Chapter 03 Basic Industrial Training Report

3.Electrical work shop

The repairs of 3 phase electrical motors, generators and blower repairs and
maintenance are some of the very common jobs. Apart from them this shop has the personnel
to rewind motors too.

Three phase induction motor repairs

I have actively participated in the repairs of about 8 to 10 3 phase induction motors

during my stay. Every motor which comes for repairs are check with the digital Megger. After
powering the tool we have to change the voltage range to 500 V and start to measure the
resistance. This tool is to measure the resistance between,

• Stator and coil no 1

• Coil no 1 and coil no 2

• Coil no 2 and coil no 3

• Coil no 3 and coil no 1

If the 4 readings are above 2 MΩ there are no short circuits present or no bursts of
coils. If we found a zero reading or low reading than 1 MΩ it says that we have a short circuit
or burst coil. Burst coil means a one where the lamination of it has dissolved or removed from
some place. Due to this the actual resistance between 2 coils are reduced and can be identified
with the use of the Meggeer. Reasons to show a low meggar reading,

• Burst of the lamination of the coil

• Deposition of rust between 2 coils

Things start from removing the fan cover and the fan at the rear of the motor. We had
to be careful in removing this fan because it is made from a hard brittle material. And most of
the time the fan is stick to the shaft because of the rust in the shaft. Most of the time we had to
used WD 40 to remove the fan.

WD 40 contains petroleum distillates and harmful or fatal if swallowed. We need to

shake it before use and it has the following properties,

• Stops squeaks

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• Drives out moisture

• Cleans and protect

• Loosens rusted parts

• Frees sticky mechanisms

After the removal of the fan we remove the 2 grease cups in the front and the rear.
Now the stator and the rotor are exposed to the outer environment so we had to be careful in
dismantling cause we have to make sure not to make any harm to those.

The next difficult part is the removal of the 2 bearings before this the 2 circlips have to
be removed. We need a hydraulic jack and a bearing puller to remove the bearings and
sometimes we had to heat the shaft and the bearing to remove it. When removing the bearing
nobody should be directly in line with the shaft. Because sometimes the bearing puller fires
backwards due to the hydraulic jack.

Then we can pull the rotor out by the help of a overhead crane. Next the motor and the
stator is given a high pressure water cleanup and a chemical cleanup. This is to drive out any
rust or corrosion present in the parts. After this these are baked in a oven to about 100 0C for 1
to 1.5 hours. This is to drive out any moisture present in the motor casing and the stator.

Finally the motor start to reassemble. A red shellac layer is sprayed on the rotrr as well
as in the stator. Function f shellac are,

• Drives out any moisture present

• Acts as a bonding agent to hold the coils in tact

• Acts as an insulation layer

We have to use a new bearings. The bearings are heated uniformly in the bearing heater
which deploys the induction heating theory. In the reassembling process bearings are fitted
with the global copper compound on their bores to facilitate easy removal of them in the next
time.

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3.1Motor testing panel

This is to check the motor whether it has sustained its name plate specifications after
the repair and maintenance. There are some name plate data we need to input the panel and it
automatically calculate the Ampere rage, Voltage and the R.P.M. of it at no load condition.
The parameters we have to input are power, frequency and the number of poles. After the
certification from the machine the repaired and maintained motors are good to go.

3.2Work in the tug

Participated to a 2 jobs in a tug. they are a repair of a main generator and a removal of
limiting switches. Before the repair of the generator we had to pull the rotor of it first. To this
we used puller bolts. The rotor was held by several chain blocks once it has removed. The job
was maintenance of the generator. The limiting switch removal was little too hard because
they were situated about 15 feet above the main deck. We had to use the safety belt to ensure
the safety of our selves. This limiting switches control the winches of the life boats.

3.4A typical name plate

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3.5Name plate terms and their meanings

Term Description

Volts Rated terminal supply voltage.

Amps Rated full load supply current.

H.P. Rated motor output.

R.P.M. Rated full load speed of the motor.

Hertz Rated supply frequency.

Frame External physical dimension of the motor. based on the NEMA standards
Motor load condition, whether it is contenious load, short time, periodic,
Duty
etc.
Date Date of manufacturing.

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Class Insulation class used for the motor construction. This specifies maximum
Insulation limit of the motor winding temperature.
NEMA
This specifies to which NEMA design class the motor belongs to.
Design
Service Factor Factor by which the motor can be overloaded beyond the full load.
NEMA Nom.
Motor operating efficiency at full load.
Efficiency
PH Specifies number of stator phases of the motor.

Pole Specifies number of poles of the motor.

SA Specifies the motor safety standard.

Specifies whether the motor windings are star (Y) connected or delta (Δ)
Y
connected.

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