Guidelines For Repair - Replacement

Guidelines for
Repair/Replace Decisions
and Performance Optimization
Electrical Apparatus
Service Association, Inc.
1331 Baur Blvd.
St. Louis, Missouri 63132 USA
314-993-2220 FAX 314-993-1269
www.easa.com
This paper was presented by Austin H. Bonnett, EASA Education and Technology Consultant
at EASA's Convention in Chicago, Illinois, June 25, 2001
ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com
16
Reliable Solutions Today!
GUIDELINES FOR REPAIR/REPLACE DECISIONS

AND PERFORMANCE OPTIMIZATION
By Austin M. Bonnett
Education and Technology Consultant
Electrical Apparatus Service Association, Inc.
St. Louis, Missouri
Chuck Yung
Technical Support Specialist
St. Louis, Missouri
ABSTRACT
For general-purpose motors, there are many cases where
replacing a failed motor with a new one of EPACT efficiency levels or better is the best choice. However, in
some cases, the motor will fail again unless the root cause
of failure is addressed through some modification to the
motor or the system.
There are also many cases where repairing the existing
motor is the best choice. This is especially true if an upgrade is required to address the cause of failure, or in
some cases, where cost, availability or unique performance is an issue. The motor service center is in an
excellent position to make these assessments. The purpose of this paper is to explore both choices and present
some of the many options available.
Quite often when a motor fails, the procedure is to remove the damaged motor from service and replace it
without a thorough evaluation of the root cause of the
failure. Depending on the motor size and the amount of
damage, the old motor may be repaired and placed into
spares inventory or even scrapped.
The problem with this approach is that the replacement
motor, whether new or rebuilt, may fail again for the same
reason. If a root cause failure analysis is conducted, it is
often possible to identify and correct the underlying
cause. All that may be required is to modify the motor,
driven equipment or system to extend the mean time
between failures (MTBF) significantly.
In most cases, where a standard motor is no longer suitThis paper was presented at EASA's Convention in
Chicago, Illinois, June 25, 2001.
MOTOR REPAIR BEST PRACTICE GUIDES

The Electrical Apparatus Service Association (EASA)
has available the following repair guidelines to assist
in providing quality motor repairs.
ANSI/EASA AR100-1998, Recommended
Practice for the Repair of Rotating Electrical Apparatus, Copyright 1998.

Association of Electrical and Mechanical Trades
(AEMT) Good Practice Guide: The Repair of
Induction Motors, Best Practices to Maintain Energy Efficiency, Crown Copyright 1998.
EASA A Guide to AC Motor Repair and Replacement, Copyright 1999.
These documents can be obtained from EASA headquarters in St. Louis to be used as reference
documents when selecting or working with a motor
repair facility.
Appendix D includes several sample pages from these
documents.
able for the application, the service center is able to make
the required modification faster than the motor manufacturer can produce a unique model.
The application checklist in Appendix A can be used to
assist in this analysis.
INTRODUCTION
The Electrical Apparatus Service Association (EASA) has
established Recommended Practices for its 2500 members around the world to assure that the repair process
does not degrade the motor performance characteris-
Guidelines for Repair/Replace Decisions and Performance Optimization

tics. This paper provides the reader with a repair guideline to implement these procedures with their local repair
organizations.
Criteria are presented to determine when the repair of
the motor is not practical and may lead to reduced efficiency levels. In some cases, it is possible to improve
the level of operating efficiency during the repair process.
EASA members rebuild electrical equipment, primarily
motors and generators. Many EASA service centers also
rebuild peripheral equipment such as pumps and
switchgear.
EASA is in the process of conducting a major test program to verify the results of these Recommended
Practices. This paper will include an update on this work
in progress.
EASA/AEMT MOTOR REWIND STUDY

INTRODUCTION
Previous studies were conducted on motors in the 10 hp
range at four-pole speeds, which do not reflect the true
degree of difficulty associated with rewinding the typical
failed motor. The EASA/AEMT Motor Rewind Study is
focusing on motors that are more typically rewound for
both the NEMA and IEC designs.
for the study. The Dowding and Mills facility in Birmingham, UK will facilitate all motor modifications and repairs
that are part of the study. The University of Nottingham
will perform the basic load testing on their dynamometers in Nottingham. There may be additional tests
performed at Dowding and Mills.
ROUND ROBIN TESTING AND TEST PROTOCOL
One motor will be selected for round robin testing to ensure the accuracy of the Nottingham University facility.
These tests will be conducted at the U.S. Electrical Motors Motor Technology Center in St. Louis, Mo. and the
Invensys Brook Crompton UK plant. Both IEEE and IEC
methods of efficiency testing will be conducted. All testing will include (at no load and full load) a loss segregation
method that allows for detailed analysis.
OTHER DELIVERABLES
It is expected that due to the large size of the sample
and the data collected additional deliverable might be
developed as part of a supplementary document. It may
be possible to update an EASA tutorial on other aspects
of motor repair that affect overall motor performance and
efficiency. Winding configuration, span, slot fill, flux density and mechanical factors will be considered.
SCHEDULE
The motors are all now at the University of Nottingham
FIGURE 1: REPAIR OR REPLACE OPTIONS
OBJECTIVE OF STUDY
The major objectives of the study include:
Issue a best practice guide for motor rewinds.
Determine whether low- and medium-voltage machines respond similarly.
Investigate the impact of repeated rewinds of the
same motor.
Establish the correlation between the static core
loss test and the running core loss test.
Evaluate the impact of physical damage to the stator core.
Failed motor
Repair
SCOPE OF PRODUCT EVALUATED

There will be at least 27 motors used in the study, most
of which will be in the 50 to 200 hp range. Both 50 and
60 Hertz will be included, as well as low- and mediumvoltage, IEC and NEMA frames, ODP and TEFC
enclosures and two- and four-pole speeds.
PARTICIPATING MANUFACTURERS
AND INSTITUTIONS
At least seven different motor manufacturers have committed to provide motors, technical data and assistance
Replace
Options
Restore
Repair to original
condition
Redesign/Upgrade
EPACT
Level Efficient
Optimize horsepower
to load
Optimize voltage
Change speed
Inverter-duty winding
Increase insulation
class
Premium
Efficient
Modify
Customized
motor
Improve enclosure
Add seals
Make bearing
modifications

FIGURE 2: REPAIR OR REPLACE DECISION PROCESS
Failed motor
Is the motor suitable for the

application?
No
Investigate replacement with suitable motor (size/enclosure).
Yes
What is the condition of the
stator core?
Significant damage or high losses
OK
Special cases
Has catastrophic failure occurred,

or is there evidence of prior
catastrophic failure?
(e.g., very expensive

motors)
Yes
No
Is the rotor damaged, or is there
severe damage to other
mechanical parts?
Is the cost of repair greater than

the cost to replace the motor?
Yes
Yes
No
No
Are replacement funds available?
No
Yes
Is it an EPACT motor?
Yes
No
Is replacement motor available?
No
Yes
Is return on investment of EPACT

motor acceptable?
Yes
No
Is lead time of replacement motor

acceptable?
No
Yes
Replace motor
Repair motor
Additional considerations include increased reliability, life expectancy and benefits of additional features, upgrades
or modifications.
and testing is under way. lt is expected that this evaluation will be complete by the end of 2001. The co-chairmen
are David Walters and Austin Bonnett. The technical
group will review progress monthly and have already held
one meeting in Birmingham.
REPAIR-REPLACE DECISION MODEL

In the past, the decision whether to repair or replace an
electric motor has been one of economics. Replacement
of an older electric motor with a more efficient model
often makes sense for a motor operating continuously.
However, in most cases the decision is more complex
(Figures 1 and 2). A motor operating infrequently, a mo-
tor with special mounting or design features, an EPACT

motor or a motor larger than those covered by EPACT
are all examples where the repair option may be the better choice.
When comparing the cost to replace or repair an electric
motor, the equation should include not only operating
cost and payback period, but also downtime and associated factors such as capital depreciation, lost
opportunities and customer good will. A replacement
EPACT motor that fails within a year or two may have a
significantly higher cost than a repair that optimizes the
motor for its unique application.

Annual energy savings of several hundred dollars are
quickly wiped out by unscheduled downtime when a
motor fails unexpectedly.
Much of todays literature emphasizes efficiency and the
cost of energy as stand-alone factors in the repair-replace decision matrix. Frequently, the cost of the motor
or its repair is a small fraction of the total cost of downtime when lost production is factored in.
Considerations (other than efficiency and simple payback) include reliability, performance and anticipated
motor life as well as availability of a replacement. Of these,
the most critical may be reliability. A motor customized
to its application will offer the greatest chance of long
life. (See Appendix C for a list of repair options.) Zero
downtime is a noble goal, one that requires commitment
and planning.
ge
volta
Line
En
v ir
on
me
ad
n
tio
ica
r
b
Lu
lo
ing
ar
ive
Be
Level 1 Basic reconditioning. Includes replacing

bearings, cleaning all parts and replacing
lubricant. Also adds seals and other accessories as agreed with customer.
Level 2 Includes Level 1 with the addition of varnish
treatment of stator windings, repair of worn
bearing fits and straightening of bent shafts.
Level 3 Includes Level 1 as well as rewinding the stator (replacing windings and insulation).
Level 4 Includes rewinding of the stator plus major
lamination repair or rotor rebar. May include
replacement of the stator laminations or
restacking of laminations. Shaft replacement
would normally fall into this category. In short,
Level 4 involves major repairs that are costly
enough to justify examining the option of replacement.
Level 5 Motors that would normally be replaced except for special circumstances faced by the
customer (i.e., no spare or unacceptable lead
time for a replacement). Level 5 includes
misapplied motors, inadequate enclosures
and pre U-frame motors. A motor that should
be replaced, if not for the owners inability to
operate without it.
Dr
ind
ing
NEMA MG 1-1998 defines Unusual Service Conditions

(Appendix B). Most readers will recognize many of these
as the norm for real-life motor applications. By itself, this
fact may be justification for repair and customization of
a failed electric motor.
TABLE 1: LEVELS OF REPAIR
nt
It makes economic sense to identify the weak link in any

process, and to detect imminent failure before it occurs.
When the weak link is strengthened, the entire process
becomes stronger. A motor subject to accidental washdown should be of a suitable enclosure, and can be
modified to further protect the motor from this hazard.
Likewise, since more than 50% of electric motor failures
start as bearing failures, bearing temperature detectors
or vibration probes are logical options in many cases, as
shown in Figure 3.
As these five levels imply, the damage resulting from

a motor failure varies widely as do the associated repair costs. An evaluation process that fails to consider
the various levels of repair is too simplistic to yield
an accurate assessment.
FIGURE 3: FAILURES BY COMPONENTS
Rotor bar 5%
Unknown 10%*
(No root cause
failure analysis
performed)
External 16%*
(Environment, voltage
and load will likely
occur again)
With todays rapidly changing technology, the motor

manufacturer is hard-pressed to incorporate emerging
technology within a 2- to 3-year period. One advantage
the service center has is its ability to deal with each
unique motor and apply new technology as it develops
to address specific concerns about that particular motors
application and environment.
This means the end user can take advantage of unique
technology that meets their unique needs.
Shaft/coupling 2%
Stator winding 16%*

(May have been voltage,
water, overload, etc.)
Bearing 51%*
* For each component shown, appropriate measures

to either prevent or predict the failure could greatly
reduce three-quarters of motor failures.
Reference: IEEE Petro-Chemical paper PCIC-94-01

Whether the concern is winding temperature, vibration
or bearing temperature, specific accessories can be incorporated into the repair process to enhance motor
life and permit the end-user to monitor the critical feature.
Consider winding temperature alone: There are 4 different RTD resistances, 14 different thermocouples and
numerous thermistors and bimetallic switches in common use. Clearly, a stock motor cannot cover all these
options. These features are a special order from motor
manufacturers and usually require long lead times. The
service center is able to tailor the motor repair to match

the monitoring equipment used by the user, incorporating special features without impacting the repair
turnaround.
Vibration monitoring is available as a continuous, online system. Accelerometers are but one item that can
be retrofitted to improve the users ability to predict
equipment failure. Non-contact shaft probes, accelerometers intended for continuous monitoring and periodic
data collection, accelerometers integral to a sophisticated continuous monitoring system; all are available
FIGURE 4 : POSSIBLE MOTOR UPGRADES AND MODIFICATIONS

Windings
Core damaged?
Rewind?
Optimize voltage?
Special coatings?
Inverter duty?
Optimize slot fill
Winding RTDs?
Repair/restack core
Replace core
Bearings
Replace bearings*
Add seals*
Install automatic
lubrication device
Special grease
Change bearing type*
Mechanical damage
to shaft and housing
Is is repairable?
If replacing shaft, is
there a better material?
Is stainless steel
warranted?
Are shaft modifications
warranted?
Other options
Upgrade enclosure
Improve sealing of
the enclosure
Upgrade paint for corrosion
resistance
Change starting method to

reduce in-rush current
Add space heaters
Precision balance rotor
Increase air flow
Special considerations
Corrosion
Special paints
Varnish treatment
Stainless steel shaft
Inverters
Spike-resistant wire
Higher corona-inception voltage
Upgrade winding bracing
Abrasion
Special energy-absorbing coatings
Improve wedging
Upgrade enclosure and add filters
Moisture
Special coatings
Shaft seals
Seal leads
Gaskets
Seal brackets
Space heaters
Heat
Add RTDs
Improve fan design
Heat exchanger
Upgrade insulation class
Severe starts
Better shaft material
Stronger shaft design
Additional winding bracing
Change starting method
* Adding seals or changing bearing types may affect efficiency.
Illustration courtesy of Siemens AG

technology today. Once a user makes the financial commitment to a particular system, it is rarely practical to
abandon it in favor of another emerging technology. That
makes the service center a partner in maintaining the
system(s) selected by each end user.
With most companies returning to their core business,
and outsourcing maintenance, the competent service
center is best qualified to assess the cause of each motor failure and develop a plan to reduce the possibility of
a repeat failure. The service center warranty ensures
the repairer has a vested interest in identifying the root
cause of the motor failure, and performing a quality repair.
Table 2 illustrates the effect on efficiency and winding

temperature.
Low voltages are especially common in rural areas,
where the motor may be operating at a considerable distance from the nearest substation. Irrigation pumps and
municipal pump stations are two examples.
While many manufacturers can deliver a motor to optimize non-standard line voltage, typical manufacturer lead
times of five to eight weeks may be prohibitive. The service center can accomplish the same voltage optimization
during a motor repair.
VOLTAGE OPTIMIZATION
An added benefit: It is common practice for manufacturers to produce motors with up to 12 leads, so that the
motor may be used on multiple voltages, often as a partwinding start or wye-start, delta-run. This means the
electrician may deal with 9 to 12 leads in the junction
box, increasing the chances of a ground failure from
abraded leads. When an electric motor is repaired, the
service center has the option of installing only the number of leads required. With only 3 or 6 leads, there is
more room in the junction box and less chance of lead
damage or misconnection during installation.
A municipal pump station is located at the end of the

power transmission line. Motor failures are common, and
winding temperatures are higher than identical motors
operating at the water treatment plant in town. Repeated
measurements have confirmed chronic low voltage.
Note: Tri-voltage motors represent a compromise between the possible applied voltages. This improves
potential availability, to the detriment of efficiency at certain applied voltages.
EXAMPLES OF UPGRADES
AND MODIFICATIONS
Once a cause of failure is determined, the service center can work with the equipment owner to identify specific
remedies to extend MTBF. The following are but a few
examples of frequent problems and solutions service centers encounter.
When a winding failure is the result of low applied voltage, the replacement motor regardless of efficiency
will be subject to the same low line voltage. The solution, then, is to redesign the motor to optimize
performance at the actual applied voltage. It is common
to apply a 230 volt motor to a 200 or 208 volt application.
Compounding the problem, the utility supplying 208 volts
is allowed to deviate and may supply even lower voltage.
VIBRATION MONITORING AND IMPROVEMENT
A Blanchard grinder begins to vibrate, and pieces of valuable precision plate are scrapped before the cause is
identified.
FIGURE 5: ROTOR BALANCING
TABLE 2: EFFICIENCY AND WINDING

TEMPERATURE
Volts
208
230
Efficiency (%)
80.6
84.4
Power factor (%)
85.0
82.7
Full load current (amps)
30.5
26.9
Inrush current (amps)
129
148
Temperature rise ( C)
91
72
Slip (%)
5.9
4.1
Design B, 4-pole, tri-voltage motor (208-230/460)
Rotor being dynamically balanced in a service center.

Vibration sensors are vital when the application is a precision grinder or similar vibration-sensitive equipment.
Installation of vibration probes can be accomplished by
the service center with minimal intrusion into the motor.
Accelerometers can be installed on the frame or in the
junction box, while non-contact shaft probes may be preferred for sleeve bearing machines. A finishing grinder in
a machine shop must hold close tolerances to minimize
scrap. Vibration from a defective bearing can be expensive.
Another good candidate for vibration sensors is a pump
motor operating in a remote location. Continuous monitoring by instrument is infinitely better than a weekly visit
by a plant operator.
The service center can install the appropriate vibration
sensing accessories on eligible motors in the course of
each repair.
Manufacturers standard motors are balanced to NEMA
MG 1-1998, Part 7 specifications while the service center can routinely balance to one-quarter of NEMA or
better. While precision manufacturing has a legitimate
need for this, many end-users request special balance
tolerances because they recognize that there is a reliability factor associated with vibration.
FIGURE 6: BEARING TEMPERATURE
DETECTORS
Probe element
Customer's
conduit
entrance
Courtesy of Minco
The cause of a plant fire is tracked back to a bearing

failure. The bearing, unmonitored, failed catastrophically.
Vibration damaged the pump seal and the pump leaked,
by which time the bearing temperature was high enough
to ignite the spewing liquid.
Bearing temperature protective devices (Figure 6) can
be installed during routine repairs to provide early warning of increased temperature. Excessive lubrication
intervals, high ambient temperature, imminent bearing
failure and other general machinery faults may cause
an increase in bearing temperature before damage occurs. A bearing RTD is not intended to just protect the
bearing, but rather to protect the machinery by alerting
personnel when an equipment fault results in an increase
in bearing temperature. Depending on the critical nature
of the machine, feedback can take the form of a light in
the control room, or automatic shutdown of the equipment.
The service center can install the appropriate temperature detectors to interface with instrumentation already
in use at the plant.
The cost to fit an electric motor with bearing thermals
may be only a few hundred dollars. That cost should be
weighed against the possible consequences of failure,
not against the cost of the motor.
CORROSION RESISTANCE
Weatherproof terminal head

Spring-loaded, fluid-seal holder
BEARING TEMPERATURE PROTECTION
Bearing
A chemical plant removed a 600 hp motor for routine

repairs. The corrosive environment had rusted through
the motor frame in numerous places, even the mounting
FIGURE 7: TYPICAL MOTOR ENCLOSURE
UPGRADES
Bracket outer wall
Courtesy of Siemens AG

FIGURE 8: STRESS RAISERS
The lines indicate the path of stresses in the shaft. Where stresses converge, the chance of failure is much higher. The sharp
inside corner of shaft C is 40% weaker than it would be with an appropriate radius.
feet. Although running when removed from service, the

motor was beyond repair and had to be replaced.
FIGURE 9: STRESS RAISERS

VENT FAN
When a motor (new or rebuilt) is placed into a known

corrosive atmosphere, the service center can take precautions to greatly improve motor life. At the simplest,
corrosion-resistant paint can be used to protect the frame.
In extreme cases, the shaft can be chrome plated, or
replaced with a stainless steel shaft to better resist corrosive materials. When caustic solutions are evident,
aluminum parts may be quickly eroded. Preventive measures may be as simple as dipping the rotor with varnish
to protect it. The rotor might even be rebarred using
bronze alloy of similar resistivity to avoid changing the
torque characteristics (rotor cage resistance should be
maintained to avoid changing motor performance). The
rotor should also be balanced after work is done to the
rotor. A precision balance requires only slightly more time
than a standard balance.
The exploded view of an open motor (Figure 7) illustrates the ease with which various degrees of weather
protection can be accomplished by the addition of covers, filters or guards. While an open motor is ill-suited to
outdoor operation, the upgraded WPII enclosure was designed for outdoor service.
HIGH-TORQUE APPLICATIONS
An electric motor driving a hammer mill application frequently experiences a broken shaft.
There are several ways to approach this problem depending on the application. One would be to replace the
shaft using material with higher tensile strength than the
original shafting. The corners should all be radiused to
minimize potential stress raisers (Figures 8 and 9). The
keyway can be machined in a manner to reduce the stress
raisers at the end of the keyway (a sled-type keyway as
opposed to a milled keyway.) In extreme cases, the keyway can be milled with a radius bottom and fitted with a
ROTOR CORE
A B
COUPLING/
PULLEY
BEARING
BEARING
F G
All of the highlighted areas create stress raisers. Points F,

H, I and J are usually the most vulnerable because of shaft
load at these points. It is hard for a shaft to fracture at
points A, B, C, D or E.
custom key. It is not necessary to modify the keyway in

the coupling.
Most service centers can machine custom shafts and
keyways to address concerns about fatigue-related failures.
WASH DOWN AND FLOODING
When a power outage occurs, the sump pumps stop and

the pit floods. Electric motors must be removed, cleaned
and dried before production can be restored.
Accidental wash down and flooding cause many electric
motor failures. To increase reliability, special seals are
installed on the shaft openings to exclude water from
the bearings (Figure 10). Special water-resistant grease
can be used to pack the bearings, to further resist washing of lubricants. Sealed bearings may be preferred when
the installation precludes regular maintenance.
The service center can seal T-leads using special potting compounds to prevent water from entering through
the lead opening. End brackets can be sealed with silicone during the assembly process. These are
inexpensive steps, but are very effective for a motor subject to flooding or inadvertent wash down. Examples of

FIGURE 10: NON-CONTACT BEARING ISOLATOR
FIGURE 11: ALTERNATIVE METHODS

OF CONNECTION
wye start - delta run
part winding
The standard-design non-contact bearing isolator consists

of two parts: The stator, which is press-fitted into a bearing
housing and is designed to retain lubricant in the housing,
and the rotor, which in combination with the stator, is
designed to keep contamination out of the bearing housing.
double delta
Courtesy of Inpro/Seals Company
candidates for this sort of modification include motors

operating below grade in pump rooms, as well as cooling tower motors.
PROTECTION FROM ABRASIVE DUST
An electric motor operates downwind of a rock quarry

and abrasive dust sandblasts the windings.
Unprotected windings do not last very long in this type
of environment. The service center can topcoat the windings with a special material that absorbs impact energy,
thus protecting the windings. Filters can be added to
exclude the dust from the motor enclosure, or additional
covers can be installed to upgrade the enclosure.
Motors operating in rock quarries, cement mills or power
plants benefit from this treatment. Motors operating near
agricultural fields may also benefit. These treatments can
also be applied to new motors before they are placed
into service.
motor will still be justified, when coupled with an appropriate starter sized for the current. Typical paybacks when
comparing energy savings against capital investment
range between 1 and 3 years, based on the cost of energy and hours of running time. Wye-delta starting
reduces inrush current to 37% and provides one-third
the torque. Part-winding start methods reduce inrush current to one-half to two-thirds while supplying one-half
the starting torque.
The service center can often reconnect an existing winding to reduce starting current and torque. (See Figure 11.)
RECONNECTION
ENERGY EFFICIENCY IMPROVEMENT
To reduce starting torque, a wye-start/delta-run connection can be used. In some cases a motor can be
reconnected, while in other cases a rewind is required.
Other starting options include a VFD or a solid-state softstarter.
There are occasions when rewinding a motor where the

opportunity may exist to enhance the motor performance
and reliability by modifying the winding configuration and
copper content. For many designs, the copper loss (I2R)
is the largest loss component (Figure 12). In some cases,
this loss can be reduced by converting from a concentric, machine-wound configuration to a traditional,
hand-inserted lap winding. In many cases, the copper
There will always be applications where reduced starting current will be required. In most cases a Design A
Nameplate NNE (%)
Full-load efficiency (%)
5-10%
Space factor (%)*
Friction and windage losses
10-15%
Original pre-EPACT
25
Machine
43.0
88.5
88.7
Rewound pre-EPACT
25
Lap
62.0
90.2
90.8
EPACT reference
25
Original pre-EPACT
50
Machine
46.0
Rewound pre-EPACT
50
Lap
60.0
EPACT reference
50
Stator core losses

15-20%
Rotor losses
Winding type
Stray load losses
TABLE 4: ENERGY EFFICIENCY IMPROVEMENT
Horsepower
FIGURE 12: TYPICAL DISTRIBUTION OF LOSSES
15-20%
Stator winding losses
91.7
91.7
91.6
92.4
92.6
35-40%
The laminated core, stator windings and rotor account for

as much as 80% of the total losses for the typical electric
motor. While losses are generally associated with lost
efficiency, they represent energy converted to heat.
93.0
Typical 4-pole, open dripproof, general purpose, T-frame motors of preenergy efficient design.
3.14 D 2
of wire
4
100
Total slot area - area of insulation
Total number of wires per slot
NEMA Standards MG 10-1994, Table 2-2 (National Electrical Manufacturers Association, Rosslyn, VA, 1994).
*Percent space factor =

D = wire diameter
content (slot fill) can also be increased. Figure 13 shows

the contrast between a relatively low slot fill (40 to 50%
where the wire is PD2/4) and one of a much higher percent slot fill (60 to 64%).
FIGURE 13: EXAMPLES OF SLOT FILL
This modification will improve heat transfer, reduce the

copper loss and winding temperature and improve motor efficiency. There will be less coil movement, and
increased resistance to moisture, due to better varnish
retention. Even though these improvements are difficult
for the service shop to quantify, they are none the less
real and will usually improve motor performance and reliability. With this modification, the motors service factor
will be improved and it will be able to withstand wider
variations in voltage, ambient and starting conditions.
Table 4 shows the possible efficiency improvements that
can be made for a generation of T frame motors produced during the 1970s and 80s. Not all motors offer
this opportunity, but for those that do this option should
be considered as a possible product improvement.
CONCLUSION
By incorporating effective technology as it becomes available, it is possible to reduce downtime, improve
productivity and operate more efficiently. Reduced costs
make an organization more profitable. Savings can be
redirected to improve other weak links. The savvy maintenance professional is always looking for ways to
Low slot fill
Improved slot fill
improve processes, and the competent service center is

able to assist in this task.
When evaluating the operating cost of an electric motor,
the cost of energy is only one variable (and often not the
biggest one) in the equation. The key to maximizing productivity is to eliminate downtime. While zero downtime
is not always possible, any significant reduction in downtime improves profitability. When downtime is measured
in thousands of dollars per hour, the payback reaped
from extending motor life can be enormous.
The economics of the repair or replace decision process
are complex. All variables must be considered in order
to select the best option.
10
REFERENCES
Principles of Large AC Motors. Electrical Apparatus
Service Association, Inc., St. Louis, MO, 2000.
Intelligent Motors Take the Lead in Predictive Maintenance. Matt OKane, U.S. Electrical Motors, St.
Louis, MO. Presented at EASA Convention 2000,
Anaheim, CA, April 5, 2000.
Ongoing Issues With AC Electric Motors. Austin
Bonnett, Education and Technology Consultant, Electrical Apparatus Service Association, Inc., St. Louis,
MO, and Cynthia Nyberg, Technical Support Specialist, Electrical Apparatus Service Association, Inc., St.
Louis, MO. Presented to the EPRI-sponsored National
Motors & Drives Steering Committee, Montreal, Quebec, Canada, June 29, 2000.
A Survey of Faults on Induction Motors in Offshore
Oil Industry, Petrochemical Industry, Gas Terminals

and Oil Refineries. Olav Vaag Thorsen, Senior Member IEEE and Magnus Dalva, Member IEEE. IEEE
Transactions on Industry Applications, Vol. 31, No. 5,
Sept./Oct. 1995.
Root Cause Failure Analysis for Large AC Induction
Motors. Austin Bonnett, Education and Technology
Consultant, Electrical Apparatus Service Association,
Inc., St. Louis, MO. Presented at EASA Convention
1999, Toronto, Ontario, Canada.
11
APPENDIX A Application Checklist

Voltage
What is the nominal voltage?
How much voltage variation is present?
Is there voltage drop when starting under load?
Is there nuisance tripping?
Are there transient peaks?
Environmental factors
What is the frequency of moisture ingression?
What is the frequency of condensation?
What is the ambient temperature range?
What other contaminants are present?
Load conditions
Are there load swings? If so, how wide?
What is the hp required versus rated hp?
What is the load pump, fan, compressor, conveyor?
How is the motor mounted / coupled?
Direct coupled
What are the thrust conditions?
Overhung load
Describe the motors mounting.
Starting method
Across-the-line
Part-winding start
Wye start, Delta run
Soft-start
Frequency of starting
What is the running time between starts?
How many starts per hour / 8-hours / 24-hours?
Is it a demand system?
Is it a constant or variable load?
Describe the cycling.
Are there load-shedding opportunities?
Describe unusual service conditions
See Appendix B, NEMA MG 1-1998, 14.3
Describe the application
How critical is the operation?
Is it a dedicated or redundant system?
What is the availability of spares or backups?
What are the consequences of shutdown?
History of failures or repairs
Has the motor been rewound? If so, how many
times?
What is the mean time between failures?
Root cause failure analysis
What is the cause of failure?
What can be done to eliminate the cause?
What is the best method to detect the condition?
Are there similar motors and applications?
APPENDIX B Unusual Service Factors, NEMA MG 1-1998, 14.3

14.3 UNUSUAL SERVICE CONDITIONS
The manufacturer should be consulted if any unusual service conditions exist which may affect the construction or
operation of the motor. Among such conditions are:
a. Exposure to:
1. Combustible, explosive, abrasive, or conducting dusts
2. Lint or very dirty operating conditions where the accumulation of dirt may interfere with normal ventilation
3. Chemical fumes, flammable or explosive gases
4. Nuclear radiation
5. Steam, salt-laden air, or oil vapor
6. Damp or very dry locations, radiant heat, vermin infestation, or atmospheres conducive to the growth of
fungus
7. Abnormal shock, vibration, or mechanical loading from
external sources
8. Abnormal axial or side thrust imposed on the motor
shaft
b. Operation where:
1. There is excessive departure from rated voltage or
frequency, or both (see 12.45 for alternating-current
motors and 12.68 for direct-current motors)
2. The deviation factor of the alternating-current supply
voltage exceeds 10 percent
3. The alternating-current supply voltage is unbalanced
by more than 1 percent (see 12.46 and 14.36)
4. The rectifier output supplying a direct-current motor is

unbalanced so that the difference between the highest
and lowest peak amplitudes of the current pulses over
one cycle exceed
10 percent of the highest pulse amplitude at rated armature current
5. Low noise levels are required
6. The power system is not grounded (see 14.31)
c. Operation at speeds above the highest rated speed
d. Operation in a poorly ventilated room, in a pit, or in an
inclined position
e. Operation where subjected to:
1. Torsional impact loads
2. Repetitive abnormal overloads
3. Reversing or electric braking
4. Frequent starting (see 12.55)
5. Out-of-phase bus transfer (see 14.45)
6. Frequent short circuits
f. Operation of machine at standstill with any winding continuously energized or of short-time-rated machine with any
winding continuously energized
g. Operation of direct-current machine where the average
armature current is less than 50 percent of the rated fullload amperes over a 24-hour period, or continuous
operation at armature current less than 50 percent of rated
current for more than 4 hours
12
APPENDIX C Repair Options

At the time of the motor repair, in addition to the task of
restoring the motor to its original condition, it is possible to
make modifications and upgrades. During the repair it may
become evident that the motor will fail again if returned to its
existing environment without modification. It may also be expedient to implement certian upgrades to enhance motor
performance, reliability and life.
The following is a list of possible options that may be considered by the repair facility.
Bearings
Enclosure sealed, shielded or open
Roller or ball (for direct couple or radial load)
External seals
Non-contact bearing isolator
Lip seal
Lubrication
Synthetic grease
Automatic grease applicators
Oil-mist systems
Forced-lube oil systems
Mineral oil for food service or potable water applications
Severe starting conditions
Increase rigidity of winding blocking
Redesign to wye start, delta run to reduce torque and
inrush current
Increase slot fill
Environmental protection
Abrasion resistance
Special coatings
Full-length slot wedges for form coil machines
Corrosion resistance
Special epoxy paints
Stainless steel shafting
Lead potting compound
Filters
Screens, baffles or covers
Power considerations
Power factor correction capacitors
Surge protection or lightning arrestors
Increase motor cooling

Directional fans
Special fans to increase air flow
Heat exchanger
Auxiliary blower (especially for VFD-fed motors)
Maximize slot fill
Special accessories
Winding temperature detectors
Bearing temperature detectors
Vibration monitoring: accelerometers or non-contact
shaft probes
Oil chamber heater and thermostat for cold climates
Leads
Bring out minimum number of leads
Seal the lead opening against moisture and chemicals
Increase the lead size
Other special considerations such as bus bar, special
lugs, etc.
Noise reduction
Add soundproofing material
Add exterior shrouding
Utilize special fan configurations
Special balance requirements
Outlet box
Size
Better enclosure for weather protection
Efficiency considerations
Voltage optimization
Upgrade insulation class
Concentric to lap conversion
Optimize span
Maximize slot fill (copper and insulation)
Connection options (wye start, delta run; part-winding
start)
Field support
Startup
Predictive maintenance
Vibration monitoring
Current analysis
Thermography
Tribology
13
APPENDIX D Motor Repair Guidelines and Resources

EASA AR100-1998 Recommended Practice - Rev. January 1998
Standards Organizations
Standards Organizations & Other Resources

The following organizations produce documents
and standards, some of which are referenced in the
EASA Recommended Practice for the Repair of Rotating Electrical Apparatus.
NEMANational Electrical
Manufacturers Association
1300 N. 17th St., Suite 1847
Rosslyn, VA 22209
(703) 841-3200
ABMAAmerican Bearing
Manufacturers Association
1200 19th St., NW, Suite 300
Washington, DC 20036
(202) 429-5155
Fax: (202) 223-4579
For Publications:
(703) 841-3201
Fax: (703) 841-3300
NFPANational Fire
Protection Association
One Batterymarch Park
Quincy, MA 02269
(617) 770-3000
Fax: (617) 770-0700
ANSIAmerican National
Standards Institute
11 West 42nd St., 13th Floor
New York, NY 10036
(212) 642-4900
Fax: (212) 302-1286
For Publications:
P. O. Box 9146
Quincy, MA 02269
(800) 344-3555
Fax: (617) 984-7057
IECInternational
Electrotechnical Commission *
3 rue de Varembe
CH 1211 Geneva 20, Switzerland
IEEEInstitute of Electrical and Electronics
Engineers, Inc.
345 East 47th St.
New York, NY 10017
(212) 705-7900
Fax: (212) 752-4929
For Publications:
445 Hoes Lane
P. O. Box 1331
Piscataway, NJ 08855-1331
(800) 678-4333
Fax: (908) 981-9667
NISTNational Institute of
Standards and Technology
Route 270
Gaithersburg, MD 20899
(301) 975-2000
ULUnderwriters Laboratories, Inc.
333 Pfingsten Rd.
Northbrook, IL 60062
(847) 272-8800, Ext. 42612
Fax: (708) 272-8129
ISOInternational Organization
of Standardization *
1 rue de Varembe
CH 1211 Geneva 20, Switzerland
MIL-STDUnited States Government
Printing Office
710 North Capitol St.
Washington, DC 20420
(202) 512-1800
Fax: (202) 512-2250
Table of Contents, Page 1
TABLE OF CONTENTS
SECTION 1: GENERAL
1.1 PURPOSE
1.2 SCOPE
1.3 IDENTIFICATION
1.3.1 Service Center Labeling
1.3.2 Records
1.3.3 Nameplate
1.4 CLEANING
1.5 TERMINAL LEADS
1.6 TERMINAL CONNECTORS
1.7 TERMINAL BOXES
1.8 COOLING SYSTEM
1.9 EXTERIOR FINISH
1.10 PACKAGING AND TRANSPORTATION
SECTION 2: MECHANICAL REPAIR
2.1 SHAFTS
2.1.1 Shaft Extensions
2.1.1.1 Diameter Tolerances
2.1.1.2 Permissible Runout
2.1.1.3 Keyseat (Keyway) Width
Tolerances
2.2 BEARINGS
2.2.1 Ball or Roller Bearings
2.2.2 Sleeve Bearings
2.2.2.1 Sleeve Bearing End-Thrust
2.2.2.2 Oil Rings
2.2.2.3 Seals
2.3 LUBRICATION
2.3.1 Grease
2.3.2 Oil
2.4 FRAME AND BEARING HOUSINGS
2.4.1 General
2.4.2 Mounting Surface Tolerances,
Eccentricity and Face Runout
2.5 LAMINATIONS
2.6 BALANCING
2.7 SLIP RINGS
2.8 COMMUTATORS
2.8.1 Machining
2.8.2 Undercutting
2.9 BRUSHHOLDERS
2.10 BRUSHES
2.11 BRUSH SETTING FOR DC MACHINES
2.12 AIR GAP MEASUREMENT OF DC
MACHINES
2.13 ACCESSORIES
TABLES
2-1 Shaft Extension Diameter Tolerances
NEMA Frame Size Machines
2-2 Shaft Extension Diameter TolerancesIEC
Frame Size Machines
2-3 Permissible Shaft Extension RunoutNEMA
Frame Size Machines
2-4 Permissible Shaft Extension RunoutIEC
Frame Size Machines
2-5 Shaft Extension Keyseat Width Tolerances
NEMA Frame Size Machines
2-6 Shaft Extension Keyseat (Keyway) Width
TolerancesIEC Frame Size Machines
2-7 Sleeve Bearing Diametral Clearance Guide
Horizontal Mounting
2-8 Labyrinth Seal Diametral Clearance Guide
2-9 Mounting Surface Tolerances, Eccentricity,
and Face RunoutNEMA Type C FaceMounting Motors and Type D Flange-Mounting Motors
2-10 Mounting Surface Tolerances, Eccentricity,
and Face RunoutNEMA Type P FlangeMounting Motors
2-11 Mounting Rabbet (Spigot) Diameter TolerancesIEC Flange-Mounted Machines
2-12 Mounting Surface Eccentricity and Face
RunoutIEC Flange-Mounted Machines
2-13 Brush-to-Brushholder Clearance
SECTION 3: REWINDING
3.1 INSPECTION
3.1.1 Windings
3.1.2 Core Laminations
3.1.3 Thermal Protectors or Sensors
3.2 REWINDING SPECIFICATION
3.3 STRIPPING OF WINDINGS
3.4 INSULATION SYSTEM
3.5 CONDUCTORS
3.6 STATOR, ROTOR, AND ARMATURE
COILS
3.6.1 Random-Wound Coils
3.6.2 Form-Wound Coils
3.7 FIELD COILS
3.7.1 Stationary Coils
3.7.2 Rotating Coils
3.8 AMORTISSEUR AND SQUIRREL CAGE
WINDINGS
Table of Contents, Page 2
* IEC and ISO standards are available through ANSI, which

is the American representative to all international standards groups.
3.9 THERMAL PROTECTORS OR SENSORS

3.10 SHAPING AND LACING OF STATOR
WINDINGS
3.11 COIL CONNECTIONS
3.11.1 Making Connections
3.11.2 Insulating Connections
3.12 WEDGES
3.13 BANDING OF ROTORS AND
ARMATURES
3.14 IMPREGNATION OF WINDINGS
SECTION 4: TESTING
4.1 SAFETY CONSIDERATIONS
4.2 INSULATION CONDITION TESTS
4.2.1 Inspection
4.2.2 Insulation Resistance Test
4.2.3 Polarization Index (P-I) Test
4.2.4 Insulation Power Factor Tests
4.2.5 Step Voltage Test
4.2.6 Turn-to-Turn Test
4.2.7 Interlaminar Insulation Test
4.2.8 Bearing Insulation Test
4.3 RECOMMENDED WINDING TESTS
4.3.1 Stator and Wound-Rotor Windings
4.3.2 Squirrel Cage Windings
4.3.3 Armature Windings
4.3.4 Shunt, Series, Interpole, Compensating and Synchronous Rotor
Windings
4.3.5 Interconnection of Windings
4.4 HIGH-POTENTIAL TESTS
4.4.1 Windings
4.4.1.1 New Windings
4.4.1.2 Reconditioned Windings
4.4.1.3 Windings Not Reconditioned
4.4.2 Accessories
4.4.2.1 New Accessories
4.4.2.2 Accessories of Machines
with Reconditioned
Windings
4.4.2.3 Accessories of Machines
with Windings Not
Reconditioned
4.5 NO-LOAD TESTS
4.5.1 Speed
4.5.2 Current
4.5.3 Cooling System
4.5.4 Sound Level
4.5.5 Bearing Temperature
4.5.6 Vibration Tests
4.6 PERFORMANCE TESTS

4.7 INSTRUMENT CALIBRATION
TABLES
4-1 High-Potential Test Using ACNew
Windings
4-2 High-Potential Test Using DCNew
Windings
4-3 High-Potential Test Using ACNew
Accessories
4-4 High-Potential Test Using DCNew
Accessories
4-5 Unfiltered Vibration LimitsResiliently
Mounted Machines
APPENDIX: ELECTRICAL TESTING

SAFETY CONSIDERATIONS
A.1 PERSONAL SAFETY
A.1.1 Training
A.1.2 Clothing
A.1.3 Supervision
A.1.4 First Aid
A.2 TEST AREA
A.2.1 Enclosure
A.2.2 Gates
A.2.3 Signs
A.2.4 Lighting
A.2.5 Safety Equipment
A.2.6 Test Unit Clearance
A.3 UNIT UNDER TEST
A.3.1 Suitability for Test
A.3.2 Exclusive Attention
A.3.3 Grounding
A.3.4 Base
A.4 TEST PANELS
A.4.1 Construction
A.4.2 Voltages
A.4.3 Warning Lights
A.4.4 Disconnect
A.4.5 Safety Switch
A.4.6 Leads
A.4.7 High-Potential Ground Test
BIBLIOGRAPHY
STANDARDS ORGANIZATIONS &
OTHER RESOURCES
Note: Sections pertaining to the repair of liquid-filled
and dry-type distribution transformers were withdrawn
from this edition of EASA Recommended Practice for the
Repair of Rotating Electrical Apparatus.
14
APPENDIX D Motor Repair Guidelines and Resources (continued)

CONTENTS
A EMT
Page
Introduction ................................................................................................ 1
Association of Electrical and Mechanical Trades
Energy Losses in Induction Motors ....................................................... 4
GOOD PRACTICE GUIDE
The Motor Repair Process ....................................................................... 7

Preliminary Inspection ..................................................................... 7
Repair or Replacement of Parts ....................................................... 9
Repairs to the Rotor Assembly ........................................................ 11
Recording the Winding Details ...................................................... 13
Stripping the Stator Winding ......................................................... 14
Specifying the Replacement Winding ............................................ 17
Cleaning and Inspecting the Stripped Stator ................................ 21
Rewinding ........................................................................................ 22
Testing the Wound Stator ............................................................... 23
Impregnating and Cleaning the Rewound Stator ......................... 24
Re-assembly ..................................................................................... 25
Testing the Assembled Motor ......................................................... 28
THE REPAIR OF
INDUCTION MOTORS
Best Practices
to Maintain Energy Efficiency
Appendix 1 ................................................................................................. 30
Winding Variations; Their Effect on Performance
Appendix 2 ................................................................................................. 34
Burn-out Ovens and Their Effect on Stator Core Losses
Appendix 3 ................................................................................................. 38
Calculation of Losses and Efficiency From Test Data
Crown Copyright 1998

All rights reserved. No part of the publication may be produced or transmitted in
any form or by any means, including photocopying and recording, without the
written permission of the copyright holder, application for which should be addressed
to the publishers. Such written permission must also be obtained before any part
of this publication is stored in a retrieval system of any nature.
Appendix 4 ................................................................................................. 40
Glossary of Terms
Appendix 5 ................................................................................................. 42
Check List of Best Practices to Maintain Energy Efficiency
ISBN: AEMT 0 9509409 3 3

Published by the Association of Electrical and Mechanical Trades
177 Bagnall Road, Basford, Nottingham, NG6 8SJ
Tel. 0115 978 0086 Fax. 0115 942 4488
L APPA
ICA
R
TR
IC
IO
SER
EA SA
US
AT
ELE
C
Reprinted with permission (1999) by

1331 Baur Blvd., St. Louis, MO 63132 U.S.A.
314-993-2220 Fax: 314-993-1269 www.easa.com
T
E A
IA
SSOC
Reliable Solutions
Today!
A Guide To AC Motor Repair And Replacement
Table Of Contents
Introduction ............................................................................................................................ 1
Plan Ahead ............................................................................................................................. 2
Why Motors Fail ..................................................................................................................... 2
Making The Decision To Repair Or Replace .............................................................................. 3
Obtaining Quality Motor Repairs .............................................................................................. 8
Specifying A Motor Rewind...................................................................................................... 11
Evaluating And Selecting A Motor Service Center ..................................................................... 13
Obtaining Motor Repairs Of The Highest Quality...................................................................... 15
EASAs Quality Initiatives ........................................................................................................ 16
About EASA .......................................................................................................................... 17
Appendix: Motor Repair Procedures ........................................................................................ 18
References ............................................................................................................................. 21
Prepared by Electrical Apparatus Service Association, Inc. in cooperation

with the U.S. Department of Energys Motor Challenge Program.
Copyright1999 Electrical Apparatus Service Association, Inc.
1331 Baur Blvd., St. Louis, MO 63132, 314-993-2220.
15

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GUIDELINES FOR REPAIR/REPLACE DECISIONS

MOTOR REPAIR BEST PRACTICE GUIDES

Practice for the Repair of Rotating Electrical Apparatus, Copyright 1998.

ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com

Guidelines for Repair/Replace Decisions and Performance Optimization

EASA/AEMT MOTOR REWIND STUDY

SCOPE OF PRODUCT EVALUATED

ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com

Guidelines for Repair/Replace Decisions and Performance Optimization

Is the motor suitable for the

Investigate replacement with suitable motor (size/enclosure).

Significant damage or high losses

Has catastrophic failure occurred,

(e.g., very expensive

Is the cost of repair greater than

Are replacement funds available?

Is replacement motor available?

Is return on investment of EPACT

Is lead time of replacement motor

REPAIR-REPLACE DECISION MODEL

tor with special mounting or design features, an EPACT

ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com

Guidelines for Repair/Replace Decisions and Performance Optimization

Level 1 Basic reconditioning. Includes replacing

NEMA MG 1-1998 defines Unusual Service Conditions

TABLE 1: LEVELS OF REPAIR

It makes economic sense to identify the weak link in any

As these five levels imply, the damage resulting from

With todays rapidly changing technology, the motor

Stator winding 16%*

* For each component shown, appropriate measures

Reference: IEEE Petro-Chemical paper PCIC-94-01

ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com

Guidelines for Repair/Replace Decisions and Performance Optimization

service center is able to tailor the motor repair to match

FIGURE 4 : POSSIBLE MOTOR UPGRADES AND MODIFICATIONS

Change starting method to

* Adding seals or changing bearing types may affect efficiency.

Illustration courtesy of Siemens AG

ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com

Guidelines for Repair/Replace Decisions and Performance Optimization

Table 2 illustrates the effect on efficiency and winding

A municipal pump station is located at the end of the

VIBRATION MONITORING AND IMPROVEMENT

TABLE 2: EFFICIENCY AND WINDING

Power factor (%)

Full load current (amps)

Inrush current (amps)

Design B, 4-pole, tri-voltage motor (208-230/460)

Rotor being dynamically balanced in a service center.

ELECTRICAL APPARATUS SERVICE ASSOCIATION, INC. www.easa.com

Guidelines for Repair/Replace Decisions and Performance Optimization

The cause of a plant fire is tracked back to a bearing

Weatherproof terminal head

BEARING TEMPERATURE PROTECTION

A chemical plant removed a 600 hp motor for routine

Bracket outer wall

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Guidelines for Repair/Replace Decisions and Performance Optimization

feet. Although running when removed from service, the

FIGURE 9: STRESS RAISERS