Motors & Variable Speed Drives: Selection, Applications, Diagnostic Testing, Protection, Control, Troubleshooting and Maintenance

ICTD International Centre for Training and Development

How long?

  • 5 days
  • in person

What are the topics?

ICTD International Centre for Training and Development


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Who should attend

This course is intended for engineers and other technical personnel who are in charge of selection, application, operation, diagnostic testing, protection, control, troubleshooting or maintenance of motors and variable speed drives.

About the course

It is estimated that electrical drives and other rotating equipment consume about 50% of the total electrical energy consumed in the world today. The cost of maintaining electrical motors can be a significant amount in the budget item of manufacturing, oil, gas, petrochemical and power industries. This course gives you a thorough understanding of electrical motor’s working, maintenance and failure modes and gives you the tools to maintain and troubleshoot electrical motors and variable speed drives.

Maximum efficiency, reliability, and longevity of the various types of motors and variable-speed drives are of great concern to many industries. These objectives can only be achieved by understanding the characteristics, selection criteria, common problems and repair techniques, preventive and predictive maintenance. This course is a MUST for anyone who is involved in the selection, applications, or maintenance of motors, and variable-speed drives. It provides the latest in technology. The course covers how this equipment operate and provides guidelines and rules that must be followed for a successful operation. Their basic design, operating characteristics, specification, selection criteria, advanced fault detection techniques, critical components as well as all maintenance issues are covered in detail.

You will gain a fundamental understanding of the installation, operation and troubleshooting of electric motors. Typical applications of electric motors in oil, gas, petrochemical, power, manufacturing, materials handling, process control are covered in detail. You will learn the basic steps in specifying, installing, wiring and commissioning motors. The concluding section of the course gives you the fundamental tools in troubleshooting motors confidently and effectively.

This course is designed to provide participants with a comprehensive understanding of the various types of motors and variable-speed drives. Participants will be able to specify select, commission and maintain these equipment for their applications. The excellent knowledge and skills that participants gained in this course will help their companies in achieving reduced capital, operating and maintenance costs along with increase in efficiency.

Course Objectives

Upon successful completion of this course, the delegates will be able to:

  • Apply the latest techniques on selection, application, operation, diagnostic testing, protection, control, troubleshooting and maintenance of motors and variable speed drives
  • Gain an in-depth knowledge on electrical machines and discuss their devices, symbols and circuits
  • Enumerate the electric motor types and demonstrate how to operate and perform their functions
  • Discuss the construction, operation and performance of 3-Phase AC induction motors
  • Emphasize the importance of motor speed control and become familiar with power electronic converters
  • Protect and select AC converters, motors & control system and conduct installation & commissioning of AC variable speed drives
  • Identify the sources of electromagnetic compatibility (EMC) and analyse & test the different types of motor failure
  • Carryout predictive maintenance techniques such as the vibration analysis
  • Conduct machinery faults diagnosis & correction using vibration analysis and corrective measures
  • Apply bearing failure analysis and discuss the importance of lubrication & oil analysis program

Course Outline

DAY 1:

  • Basic Principles of Electrical Machines
  • Introduction to Electrical Machines
  • AC Power Systems
  • Meters Used in Troubleshooting
  • Electrical Devices, Symbols and Circuits
  • Devices and Symbols
  • Electrical Circuits
  • Reading and Understanding Electrical Drawings
  • Reading and Understanding Ladder Logic
  • Wires and Terminal Numbering
  • Electric Motors Types, Operations and Performance
  • Fundamentals of Motor Technology
  • Basic Principles of Rotating Electrical Machines
  • Fundamental Principles of Speed Control
  • Efficiency, Torque, Inertia, Horsepower / Power Factor
  • Torque -Speed Curves
  • Induction / Wound Rotor /Synchronous Motor Types
  • Basic Construction of a Motor
  • Principles of Operation and Performance

DAY 2:

  • 3-Phase AC Induction Motors
  • Basic Construction
  • Principles of Operation
  • The Equivalent Circuit
  • Electrical and Mechanical Performance
  • Motor Acceleration
  • AC Induction Generator Performance
  • Efficiency of Electric Motors
  • Rating of AC Induction Motors
  • Electric Motor Duty Cycles
  • Cooling and Ventilation of Electric Motors (IC)
  • Degree of Protection of Motor Enclosures (IP)
  • Construction and Mounting of AC Induction Motors
  • Anti-Condensation Heaters
  • Methods of Starting AC Induction Motors
  • Motor Speed Control
  • The Need for Variable Speed Drives
  • Fundamental Principles
  • Torque-Speed Curves for Variable Speed Drives
  • Types of Variable Speed Drives
  • Mechanical Variable Speed Drive Methods
  • Hydraulic Variable Speed Drive Methods
  • Electromagnetic or ‘Eddy Current’ Coupling
  • Electrical Variable Speed Drive Methods
  • Power Electronic Converters
  • Power Diodes
  • Power Thyristors
  • Commutation
  • Power Electronic Rectifiers (AC/DC Converters)
  • Gate Commutated Inverters (DC/AC Converters)
  • Gate Controlled Power Electronic Devices
  • Other Power Converter Circuit Components

DAY 3:

  • Protection of AC Converters & Motors
  • AC Frequency Converter Protection Circuits
  • Operator Information and Fault Diagnostics
  • Electric Motor Protection
  • Thermal Overload Protection - Current Sensors
  • Thermal Overload Protection - Direct Temperature Sensing
  • Control Systems for AC Variable Speed Drives
  • The Overall Control System
  • Power Supply to the Control System
  • The DC Bus Charging Control System
  • The PWM Rectifier for AC Converters
  • Variable Speed Drive Control Loops
  • Vector Control for AC Drives
  • Current Feedback in AC Variable Speed Drives
  • Speed Feedback from the Motor
  • Selection of AC Converters
  • The Basic Selection Procedure
  • The Loadability of Converter Fed Squirrel Cage Motors
  • Operation in the Constant Power Region
  • The Nature of the Machine Load
  • The Requirements for Starting
  • The Requirements for Stopping
  • Control of Speed, Torque and Accuracy
  • Selecting the Correct Size of Motor and Converter
  • Installation & Commissioning of AC Variable Speed Drives
  • General Installation and Environmental Requirements
  • Power Supply Connections and Earthing Requirements
  • Start/Stop Control of AC Drives
  • Installing AC Converters Into Metal Enclosures
  • Control Wiring for Variable Speed Drives
  • Commissioning Variable Speed Drives

DAY 4:

  • Electromagnetic Compatibility (EMC)
  • The Sources of Electromagnetic Interference
  • Harmonics Generated on the Supply Side of AC Converters
  • Power Factor and Displacement Factor
  • Voltages and Current on the Motor Side of PWM Inverters
  • Motor Failure Analysis & Testing
  • Types of Motor Failure
  • Common Causes of Motor Failure
  • Modern Developments
  • Insulation Life And Resistance
  • Polarization Index
  • DC Hipot
  • DC Ramp Test
  • AC Hipot
  • Capacitance Test
  • Dissipation Factor
  • Partial Discharge
  • Surge Test
  • Mechanical Testing
  • Online Testing
  • Predictive Maintenance Techniques: Basics
  • Maintenance Philosophies
  • Evolution of Maintenance Philosophies
  • Plant Machinery Classification and Recommendations
  • Principles of Predictive Maintenance
  • Predictive Maintenance Techniques
  • Vibration Analysis - A key Predictive Maintenance Technique

DAY 5:

  • Predictive Maintenance Techniques: Vibration Basics
  • Spring -Mass System: Mass, Stiffness, Damping
  • System Response
  • What is Vibration?
  • The Nature of Vibration
  • Harmonics
  • Limits and Standards of Vibration (ISO 2372, API, AGMA, IRD)
  • Machinery Faults Diagnosis & Correction Using Vibration Analysis & Corrective Measures
  • Unbalance
  • Eccentric Rotor
  • Bent Shaft
  • Misalignment
  • Mechanical Looseness
  • Resonance
  • Rotor Rubs
  • Journal Bearings
  • Rolling Element Bearings
  • Gearing Defects
  • Belt Defects
  • Electrical Problems
  • Flow Related Vibrations
  • Rotor Crack
  • Bearing Failure Analysis
  • The Bearing
  • Failure Analysis
  • Bearing Failures
  • Grease and Greasing
  • The Belt Drive
  • Balance
  • Storage Issues
  • Services Factor Loading
  • Lubrication & Oil Analysis Program
  • Oil Fundamentals
  • Condition-Based Maintenance and Oil Analysis
  • Setting Up an Oil Analysis Program
  • Oil Analysis - Sampling Methods
  • Oil Analysis - Lubricant Properties
  • Oil Analysis - Contaminants in Lubricants
  • Particle Analysis Techniques
  • Alarm Limits for Various Machines (source - National Tribology Services)

Course Methodology

A variety of methodologies will be used during the course that includes:

  • (30%) Based on Case Studies
  • (30%) Techniques
  • (30%) Role Play
  • (10%) Concepts
  • Pre-test and Post-test
  • Variety of Learning Methods
  • Lectures
  • Case Studies and Self Questionaires
  • Group Work
  • Discussion
  • Presentation

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Motors & Variable Speed Drives: Selection, Applications, Diagnostic Testing, Protection, Control, Troubleshooting and Maintenance at ICTD International Centre for Training and Development

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