CENTRAL PHILIPPINE UNIVERSITY

COLLEGE OF ENGINEERING
SECOND SEMESTER S.Y. 2005-2006
WORK TERM REPORT

OPERATION AND MAINTENANCE OF THREE-PHASE

INDUCTION MOTORS

Panay Power Corporation

Raphael T. Socion

Electrical Engineering

May 20,2006

In Partial fulfillment of the requirements of the

B.S. Electrical Engineering Degree

Supervisor’s Approval: to be completed by Co-op Company Supervisor

I approve the release of this report to Central Philippine University for evaluation purposes only.

The report is to be considered NOT CONFIDENTIAL CONFIDENTIAL (select one)

Signature ECI Manager May 25, 2006

Manuel E. Jason

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 Table of Contents

Page

I. Title Page 1

II. Letter of Transmittal 1

III. Table of contents 2

IV. Introduction 3

V. Induction motor principle 4

VI. Construction of three-phase induction motor 4

a. Stator 4
b. Rotor 5
c. Others 6

VII. Classification of induction motor 6

VIII. Motor Slip and Rotor Speed 8

IX. Maintenance 8
a. Preventive 8
b. Corrective 10

X. Induction motor starting method 11

XI. Induction motor starting circuit and protection 12

XII. Induction motor ratings 14

XIII. Conclusion 15

XIV. Definition of terms 16

XV. List of references 17

2
 Introduction

Three-phase induction motor converts electrical energy into mechanical energy.

Similar to other electrical machine, three-phase induction motor consists of two main
parts; the stationary part called as stator and the rotating part known as rotor.
Armature winding can be found on the stator while the field poles are in the rotor.
When the armature winding is supplied with current electromagnetic flux is produce.
Then voltage will be induced in the rotor through induction where the name of the
motor came from. After that current will be in the rotor creating field poles resulting in
the build-up of electromotive force causing the rotor to rotate in a definite direction.

This motor is supplied with three-phase power and has a capacity of 1hp up to 500hp.
Generally there are two types of three-phase induction motor. The Squirrel-Cage rotor
induction motor and the Wound-Rotor induction motor. They only differ in the
construction of their rotor, in fact the rotor can either place on the same stator
provided they have the same rating. In the two type of motor squirrel-cage induction
motor is most widely used motor because of its desirable characteristics. Squirrel-
cage induction motor is lower in cost per horsepower compared to any other AC
motor. It has good starting torque and overload capacity, very efficient, rugged, and
trouble free. The motor can operate in an atmosphere containing dirt, moisture,
corrosive or explosive fumes and it can even be constructed to perform submerged in
oil or water.

Squirrel-Cage induction motor is a constant speed motor and because of these

Wound-Rotor replaced the latter when it is necessary to control the speed of the
motor. The speed of the wound rotor can be vary by inserting a resistor controller to
the brushes riding on the slip rings; the greater the resistance inserted the lower the
speed or vice versa.

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V. Induction-Motor Principle1

In the electric motor, conversion of electric power (or energy) to mechanical power (or
energy) takes place in the rotating part of the machine. In the DC motor and in one
type of AC motor, the electrical power is conducted directly to the rotor through
brushes and a commutator; in this respect it is possible to designate such a machine
as conduction motor. In the most common type of AC motor, electrical power is not
conducted to the rotor directly; the rotor receives its power inductively in exactly the
same way as the secondary winding of a transformer receives its power. It is for this
reason that motors of this type are known as induction motors.

The principle of the induction motor was first discovered by Arago in 1824, when he
observed the following interesting phenomenon: if a non-magnetic disk and a
compass are pivoted with their axes are parallel, so that one or both of the compass
poles are located near the edge of the disk, the compass will rotate if the disk is made
to spin, or the disk will rotate if the compass is made to spin. The direction of the
induced rotation in one element is always the same as that imparted to other.

VI. Construction of three-phase induction motor

Three-phase construction motor consists of two main parts, the stationary parts called
stator and other part is called as the rotor. Other important parts include Fan blade
located at the rear of the motor or non-drive end and motor frame or the housing.

a. STATOR
The motor non-rotating part is called the stator. It consists of a cylindrical laminated
slotted core welded to the frame. Coil windings are properly place into slotted core.
Insulating materials are apply into the coil windings to protect it from short-circuit
with the core. Insulating material such as electrical varnish, spaghetti tubes, Mylar
are commonly used. In one manufacturing process, the armature is first wound into
slots and properly connected. After that insulating varnish is apply evenly in the
core winding and baked it into oven.

1
Siskind, Charles E. Electrical Machines; Polyphase Induction Motors; 2nd Edition; pg 346

4
 b. ROTOR

Rotating part of the motor is called as the rotor. It is consists of conducting

materials place properly to form a cylindrical object. This part is pressed into shaft
for rotation.

Cut-away picture of Squirrel –Cage rotor Squirrel-Cage Rotor with bearing

Typical induction motors

Generally there are two types of induction motor rotors that can be place inside the
stator; the Squirrel-Cage rotor induction motor and the Wound-Rotor induction motor.
Both designs employ a slotted core that is tightly pressed on a shaft.

A squirrel-cage induction motor consists of a series of conducting bars usually

aluminum laid into slots carved in the face of the rotor projecting outward facing the
stator and shorted at either end by large shorting end ring with projecting fins for
cooling.

The design is referred to as a squirrel-cage rotor because the conductors are not
parallel to the shaft axis; instead they are skewed. And the design result in smoother
and quieter operation.

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Other type of induction motor rotor is known as Wound Rotor. This rotor has a
complete set of three-phase windings that are exactly similar to the winding in the
stator. Rotor winding are usually connected in star Y. The ends of rotor wire are
connected to three slip ring adjacent to the rotor core. Because rotor windings are
accessible through the slip rings, extra resistance can be place to modify the torque-
speed characteristic of the motor.

c. OTHER PARTS

Motor frame is where the stator being house. It is the body of the motor. This is the
external physical part of the motor design to protect the motor from any hazardous
object, such as oil, water and dirt. It has a dip thin grove design for cooling, a
flanged or foot use for mounting and a terminal block where the terminal of the
motor can be access. Nameplate also attached to the body or in some case printed
on the body. Bearing specification is also printed. Both the drive-end bearing and
non-drive end bearing are classified for maintenance purposes.

Motor fan and its cover is another vital part of the motor. It is attached to the shaft
of the rotor. It is used for cooling of the motor body.

VII. Classification of induction motors2

Design class A

Design class A motors are the standard motor design, with a normal starting
torque, a normal starting current, and low slip. The full-load slip of design A motors
must be less than 5%, and must be less than that design B motor of equivalent.
The pullout torque is 200 to 300% of the full-load torque and occurs at a low slip
(less than 20%). The starting torque of this design is at less least the rated torque
for larger motors, and is 200% or more of the rated torque for smaller motors. The
problem with this class is its very high starting current, typically 500 to 800% 0f
rated current. In sizes above 7.5 hp, reduced voltage starting is used to avoid
voltage dip problems in the power system. In the past, design class A motors wire
the standard for most applications below 7.5 hp and above 200 hp, but design
class B motors largely have replaced them recently. Typical applications for these
motors are driving fans, blowers, pumps, lathes, and other machine tools.

Design class B

Design class B motors have a normal starting torque, a lower starting current, and
low slip. This motor produces about the same starting torque as the class A motor
with about 25% less current. The motor pullout torque is greater than or equal to
2
Al-Hawary, Mohamed E. Principles of Electric Machines with Power Electronic
Application; Induction motors; 2nd Edition, pg. 351-354

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200% of the rated load torque, but less than that of the class A design because of
the increased rotor reactance. Rotor slip is still relatively low (less than 5%) at full
load. Applications are similar to those for design A, but design B is preferred
because of its lower starting-current requirements. Design class B motors have
largely replaced class A motors in recent installations.

Design class C

Design class C motors have a high starting toque with low starting currents and
low slip (less than 5%) at full load. The pullout torque is slightly lower than that of
class A motors, while the starting torque is up to 250% of the full load torque.
These motors are built from double-cage rotors, so they are more expensive than
motors in class A and B. they are use for high starting-torque loads, such as
loaded pumps, compressors, and conveyors.

Design class D

Design class D rotors have a very high starting torque (275% or more of the rated
torque) and a low starting current. They also have a high slip at full load. They are
essentially class A induction motors, but with the rotor bars made smaller and with
a higher-resistance material. The high rotor resistance shifts the peak torque to a
very low speed (100% slip). Full-load slip for these motors is quite high because of
the high rotor resistance. It is typically 7 to 11%. But may go as high as 17% or
more. These motors are used in applications requiring the acceleration of
extremely high inertia-type loads, especially the large flywheels used in punch
presses or shears.

In addition to these four design classes, NEMA used to recognize design classes E
and F, which were called soft-start induction motors. These design were
distinguished by having very low starting currents and were used for low-starting-
toque loads in situations where starting currents were problem. These designs are
now obsolete.
Continual improvements in the quality of the steels, casting technique, the
insulation, and the construction features used in the induction motors, resulted in a
smaller motor for a given power output, yielding considerable savings in
construction costs. In fact a 100-hp motor of today’s design is the same physical as
a 7.5-hp motor of 1897.
Improvements in induction-motor design were not associated with
improvements in operating efficiency. More effort was given to reducing the initial
cost of the machines than to increasing their efficiency. The reason is that
electricity was so inexpensive, making the capital cost of a motor the principal
criterion used by end users in its selection.
The lifetime operating cost of machines has recently become more important,
while the initial installation cost has become relatively less important. Therefore,
both manufacturers and users have placed new emphasis on motor efficiency.

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 High-efficiency induction motors are forming an ever-increasing share of the
market. To improve the efficiency of these motors compared to the traditional
standard-efficiency designs, the following techniques are used.

1. To reduce copper losses in the stator windings more copper are used.
2. The rotor and stator core length is increased to reduce the magnetic flux density
in the air gap, to reduce the magnetic saturation. This decreases core losses.
3. More steel is used in the stator, allowing greater heat transfer out of the motor
and reducing its operating temperature. The rotor’s fan is then redesigned to
reduce windage losses.
4. The steel used in the stator is special high-grade electrical steel that allows low
hysteresis.
5. The steel is made of laminations that are very close together, and the steel has
a very high internal resistivity. Both effects to reduce the eddy-current losses.
6. The rotor is carefully machined to produce a uniform air-gap, reducing stray load
losses.

VIII. SLIP AND ROTOR SPEED3

Although the rotor of an induction motor must rotate in the same direction as the
revolving field, it cannot do so at synchronous speed. In other words, there must be
relative motion between revolving field and rotating rotor because rotor power can be
developed only when the rotor conductors are cut by lines of force when the latter
move faster than the former; under this condition the generated rotor voltage causes a
current to flow in its low-resistance winding. The difference between the synchronous
speed and the actual rotor speed is called the slip speed. It is the number of
revolutions per minute by which a point on the rotor continuous to slip behind a point
on a fictitious revolving pole. Thus, in four-pole 60-cycle motor, the slip would be 50
rpm if the actual rotor speed were 1750 rpm. Slip is generally specified in terms of the
synchronous speed.

IX. MAINTENACE

a. PREVENTIVE MAINTENANCE

Preventive maintenance is describe as a regular work with a primary

focus, which is to prevent something from going wrong. Otherwise known as
scheduled maintenance.

3
Siskind, Charles E. Electrical Machines; Polyphase Induction Motors; 2nd Edition; pg 358

8
 The activity usually base in the number of hours the unit put unto
operation. It shall be performed at the appropriate interval as indicated in
the maintenance interval schedule. Large company like Panay Power
Corporation in Iloilo city, a subsidiary of Mirant Philippines employ a
computerize maintenance management system. This computer base
management system
Use to track down equipment when put into operation.
The computer is monitoring all instruments and materials. The
planning unit department specifies the frequency of schedule of PM to
equipment and computer will generate a work order when the time comes.

Following are preventive maintenance procedures for three-phase induction

motor after securing a work order.

1. Clean motor frame and fan from oil and dirt.

2. Check motor frame and fan from any defects

3. Bearing test:
Using stethoscope design for motor bearing test check the bearing
by just pointing the tip of instrument to the bearing and observe if theirs
unusual noise.

4. Insulation test:
Use insulation tester e.g. MEGGER tester to determine the status
of motor insulation.
Insulation resistance must be >1Mohm

5. Winding resistance test:

Use DLRO (Digital Low Resistance Ohmmeter) to measure the
resistance of the winding. Result must be almost similar in each winding
coil.

6. Retighten terminal and spray contact cleaner to the terminal connection

to increase contact.

7. Test run:
Connect the motor to power supply and test run the motor.
Measure motor line currents. Motor currents must be balance and within the
rating.

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b. CORRECTIVE MAINTENANCE

Corrective maintenance is a work after something has going wrong. When

the motor doesn’t operate according to the specified characteristics the
motor needs to be repair and reconditioned it undergo corrective
maintenance.
The activity is the next to undertake after the motor failed the test in the
preventive maintenance. In some case motor becomes defective and it
needs corrective maintenance.

Following are the corrective maintenance on three-phase induction motor.

1. Bearing replacement;
Motor bearing is replace with its specified bearing. Tolls include
bearing puller, refitting tools and grease oil. Bearing specification in some
motor is place in the nameplate.

2. Insulation reconditioning
• Disassemble motor and pull-out rotor
• Clean stator and frame using motor cleaner
• Place motor stator in the oven
• Apply electrical insulating varnish in the winding
• put motor stator oven
• Assemble and test motor

3. Stator rewinding
In our experience stator winding is more prone to defect than the
rotor especially for squirrel-gage rotor induction motor. Common defect is
burned winding:

• Disassemble motor pull-out rotor

• Rewind stator winding:

1. Take down notes necessary data of motor such as:
a. Type of coil winding
i. Whole coiled
ii. Half coiled
b. Stator connection
i. Delta
ii. Star
iii. Double delta
c. Number of turns
d. Number of poles
e. No of coils
f. Sample coil size
2. Pull-out winding & clean slotted core

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 3. Put Mylar insulator unto slots
4. Coil the magnetic wire
5. Place coil unto slots
6. Connect coils accordingly
7. Place spaghetti tubing in spliced & end of each winding
8. Arrange the winding & thigh with cotton strands
9. Apply electrical insulating varnish
10. Baked

• Apply electrical insulating varnish

• Assemble & test motor

X. Induction motor starting method

Rotor current at starting is much higher than that at full load. Although induction
motor designs provide for a rugged construction that can withstand large starting
currents, it is undesirable to start induction motors with full-applied voltage. One
reason for this is simply the current overloading of the source circuit, which may not
be able to withstand the current inrush. A second reason is that the large drop in
voltage (due to feeder impedance) may result in voltage dip (a reduce voltage)
supply at the stator terminals that does not result in sufficient starting torque. The
rotor may not stop at all.
For squirrel-Cage induction motors, the starting current can vary widely depending
primarily on the motor’s rated power and on the effective rotor resistance at starting.
To estimate the rotor current at starting conditions, all squirrel-cage motors now
have a starting code letter (not to be confused with their design class letter) on their
nameplates.
Methods for reducing the starting current in an induction motor can be classified
into two categories; method that apply reduced voltage to the stator at starting, and
those that increase the resistance of the rotor circuit at starting and decrease it as
the motor speed in increased.

Reduced-Voltage Starting

For low-rotor-resistance squirrel-Cage motors, a three-phase autotransformer is

employed. At starting a low value of voltage is applied to the stator, which is then
restored to full voltage when the rotor speed is within 25% of full-load value.
An alternative method is the Y/∆ switching technique, which requires that both
ends of each phase of the stator windings be accessible. At standstill the stator is
connected in Y, and as full speed is approached, a switch is activated to connect the
stator in a ∆-connection. The effect of Y/∆ switching is equivalent to an
autotransformer starter with a ratio of 1/ 3 .
4
Al-Hawary, Mohamed E. Principles of Electric Machines with Power Electronic
Application; Induction motors; 2nd Edition, pg. 355-357

11
 Variable-Resistance Starting

The basic principle involved in variable-resistance starting is to cause the root

resistance at standstill to be several times as much as its value when the motor is
running at full speed. There are two basic methods to achieved this:

1. External-Resistance Starting This method is used for the wound-rotor induction

motor, where a three-phase bank of resistors is connected to the rotor slip rings at
starting. As a result, a reduced starting current is obtained simultaneously with an
increased starting torque. It is clear that high starting torques can be achieved
simply by inserting additional rotor resistance of value corresponding to the
maximum torque production at the starting. One advantage of this method is that
energy lost is dissipated through the environment, not within the motor itself.

2. Deep-Bar and Double-Squirrel-Cage Rotors the main idea is that the frequency
of induced voltages in the rotor is equal to the product of slip and synchronous
frequency. At standstill, the slip is unity, and 60-Hz frequencies currents flow in the
rotor circuit, while at full speed, a frequency of 2 to 3 Hz are common. It is therefore
clear that if the rotor circuit is arranged such that a higher effective resistance is
offered by the rotor at starting, and a lower value of effective resistance is obtained
at running, the desired effect is obtained.

XI. Induction Motor Starting Circuit and Protection

A typical full-voltage or across-the-line magnetic induction motor starter is shown
below. The operation of this circuit is very simple. When the start button is pressed,
the relay (or contactor) coil m is energized. Causing the normally open contacts m1,
m2, and m3 to shut. When these contacts shut, power is applied to the induction
motor, and the motor stars. Contact m4 also shuts, which shorts out the starting
switch, allowing the operator to release it without removing power from the m relay.
When the stop button is pressed, the m relay is deenergized, and the m contacts
open, stooping the motor.
A magnetic motor starter circuit of this sort has several built-in protective features:

1. Short-circuit protection
2. Overload protection
3. Under voltage protection

Short-circuit protection for the motor is provide by fuses f1, f2, and f3. If a sudden
short circuit develops within the motor and causes a current flow many times larger
than the rated current, these fuses will blow, disconnecting the motor from the
power supply and preventing it from burning up. However, these fuses must not
burn up during normal motor starting, so they open the circuit. This means that
short circuits through a high resistance and/or excessive motor loads will not be
cleared by the fuses.

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Overload protection for the motor is provided by the devices labeled ol in the
figure. This overload protection devices consists of two parts, an overload heater
element and overload contacts. Under normal conditions, the overload contacts
are shut. However, when the temperature of the elements rises far enough, the ol
contacts open, deenergizing the m relay, which in turn opens the normally open m
contacts and removes power from the motor.
When an induction motor is overloaded, it is eventually damaged by the excessive
heating caused by its high currents. However, this damage takes time, and an
induction motor will not normally be hurt by brief periods of high currents (such as
starting currents). only if the high current is sustained will damage occur. The
overload heater elements also depend on the heat for their operation, so they will
not be affected by brief periods of high current during starting, and yet they will
operate during long periods of high current, removing power from the motor before
it can be damaged.

Undervoltage protection is provided by the controller as well. Notice from the figure
that the control power for the m relay comes from directly across the lines to the
motor. if the voltage applied to the m relay will also fall and the relay will
deenergize. The m contacts then open, removing power from the motor terminals
..

A typical across-the-line starter for an induction motor.

DS – disconnect switch
OL – overload heater
m – relay coil; contacts change state when the coil energizes
m1,m2,m3,m4 – contact open when coil deenergized
f1,f2,f3 – fuse
start,stop – push button

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XII. INDUCTION MOTOR RATING

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XIII. CONCLUSION

Therefore it can be concluded that the most popular and widely used type of AC
motor is induction motor particularly Squirrel-Cage Induction Motor, because of its
simplicity and ease of operation. An induction motor does not have a separate field
current circuit; instead it depends on the transformer action to induce voltages and
current in its field circuit induction motor is basically a rotating transformer. Its
equivalent circuit is similar to that of a transformer, except for the effects of varying
speed in the case of Wound-Rotor Induction Motor. Induction motor is rugged, trouble
free, and can operate at atmosphere containing dirt and moisture and can be
constructed to perform submerged in oil and water.

There are two basic part of induction motor, the stationary part called stator and
rotating part called rotor. Two type of motor differ only in the construction of their rotor.
Squirrel-Cage Induction Motor operates at constant speed while Wound-Rotor
Induction Motor can be varies though inserting a resistance in the brushes.

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XIV. Definition of terms
Armature - moving part in electromagnetic device: the moving part in an
electromagnetic device, wound with coils that carry a current. In a generator, an
electric current is induced in the coils when they revolve through a magnetic field.

Bearing - housing for moving machine part: the part of a machine that supports a
sliding or rotating part

Corrective maintenance - is a work after something has going wrong

Coil - wire spiral for electric current: a spiral of wire through which an electric current
is passed to create a magnetic field or to function as an inductor

Electromagnetic induction - transfer of power between electric circuits: the transfer

of power between one electric circuit and another caused by changes in the magnetic
field linking them

Electromotive force - force causing electricity flow: a force that causes the flow of
electricity from one point to another

Induction - the process by which electric or magnetic forces are created in a circuit by
being in proximity to an electric or magnetic field or a varying current without physical
contact

Ohmmeter - instrument measuring resistance: an instrument that measures electrical

resistance in ohms

Preventive maintenance - is described as a regular work with a primary focus, which

is to prevent something from going wrong. Otherwise known as scheduled
maintenance.

Rotor - consists of a laminated steel core press fitted to the steel shaft. Like the stator,
the rotor core also has windings set into slots, but these are deployed about its
outer circumference.
Slip Ring - part of machine: a metal ring in a generator or motor to which current is
delivered or from which it is removed by brushes

Stator - stationary part around which rotor turns: a stationary part in a machine, e.g. a
motor or generator, around which or in which a rotor rotates

Synchronous speed - system for transmitting movement: a system used to transmit

angular rotation or position in a generator to a motor

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 References

Al-Hawary, Mohamed E. Principles of Electric Machines with Power

Electronic Applications. 2nd Edition

Chapman, Stephen J. Electric Machinery Fundamentals; Induction

motors: 2nd Edition

Siskind, Charles. Electrical Machines; Induction Motors. 2nd Editions

17