JOB 4: Motor Testing Flashcards
What type of damage has been identified in the 4th press top roll drive motor (7012M_3410)?
Bearing failure identified through vibration analysis- this showed damage to the outer race bearing coupling side
MTC sensor also picked up excessive vibration
What methods were used to diagnose the damage in the motor?
Diagnosis methods used was vibration analysis carried out by the mechanical department and condition monitoring
Why is pre-shutdown preparation necessary before replacing the motor?
Pre-shutdown preparation is essential as it ensures the job goes as smoothly as possible with the additional time constraints.
as the lifting equipment was inspected it minimises down time and prevents installation issues.
HF braiding inspected so replacement could be prepared as necessary (13m)
What steps need to be taken to prepare the hoist before the motor replacement?
Steps for hoist preparation:
- has to be in date and inspected every 6 months based on loler regulations
-does it function as required (functionality tested) does it drive and operate from remote?
- are the cables safe- known for having the cable remote to have exposed cable
-without the hoist no work can commence
Why is it important to check the stock and condition of HF earth braiding?
Importance of checking HF earth braiding as it removed the eddy currents from the motor bearings to protect the motor.
Improper earthing increases the risk of electrical faults and failures through electrical interference and can cause safety issues
What tests should be conducted on the spare motor (MOTKL-01609) before installation? (visual)
Visual Inspections:
Damaged coolling fins
damaged fan
cracked or damaged casing
check the shaft spins and its damaged
terminal boxes are dry etc
Where is the spare motor located?
FRS
What is the purpose of performing a winding balance check and Insulation Resistance (IR) test?
Winding Balance check:
Balance testing on a motor is essential to ensure smooth operation and extend the motor’s lifespan. Imbalances can cause vibrations, which lead to excessive wear and tear on components, reduced efficiency, and potential mechanical failures. By performing balance testing, issues can be identified and corrected early, ensuring the motor runs smoothly, operates quietly, and maintains optimal performance and reliability. This preventive measure helps avoid downtime, contributing to overall system stability and longevity
Insulation resistance:
Insulation resistance testing on a motor is performed to assess the condition of the motor’s insulation system. This test helps ensure that the insulation around the motor’s windings is intact and effective in preventing electrical leakage. High insulation resistance indicates good insulation quality, which is crucial for the safe and efficient operation of the motor. Regular testing can detect deterioration, prevent electrical faults, reduce the risk of short circuits, and extend the motor’s lifespan.
What is the function of a DTI (Dial Test Indicator) set-up on the encoder stub shaft?
- ensures the shaft is concentric - if not this will impact the speed and position reading taken at the encoder
-important to ensure accurate signal transmission between encoder and control system
-minimises down time as it ensures system and equipment accuracy
Why is it necessary to check the direction/handing of the fan before installation?
Fans are used to cool a motor to prevent excessive heat that could lead to motor insulation failure
- fans are designed to pull air in to cool the motor unit, if incorrectly handed this wouldn’t not occur
What could be the potential consequences of not replacing the damaged motor in time?
Complete motor failure resulting in loss of production
could cause damage to the gearbox or roll
creates an unsafe environment
increased cost of repair
lead to insufficient operation of the machine
How does static vibration analysis help in diagnosing motor issues?
Condition based monitoring allowed the issues to be identified and dealt with
- static vibration analysis highlighted increased levels of outer race damage on the coupling end bearing of the 4th press top roll drive motor. early detection allowed time for an effective and safe shut plan to organised and prepared preventing damage or unexpected failure
Why is it important to visually inspect the spare motor before installation?
-allows you to confirm the motor is correct and appropriate the change
- don’t want to install a damage motor that will not last
- ensures the alignment of the motor shaft
-inspect collin fan to ensure effective cooling
What role does mechanical discussion play in the relocation and coupling of the spare motor?
- advise/ input on how to safely move a 9 tonne motor from storage to location (FRS0M to 14.5 meter level)
- assist with the lift and equipment
-carry out motor alignment before coupling
How might the differences in fan direction between the installed and spare motors impact the operation?
inefficient cooling of the motor leading to overheating and failure
What is the main purpose of the Health and Safety at Work Act 1974?
Main purpose of the Health and Safety at Work Act 1974 to provide regulations for employers and employees in regards to workplace safety
How does Palm Paper ensure compliance with health and safety regulations?
Provide a safe working environment
provides training and competency skillset
had up to date ssow and ops
ppe provided
Why is it important for employers to maintain machinery and equipment?
- efficiency and profitability
- maintained machines have less down time
- safer for employees as it reduces chances of electrical or mechanical failure
-improves lifespan of the equipment
What are risk assessments, and why are they necessary in the workplace?
Risk assessment are health and safety documents that outline all possible workplace hazards and documents the control measures that should be in place to limit employees exposure to risk, preventing injuries .
-legal compliance
- improved safety
How do written health and safety policies contribute to a safer working environment?
- generates a safety first culture
-documents to reference as they are accessible
-sets clear guidlines
What are Safe Systems of Work (SSOW), and how do they impact daily operations?
Can you list three SSOW procedures followed at Palm Paper and explain their importance?
T
Why is it important to have specific SSOWs for tasks like electrical maintenance and lifting equipment use?
What types of training are provided to employees to ensure workplace safety?
ty
How did completing training in Manual Handling and Health and Safety at Work help in carrying out motor testing?
Why is ongoing training necessary for employees in an industrial environment?
What is the role of PPE in ensuring workplace safety?
What types of PPE were used in the described scenario, and why were they necessary?
Why is high-visibility clothing important in areas with vehicle movement?
How do the LOLER 1998 regulations affect the use of lifting equipment?
What is the purpose of the Electricity at Work Regulations 1989?
Purpose of Electricity at Work Regulations 1989
How does RIDDOR contribute to workplace safety?
Contribution of RIDDOR to safety
Why is the Personal Protective Equipment at Work Regulations 1992 essential for industrial environments?
Importance of PPE at Work Regulations 1992
What are the key provisions of the Working at Height Regulations 2005?
Key provisions of Working at Height Regulations 2005
How does BS 7121 help ensure the safe use of cranes?
Role of BS 7121 in crane safety
What are the key objectives of a maintenance task?
Key objectives of maintenance tasks
Why is it important to document work completed, fault locations, and maintenance requirements?
Importance of documentation in maintenance
What types of tools are typically used in motor maintenance?
Typical tools used in motor maintenance
Why are calculations sometimes required during maintenance tasks?
Reasons for calculations in maintenance
Why is wearing PPE essential before starting a maintenance task?
Essentiality of PPE before maintenance
What PPE is required for this specific maintenance task?
Required PPE for maintenance task
What is the purpose of a Pre-Task Assessment (PTA)?
Purpose of Pre-Task Assessment
Why is it necessary to gather relevant drawings and DCS screenshots before starting the task?
Necessity of gathering drawings and screenshots
How does identifying the location of the faulty motor and its replacement aid in the maintenance process?
Role of identifying motor location in maintenance
What safety checks are performed before beginning the maintenance task?
Safety checks before maintenance
What risks and hazards are typically documented in a PTA?
Risks and hazards in PTA
What tools were gathered before heading to the work area?
Tools gathered before work area
Why was the motor moved to an area with better access before maintenance?
Reason for moving motor for access
What are some key visual checks performed on the motor before installation?
Key visual checks on motor
What is the significance of ensuring the terminal box is clean and dry?
Significance of clean and dry terminal box
Why is it important to check the motor shaft for signs of damage?
Importance of checking motor shaft
What does an insulation resistance test measure?
Insulation resistance test measures
How does insulation resistance testing help prevent electrical faults?
Role of insulation resistance testing
What do the insulation resistance test results indicate about the motor’s condition?
Indications from insulation resistance test results
Why is balance testing conducted on a motor?
Purpose of balance testing on motor
How do imbalances in a motor affect its performance and lifespan?
Effects of imbalances on motor performance
What were the results of the balance testing, and what do they suggest?
Results of balance testing and implications
Why was the encoder module not fitted?
Reason for not fitting encoder module
What is the function of the encoder module in the motor system?
Function of encoder module
What aspects of the old motor were inspected before removal?
Aspects inspected on old motor
Why is it important to check for High Frequency braiding in the motor?
Importance of checking High Frequency braiding
What information was updated on the work order after analyzing the lifting route?
Information updated on work order
Why is it important to clean the work area and remove all debris and tools?
Importance of cleaning work area
How does documenting and emailing test results benefit supervisors?
Benefits of documenting test results
What steps are involved in updating a work order?
Steps in updating a work order
Why is it necessary to update the work order before it can continue to be progressed?
Necessity of updating work order
What safety benefits come from maintaining a clean work area?
Safety benefits of clean work area
How can accurate test result documentation impact project outcomes?
Impact of accurate documentation on outcomes
Who are the relevant supervisors that receive the test results, and what do they do with the findings?
Relevant supervisors and their actions
What tools or systems are used to update work orders in your workplace?
Tools used for updating work orders
what are eddy currents?
