635955327797547484

Prepared By
ICF Consulting India Pvt. Ltd., 3rd Floor, Ashoka Estate, Barakhamba Road, New Delhi
Ph : 011-43543000 / 43543027 Fax: 43543001 web: https\\www.icfi.com
1. Pay attention while purchasing a New Motor

Ensure quality of the motor
Ensure proper motor identification
Ensure maintaining a product catalogue
To do
Purchase from a reputed vendor /
brand. Avoid purchasing from
local manufacturers
Dont purchase the motor only by
loweest first cost, estimate overall
cost of the motor during life
period
Prepare and maintain a product

catalogue
Prepare motor data card for every
purchased motor
Dont purchase a
missing nameplate
motor
with
How
When
Before purchase
Asks the maufacturer During purchase

to
provide
OEM
certificate indicating
service life
Ask the manufacturer
to provide life cycle
cost (LCC) over 10
years period. The LCC
must include first
cost, O&M cost, spare
parts
cost
and
replacement cost.
Regular update
Ask for product
catalogues when you
interact with
suppliers / vendors
Record motor id, date After purchase
of purchase, name
plate details, supplier,
cost etc. for each new
motor purchased
Physically observe the During Purchase
nameplate properly
tagged on the motor
frame
Prepared By
2. Maintain the Motor Name Plate and Understand the

Details
Ensure the name plate of motor properly visible and displayed
Understand the name plate details
To do
Dont instal a motor with missing
nameplate
See that the details of the motor
are displayed in the nameplate
and understand the details
Rated Volts & Full Load
Amps
Rated Full Load Speed
Class of Insulation
Rated HP or KW
Efficiency at Full Load
Power Factor at Full Load
Ensure that the name plate
details are visible and readable
How
Physically observe the
nameplate properly
tagged on the motor
frame
Physical inspection
When
During installation
Clean the name plate

suface from dirt &
dust
Once in a month
or whenever found
dirty
During installation
3. Ensure proper loading of Motor

The motor loading should be 80% - 95%
Underloading and Overloading should be avaoided
To do
How
Conduct a motor load survey
Measure line current
by simple clamp-on
meter and see that it
is neither less than
60% nor more than
100% of the name
plate rating current
Replace the motor with a suitable Analyse from the
rating of motor, if the loading is
results of motor load
less than 60% continously
survey
When
Once in six
months
After the motor

load survey
Prepared By
4. Check Power Quality at Motor Input

Check Voltage and current unblance
To do
How
Ensure that the voltage unbalance Measure the input
is below 5%
voltage in all the three
phases at MCC and at
motor junction box by
hand held digital volt
meters
Refer to best practice
guidebook on how to
calculate
voltage
unbalance (%)
Ensure that the incoming voltage Physically
check
supply from the grid is balanced
voltage reading in the
trivector meter at HV
and LV side of the
transformer
If incoming voltage
from grid is balanced,
but LV side voltage is
unbalaced, check the
transformer setting
Check for loose, corrosive
Use hand held
contacts at MCC and motor
portable infrared
junction boxes
thermopointer to
measure the junction
Ensure that the surface
temperature
temperature of all contact points
is not more than 40 degree
centigrade above ambient.
Ensure that the there is balanced Use clamp-on meters
current in each phase of the
to measure the
motor
current. If severe
current unbance is
observed, inform
electrical maint. team
When
Once
in
months
six
Once in a week
Once in a month
Once in six
months
Once in a month
Prepared By
5. Keep, Maintain & Use Portable Simple Gadgets and Tools

Use these tools in performance monitoring and maintenance activities
To do
How
When
Keep, maintain and use simple
Usage during
gadgets and tools
performance
monitoring and
Clamp-on meter (Current)
maintenance
Multimeter (Many electrical
activities
parameters)
Stroboscope (Speed)
Tachometer (Speed)
Infrared thermopinter
(temperature)
Megger (earth resistance)
Calibrate the instruments
Once in two years
Through outside
periodically
calibrating agencies
Use hand gloves, safety shoes,
helments during inspection and
maintenance work
Follow this as a
mandatory practice
Daily
6. Adopt proper lubrication practice

Use right lubricant, proper quantity
To do
Use good quality grease from
reputed suppliers like Indian Oil

Companies
Replenish the grease with proper
quantity at right frequency
at proper frequency for

How
Refer to the OEM
guideline for the type
of grease to be used
Use grease guns to
inject new grease to
the bearing housing
Refer to the best
practice manual for
quantity of grease to
be replenished
motor bearings
When
Through out
service life of
motor
As per OEM
guideline
If OEM guideline is
not available,
physically check
the bearing
housing for
replenishment
Prepared By
7. Maintain Bearing Surface Temperature within limits

The bearing surface temperature increases due to poor lubrication, improper
bearing fitting or damaged bearing
To do
How
When
Measure the bearing surface
Once in 15 days
Use infrared
temperature periodically by onthermopointer to
line temperature monitoring
measure the surface
gadgets
temperature
Compare the observed surface
Once in 15 days
Refer table A for
temperature with allowable limits
comparision with the
allowable limit of the
the surface
temperature
The differential
temperature aboove
ambient should be
within 40 degree
centigrade.
8. Assess the Condition of the Motor through On-line

Temperature Monitoring Techniques
Dont allow loose/corrosive contacts at electrical joints
Dont allow severe current unbalance
To do
How
Measure all contact temperatures Use infrared
from MCC to junction box, motor
thermopointer or
body and all bearing housing
thermography camera
for temperature
measurement
Compare the observed surface
Refer to Table B for
temperature with allowable limits
the guidelines
(Refer to best practice manual for
the guidelines)
When
Once in six
months
Prepared By
9. Adopt Good Maintenance Practice

Adopt good preventive and predictive maintenance practice
To do
How
Check for abnormal noise,
Visula inspection
unusual smell and general
through human
cleanliness
sensors such as
touch, ear, nose, eye
etc.
Ensure that there is no dirt, dust, Perform
general
unwanted material and improper
cleaning
by
clean
ventilation to the motor location
cloths,
cottons,
brushes
and
tiny
blowers
Check lubrication
Visually inspect
grease quantity and
colour in the bearing
housing
Measure the surface
temperature of the
bearing housing
Check input power supply quality Observe phase-toto the motor
phase voltage and
current from MCC
panel meters
Direct measurement
at MCC and motor
junction box
Check Proper functioning of
Physically observe the
MCC panel display meters
indicator lamp and
working condition of
all panel meters
When
Every shift
Daily
Every shift
Once in a week
Every shift
Once in a month
Every shift
Prepared By
10. Maintain History Card of Motor Failure

Create databank on important information of motor failure incidents
To do
How
When
Record details about any failure in Refer to the template
Subsequent to
the motor
motor failure
in Table C
11. Ensure Good Quality of Motor Rewinding

Accept motors from the work shop which have been properly rewound
To do
How
When
Select a good vendor for rewinding Physically visit to the
Once in a year
vendor workshop for
seeing its capacity,
trained manpower,
tools & tackles and
past record in
providing services
Check for motor no-load current
After rewinding
Ask the vendor to
after rewinding
show the result by
direct measurement
( The value should be
between 30-50 % of
the full load current )
Check motor efficiency
After rewinding
Ask the vendor to
provide efficiency test
certificate on full load
Prepared By
Table A
Table for Temperature limit on Bearing Housing
Speed (in
RPM)
1000
Speed (in
RPM)
1500
Speed (in
RPM)
3000
Shaft Diameter
(in mm)
Temperature
above
Ambient (in
C)
Shaft Diameter
(in mm)
Temperature
above Ambient
(in C)
Shaft Diameter
(in mm)
Temperature
above
Ambient (in
C)
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
Ambient
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
Ambient
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
3
7
11
16
20
24
28
32
36
41
45
49
53
57
61
66
70
74
78
82
86
91
95
99
103
107
2
3
4
6
7
9
10
11
13
14
16
17
18
20
21
23
24
1
3
5
7
9
11
13
16
18
20
22
24
26
28
30
32
34
36
38
41
43
45
Prepared By
Table B
Criticality Criteria to Judge the Condition of Electrical Joints
Sl. No
Criteria
(Differential Temperature
Above Ambient)
Criticality
Condition
Recommended Action
Up to 10 C
Non- Critical
No action is needed
Between 10 to 20 C
Less Critical
Regular Monitoring is needed
Between 20 to 40 C
Semi-Critical
Above 40 C
Critical
Close monitoring needed. Should

be attended in the next
opportunity.
Should be attended immediately
as per the severity.
Table C
Motor Id :
Location:
Motor Rating:
Date
Observation
Type of
Failure
Action
Taken
(dd/mm/yyyy)
(Failure details)
(Mechanical /
Electrical /
Others
(Maintenance
Action)
Stoppage
Time
Remark
(in minutes
/ hours)
(Any specific
observation)
Prepared By
WB-GEF Cell
Bureau of Energy Efficiency

Ministry of Power, Govt. of India
4th Floor, Sewa Bhawan, R.K.Puram
New Delhi 110066
www.bee-india.nic.in
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Prepared By

1. Pay attention while purchasing a New Motor

Prepare and maintain a product

Asks the maufacturer During purchase

2. Maintain the Motor Name Plate and Understand the

Clean the name plate

3. Ensure proper loading of Motor

After the motor

4. Check Power Quality at Motor Input

5. Keep, Maintain & Use Portable Simple Gadgets and Tools

6. Adopt proper lubrication practice

reputed suppliers like Indian Oil

quantity at right frequency

at proper frequency for

7. Maintain Bearing Surface Temperature within limits

8. Assess the Condition of the Motor through On-line

9. Adopt Good Maintenance Practice

10. Maintain History Card of Motor Failure

11. Ensure Good Quality of Motor Rewinding

Regular Monitoring is needed

Close monitoring needed. Should

Bureau of Energy Efficiency

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