Avoid efficiency loss during motor repairs

Assessing the motor before repairs and a well thought-out preventive maintenance program can help reduce efficiency loss and keep operations running smoothly.


Assessing the motor before repairs and a well thought-out preventive maintenance program can help reduce efficiency loss and keep operations running smoothly. Courtesy: L&S ElectricIn many businesses, electric motors are representative of a substantial capital investment. They also result in some of the highest costs for the ongoing operation of the business. At times, the company may end up paying ten times as much in energy as they do for the initial cost of the motor. The motor's efficiency is a key aspect during the repair process and should be a major consideration. 

Having a well thought out preventive maintenance program at the facility is one way to contribute to reducing problems with electric motors. Like any piece of equipment, however, motors will eventually break down, and repairs will need to be made. A motor rewind is common electrical motor repairs and can provide many benefits for users. 

It is commonly believed that rewinds cause a motor to lose efficiency, but that is an outdated understanding. When the proper materials and methods are used for rewinding, it will not have a significant impact on the reliability or the efficiency of the motor. In fact, it might improve both the power and the reliability associated with an electric motor when the rewind is performed by a trained and qualified service provider.

The need to assess the motor

Before any repairs take place, the motor needs to be fully accessed to ensure best practices are being followed. This is also where choosing the proper service provider is going to make a difference. When they fix the motor, they can make the appropriate inspection of it before the rewind takes place. This includes recording any data from the nameplate and documenting the procedure that will be used.

There are also factors to consider before the motor is disassembled. These will help ensure that the repair will not affect the efficiency or operation of the motor in a negative way. Some of the components of the motor that will be inspected visually include:

  • Bearing cap and end bracket
  • Shaft rotation
  • Bearing type, size, and clearance
  • Checks for contamination
  • Signs of bearing wear
  • Signs of heat damage.

It will also be determined if the motor winding is at the original factory setting or if it has been rewound at some time in the past. Careful measurements will be taken so the winding can be replicated accurately.

There are opportunities to improve motor efficiency during motor rewinds. Numerous factors such as putting more copper into the stator slots or increasing the wire diameter can be considered.

There may also be times when it is a better decision to replace the motor rather than do a motor rewind. This may be the case if there is damage to the motor core. The decision on whether to rewind the motor or replace it can be determined by the service provider and then the appropriate action can be taken.

- David Manney is a marketing administrator at L&S Electric. This article originally appeared on L&S Electric Watts New Blog. L&S Electric Inc. is a CFE Media content partner.

The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
Pipe fabrication and IIoT; 2017 Product of the Year finalists
The future of electrical safety; Four keys to RPM success; Picking the right weld fume option
A new approach to the Skills Gap; Community colleges may hold the key for manufacturing; 2017 Engineering Leaders Under 40
Control room technology innovation; Practical approaches to corrosion protection; Pipeline regulator revises quality programs
The cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Power system design for high-performance buildings; mitigating arc flash hazards
VFDs improving motion control applications; Powering automation and IIoT wirelessly; Connecting the dots
Natural gas engines; New applications for fuel cells; Large engines become more efficient; Extending boiler life

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
This digital report explains how plant engineers and subject matter experts (SME) need support for time series data and its many challenges.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Maintenance Manager; California Oils Corp.
Associate, Electrical Engineering; Wood Harbinger
Control Systems Engineer; Robert Bosch Corp.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me