part-winding start
Wye start, Delta run Soft-start
APPENDIX B Unusual Service Factors, NEMA MG 1-1998, 14.3
14.3 UNUSUAL SERVICE CONDITIONS
The manufacturer should be consulted if any unusual ser-
vice conditions exist which may affect the construction or
operation of the motor. Among such conditions are:
a. Exposure to:
1. Combustible, explosive, abrasive, or conducting dusts
2. Lint or very dirty operating conditions where the accu-
mulation of dirt may interfere with normal ventilation
3. Chemical fumes, flammable or explosive gases
4. Nuclear radiation
5. Steam, salt-laden air, or oil vapor
6. Damp or very dry locations, radiant heat, vermin in-
festation, or atmospheres conducive to the growth of
fungus
7. Abnormal shock, vibration, or mechanical loading from
external sources
8. Abnormal axial or side thrust imposed on the motor
shaft
b. Operation where:
1. There is excessive departure from rated voltage or
frequency, or both (see 12.45 for alternating-current
motors and 12.68 for direct-current motors)
2. The deviation factor of the alternating-current supply
voltage exceeds 10 percent
3. The alternating-current supply voltage is unbalanced
by more than 1 percent (see 12.46 and 14.36)
ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com
Frequency of starting
What is the running time between starts?
How many starts per hour / 8-hours / 24-hours?
Is it a demand system?
Is it a constant or variable load?
Describe the cycling.
Are there load-shedding opportunities?
Describe unusual service conditions
See Appendix B, NEMA MG 1-1998, 14.3
Describe the application
How critical is the operation?
Is it a dedicated or redundant system?
What is the availability of spares or backups?
What are the consequences of shutdown?
History of failures or repairs
Has the motor been rewound? If so, how many
times?
What is the mean time between failures?
Root cause failure analysis
What is the cause of failure?
What can be done to eliminate the cause?
What is the best method to detect the condition?
Are there similar motors and applications?
4. The rectifier output supplying a direct-current motor is
unbalanced so that the difference between the highest
and lowest peak amplitudes of the current pulses over
one cycle exceed
10 percent of the highest pulse amplitude at rated arma-
ture current
5. Low noise levels are required
6. The power system is not grounded (see 14.31)
c. Operation at speeds above the highest rated speed
d. Operation in a poorly ventilated room, in a pit, or in an
inclined position
e. Operation where subjected to:
1. Torsional impact loads
2. Repetitive abnormal overloads
3. Reversing or electric braking
4. Frequent starting (see 12.55)
5. Out-of-phase bus transfer (see 14.45)
6. Frequent short circuits
f. Operation of machine at standstill with any winding con-
tinuously energized or of short-time-rated machine with any
winding continuously energized
g. Operation of direct-current machine where the average
armature current is less than 50 percent of the rated full-
load amperes over a 24-hour period, or continuous
operation at armature current less than 50 percent of rated
current for more than 4 hours
12
 Guidelines for Repair/Replace Decisions and Performance Optimization

APPENDIX C Repair Options

At the time of the motor repair, in addition to the task of Increase motor cooling
restoring the motor to its original condition, it is possible to Directional fans
make modifications and upgrades. During the repair it may Special fans to increase air flow
become evident that the motor will fail again if returned to its Heat exchanger
existing environment without modification. It may also be ex- Auxiliary blower (especially for VFD-fed motors)
pedient to implement certian upgrades to enhance motor Maximize slot fill
performance, reliability and life. Special accessories
The following is a list of possible options that may be con- Winding temperature detectors
sidered by the repair facility. Bearing temperature detectors
Vibration monitoring: accelerometers or non-contact
Bearings shaft probes
Enclosure sealed, shielded or open Oil chamber heater and thermostat for cold climates
Roller or ball (for direct couple or radial load) Leads
External seals Bring out minimum number of leads
Non-contact bearing isolator Seal the lead opening against moisture and chemicals
Lip seal Increase the lead size
Lubrication Other special considerations such as bus bar, special
Synthetic grease lugs, etc.
Automatic grease applicators Noise reduction
Oil-mist systems Add soundproofing material
Forced-lube oil systems Add exterior shrouding
Mineral oil for food service or potable water applica- Utilize special fan configurations
tions Special balance requirements
Severe starting conditions Outlet box
Increase rigidity of winding blocking Size
Redesign to wye start, delta run to reduce torque and Better enclosure for weather protection
inrush current Efficiency considerations
Increase slot fill Voltage optimization
Environmental protection Upgrade insulation class
Abrasion resistance Concentric to lap conversion
Special coatings Optimize span
Full-length slot wedges for form coil machines Maximize slot fill (copper and insulation)
Corrosion resistance Connection options (wye start, delta run; part-winding
Special epoxy paints start)
Stainless steel shafting Field support
Lead potting compound Startup
Filters Predictive maintenance
Screens, baffles or covers Vibration monitoring
Power considerations Current analysis
Power factor correction capacitors Thermography
Surge protection or lightning arrestors Tribology

ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com 13

 Guidelines for Repair/Replace Decisions and Performance Optimization

APPENDIX D Motor Repair Guidelines and Resources

EASA AR100-1998 Recommended Practice - Rev. January 1998 Standards Organizations

Standards Organizations & Other Resources

The following organizations produce documents NEMANational Electrical

and standards, some of which are referenced in the Manufacturers Association
EASA Recommended Practice for the Repair of Ro- 1300 N. 17th St., Suite 1847
tating Electrical Apparatus. Rosslyn, VA 22209
(703) 841-3200
ABMAAmerican Bearing For Publications:
Manufacturers Association (703) 841-3201
1200 19th St., NW, Suite 300 Fax: (703) 841-3300
Washington, DC 20036
(202) 429-5155 NFPANational Fire
Fax: (202) 223-4579 Protection Association
One Batterymarch Park
ANSIAmerican National Quincy, MA 02269
Standards Institute (617) 770-3000
11 West 42nd St., 13th Floor Fax: (617) 770-0700
New York, NY 10036
(212) 642-4900 For Publications:
Fax: (212) 302-1286 P. O. Box 9146
Quincy, MA 02269
IECInternational (800) 344-3555
Electrotechnical Commission * Fax: (617) 984-7057
3 rue de Varembe
CH 1211 Geneva 20, Switzerland NISTNational Institute of
Standards and Technology
IEEEInstitute of Electrical and Electronics Route 270
Engineers, Inc. Gaithersburg, MD 20899
345 East 47th St. (301) 975-2000
New York, NY 10017
(212) 705-7900 ULUnderwriters Laboratories, Inc.
Fax: (212) 752-4929 333 Pfingsten Rd.
Northbrook, IL 60062
For Publications: (847) 272-8800, Ext. 42612
445 Hoes Lane Fax: (708) 272-8129
P. O. Box 1331
Piscataway, NJ 08855-1331
(800) 678-4333
Fax: (908) 981-9667

ISOInternational Organization
of Standardization *
1 rue de Varembe
CH 1211 Geneva 20, Switzerland

MIL-STDUnited States Government

Printing Office
710 North Capitol St.
Washington, DC 20420 * IEC and ISO standards are available through ANSI, which
(202) 512-1800 is the American representative to all international stan-
Fax: (202) 512-2250 dards groups.

EASA AR100-1998 Recommended Practice - Rev. January 1998 Table of Contents, Page 1 Table of Contents, Page 2 EASA AR100-1998 Recommended Practice - Rev. January 1998

TABLE OF CONTENTS 3.9 THERMAL PROTECTORS OR SENSORS 4.6 PERFORMANCE TESTS

3.10 SHAPING AND LACING OF STATOR 4.7 INSTRUMENT CALIBRATION
WINDINGS TABLES
3.11 COIL CONNECTIONS 4-1 High-Potential Test Using ACNew
SECTION 1: GENERAL 2.13 ACCESSORIES
3.11.1 Making Connections Windings
1.1 PURPOSE TABLES
3.11.2 Insulating Connections 4-2 High-Potential Test Using DCNew
1.2 SCOPE 2-1 Shaft Extension Diameter Tolerances Windings
3.12 WEDGES
1.3 IDENTIFICATION NEMA Frame Size Machines
3.13 BANDING OF ROTORS AND 4-3 High-Potential Test Using ACNew
1.3.1 Service Center Labeling 2-2 Shaft Extension Diameter TolerancesIEC Accessories
ARMATURES
1.3.2 Records Frame Size Machines
3.14 IMPREGNATION OF WINDINGS 4-4 High-Potential Test Using DCNew
1.3.3 Nameplate 2-3 Permissible Shaft Extension RunoutNEMA Accessories
Frame Size Machines
1.4 CLEANING 4-5 Unfiltered Vibration LimitsResiliently
2-4 Permissible Shaft Extension RunoutIEC SECTION 4: TESTING
1.5 TERMINAL LEADS Mounted Machines
Frame Size Machines 4.1 SAFETY CONSIDERATIONS
1.6 TERMINAL CONNECTORS
2-5 Shaft Extension Keyseat Width Tolerances 4.2 INSULATION CONDITION TESTS
1.7 TERMINAL BOXES APPENDIX: ELECTRICAL TESTING
NEMA Frame Size Machines 4.2.1 Inspection
1.8 COOLING SYSTEM SAFETY CONSIDERATIONS
2-6 Shaft Extension Keyseat (Keyway) Width 4.2.2 Insulation Resistance Test
1.9 EXTERIOR FINISH TolerancesIEC Frame Size Machines A.1 PERSONAL SAFETY
4.2.3 Polarization Index (P-I) Test
1.10 PACKAGING AND TRANSPORTATION 2-7 Sleeve Bearing Diametral Clearance Guide A.1.1 Training
4.2.4 Insulation Power Factor Tests
Horizontal Mounting A.1.2 Clothing
4.2.5 Step Voltage Test
2-8 Labyrinth Seal Diametral Clearance Guide A.1.3 Supervision
SECTION 2: MECHANICAL REPAIR 4.2.6 Turn-to-Turn Test
2-9 Mounting Surface Tolerances, Eccentricity, A.1.4 First Aid
2.1 SHAFTS 4.2.7 Interlaminar Insulation Test
and Face RunoutNEMA Type C Face- A.2 TEST AREA
2.1.1 Shaft Extensions 4.2.8 Bearing Insulation Test
Mounting Motors and Type D Flange-Mount- A.2.1 Enclosure
2.1.1.1 Diameter Tolerances 4.3 RECOMMENDED WINDING TESTS
ing Motors A.2.2 Gates
2.1.1.2 Permissible Runout 4.3.1 Stator and Wound-Rotor Windings
2-10 Mounting Surface Tolerances, Eccentricity, A.2.3 Signs
2.1.1.3 Keyseat (Keyway) Width and Face RunoutNEMA Type P Flange- 4.3.2 Squirrel Cage Windings
Tolerances A.2.4 Lighting
Mounting Motors 4.3.3 Armature Windings
2.2 BEARINGS A.2.5 Safety Equipment
2-11 Mounting Rabbet (Spigot) Diameter Toler- 4.3.4 Shunt, Series, Interpole, Compen-
2.2.1 Ball or Roller Bearings sating and Synchronous Rotor A.2.6 Test Unit Clearance
ancesIEC Flange-Mounted Machines
2.2.2 Sleeve Bearings Windings A.3 UNIT UNDER TEST
2-12 Mounting Surface Eccentricity and Face
2.2.2.1 Sleeve Bearing End-Thrust 4.3.5 Interconnection of Windings A.3.1 Suitability for Test
RunoutIEC Flange-Mounted Machines
2.2.2.2 Oil Rings 4.4 HIGH-POTENTIAL TESTS A.3.2 Exclusive Attention
2-13 Brush-to-Brushholder Clearance
2.2.2.3 Seals 4.4.1 Windings A.3.3 Grounding
2.3 LUBRICATION 4.4.1.1 New Windings A.3.4 Base
SECTION 3: REWINDING 4.4.1.2 Reconditioned Windings A.4 TEST PANELS
2.3.1 Grease
3.1 INSPECTION 4.4.1.3 Windings Not Recondi- A.4.1 Construction
2.3.2 Oil
3.1.1 Windings tioned A.4.2 Voltages
2.4 FRAME AND BEARING HOUSINGS
3.1.2 Core Laminations 4.4.2 Accessories A.4.3 Warning Lights
2.4.1 General
3.1.3 Thermal Protectors or Sensors 4.4.2.1 New Accessories A.4.4 Disconnect
2.4.2 Mounting Surface Tolerances,
3.2 REWINDING SPECIFICATION 4.4.2.2 Accessories of Machines A.4.5 Safety Switch
Eccentricity and Face Runout
3.3 STRIPPING OF WINDINGS with Reconditioned A.4.6 Leads
2.5 LAMINATIONS
3.4 INSULATION SYSTEM Windings A.4.7 High-Potential Ground Test
2.6 BALANCING
3.5 CONDUCTORS 4.4.2.3 Accessories of Machines
2.7 SLIP RINGS
3.6 STATOR, ROTOR, AND ARMATURE with Windings Not
2.8 COMMUTATORS BIBLIOGRAPHY
COILS Reconditioned
2.8.1 Machining
3.6.1 Random-Wound Coils 4.5 NO-LOAD TESTS
2.8.2 Undercutting STANDARDS ORGANIZATIONS &
3.6.2 Form-Wound Coils 4.5.1 Speed
2.9 BRUSHHOLDERS OTHER RESOURCES
3.7 FIELD COILS 4.5.2 Current
2.10 BRUSHES
3.7.1 Stationary Coils 4.5.3 Cooling System
2.11 BRUSH SETTING FOR DC MACHINES Note: Sections pertaining to the repair of liquid-filled
3.7.2 Rotating Coils 4.5.4 Sound Level and dry-type distribution transformers were withdrawn
2.12 AIR GAP MEASUREMENT OF DC
3.8 AMORTISSEUR AND SQUIRREL CAGE 4.5.5 Bearing Temperature from this edition of EASA Recommended Practice for the
MACHINES
WINDINGS 4.5.6 Vibration Tests Repair of Rotating Electrical Apparatus.

ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com 14

 Guidelines for Repair/Replace Decisions and Performance Optimization

APPENDIX D Motor Repair Guidelines and Resources (continued)

CONTENTS
A EMT
Page
Association of Electrical and Mechanical Trades Introduction ................................................................................................ 1

Energy Losses in Induction Motors ....................................................... 4

GOOD PRACTICE GUIDE
The Motor Repair Process ....................................................................... 7
Preliminary Inspection ..................................................................... 7
Repair or Replacement of Parts ....................................................... 9
THE REPAIR OF Repairs to the Rotor Assembly ........................................................ 11
INDUCTION MOTORS Recording the Winding Details ...................................................... 13
Stripping the Stator Winding ......................................................... 14
Best Practices Specifying the Replacement Winding ............................................ 17
to Maintain Energy Efficiency Cleaning and Inspecting the Stripped Stator ................................ 21
Rewinding ........................................................................................ 22
Testing the Wound Stator ............................................................... 23
Impregnating and Cleaning the Rewound Stator ......................... 24
Re-assembly ..................................................................................... 25
Testing the Assembled Motor ......................................................... 28

Appendix 1 ................................................................................................. 30
Winding Variations; Their Effect on Performance

Appendix 2 ................................................................................................. 34
Burn-out Ovens and Their Effect on Stator Core Losses

Appendix 3 ................................................................................................. 38
Crown Copyright 1998 Calculation of Losses and Efficiency From Test Data
All rights reserved. No part of the publication may be produced or transmitted in
any form or by any means, including photocopying and recording, without the Appendix 4 ................................................................................................. 40
written permission of the copyright holder, application for which should be addressed Glossary of Terms
to the publishers. Such written permission must also be obtained before any part
of this publication is stored in a retrieval system of any nature.
Appendix 5 ................................................................................................. 42
ISBN: AEMT 0 9509409 3 3 Check List of Best Practices to Maintain Energy Efficiency
Published by the Association of Electrical and Mechanical Trades
177 Bagnall Road, Basford, Nottingham, NG6 8SJ
Tel. 0115 978 0086 Fax. 0115 942 4488

Reprinted with permission (1999) by

Electrical Apparatus Service Association, Inc.
1331 Baur Blvd., St. Louis, MO 63132 U.S.A.
314-993-2220 Fax: 314-993-1269 www.easa.com

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Reliable Solutions
Today!

A Guide To AC Motor Repair And Replacement

Table Of Contents
Introduction ............................................................................................................................ 1

Plan Ahead ............................................................................................................................. 2

Why Motors Fail ..................................................................................................................... 2

Making The Decision To Repair Or Replace .............................................................................. 3

Obtaining Quality Motor Repairs .............................................................................................. 8

Specifying A Motor Rewind...................................................................................................... 11

Evaluating And Selecting A Motor Service Center ..................................................................... 13

Obtaining Motor Repairs Of The Highest Quality...................................................................... 15

EASAs Quality Initiatives ........................................................................................................ 16

About EASA .......................................................................................................................... 17

Appendix: Motor Repair Procedures ........................................................................................ 18

References ............................................................................................................................. 21

Prepared by Electrical Apparatus Service Association, Inc. in cooperation

with the U.S. Department of Energys Motor Challenge Program.
Copyright1999 Electrical Apparatus Service Association, Inc.
1331 Baur Blvd., St. Louis, MO 63132, 314-993-2220.

ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com 15