COURSE OVERVIEW:

The fundamental meaning of this course is the bridge between electrical engineering and mechanical maintenance, focusing on the electric motor as a singular, integrated system. While most maintenance programs treat motors as either purely electrical or purely mechanical, this curriculum addresses the critical interface where these two disciplines meet. Participants will explore how electrical anomalies like power quality and harmonics create mechanical stress, and conversely, how mechanical issues like misalignment and unbalance lead to electrical failure.

The scope of this training involves a deep dive into the "Top Five" failure modes of industrial motors: bearings, stator windings, external factors, rotors, and shafts. It involves technical instruction on interpreting both vibration signatures and Motor Current Signature Analysis (MCSA) to pinpoint the root cause of degradation. Attendees will examine the specific impact of Variable Frequency Drives (VFDs) on motor longevity, including the devastating effects of EDM (Electrical Discharge Machining) and common-mode voltage on bearing surfaces.

Coverage includes precision installation techniques, advanced insulation testing (surge, hi-pot, and polarization index), and the implementation of a proactive motor management program. The curriculum emphasizes the use of thermal imaging and ultrasound as early-warning tools to prevent catastrophic burnouts. By the end of this course, participants will be able to diagnose complex motor issues, implement precision lubrication strategies for electric machines, and extend the mean time between failures of their facility's most critical prime movers.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Define the integrated electrical and mechanical failure modes of induction motors.
• Interpret Motor Current Signature Analysis (MCSA) to detect rotor bar defects.
• Identify the mechanical impact of poor power quality and voltage unbalance.
• Master the use of Insulation Resistance (IR) and Polarization Index (PI) testing.
• Analyze the impact of VFDs on bearing life and stator insulation integrity.
• Implement precision shaft alignment and balancing for motor-driven systems.
• Detect early-stage bearing failure using high-frequency ultrasound.
• Utilize Infrared Thermography to identify loose connections and cooling issues.
• Calculate the optimal lubrication frequency and quantity for motor bearings.
• Perform Root Cause Failure Analysis (RCFA) on burned stator windings.
• Evaluate the cost-benefit of motor "Repair vs. Replace" decisions.
• Design a comprehensive "Motor Health" dashboard for critical assets.

TARGET AUDIENCE:

This course is designed for Electrical Engineers, Mechanical Reliability Engineers, Maintenance Supervisors, Electricians, and Rotating Equipment Specialists.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.