How do you prevent overheating and damage in electrical machines?

Above this, Ensure that the assembly of the relevant equipment and accessories is carried out in accordance with the manufacturer’s recommendations by trained personnel. I recall an incident where a device designed to handle 24KA at 20 KV and a temperature of over 110 degrees for 80% of its rated capacity was compromised. This was due to a minor assembly error made by an untrained individual.

There are several ways to prevent overheating and damage in electrical machines. The first is to ensure that the machines are properly sized and rated for the load that they will be carrying. Additionally, the machines should be regularly inspected and maintained, including cleaning and lubricating all moving parts. It's also important to keep the environment around the machines cool and dry, as high temperatures and humidity can cause damage. Finally, using surge protectors and uninterruptible power supplies can help to protect the machines from power surges and fluctuations.

To prevent overheating and damages of the electrical machines , and not only is : Preventive maintenance . 1. Reggular inspections , preferably based on a maintenance schedule CMS. 2. Cleaning. 3. Lubrication 4. Tighten connections. 5. Testing periodically. 6. Scheduled Replacement of : capacitors, brushes etc. 7. Consideration of the environmental factors; moisture prevention, correct temperature. 8. Training of the operating and maintenance personnel. 9. Documentation. Keeping the trace for all n activities , preferably by using an electronic CMS / Database 10. Contingency plan in place / backup equipment. Preventive maintenance ensure the optimal performance and longevity of the equipment.

By doing regular maintenance and thermography of perticular panel we can reduce the num of overheating, conditioning monitoring is also a best idea for reliability improvement of perticular asset.

There are special cases where a motor is expected to provide high torque at lower rpm. There are two considerations when designing such a system. 1) if the motor RPM is always lower than 1800, specify a four pole motor. At 60 hz this motor will operate at ~1800 RPM with twice the torque as a two pole motor. 2) Provide a forced air cooling fan to cool the motor during operation because the built in fan may not be moving fast enough to provide sufficient cooling air flow to keep the motor cool. I have seen many cases where these two points were not observed and motor over heating was the result.

I agree that temperature is the most reliable indicator. However, there are several challenges with it. 1- Many old motors do not come with preinstalled temperature detectors/RTDs. So you won't have those readings. In most cases, management will not justify spending the money to install RTDs 2- Infrared reading is almost pointless. You need winding/component temperature readings; you will not be able to get those with infrared in such a reliable way 3- Even with preinstalled RTDs, who actually check the alarms? Some do not even have alarms, so it becomes a reactive approach instead of a proactive one.

Monitoring is highly recommended but action taken with monitoring is more effective , for the example let’s say we have a High voltage transformer with 3 coils we have a PT100 ( temp sensor) on each coil , going into monitoring unit . That monitor unit has a dry contact that will active fans when temp reach a first stage alarm 80 degrees C, second stage will be 110c alarm for high temp, next stage will be 130C will disconnect the transformer from power to protect the equipment from damaged .

Overheating and damage to electrical machines can be prevented by the following: 1. Ensure that the machine does not operate beyond its rated capacities. 2. For large sized machines (for that matter all electrical machines) follow the manufacturers operation and maintenance manual. 3. Ventilation of the machine is to be ensured as per the design recommendations. For large sized machines the properties of the coolants are to be maintained at optimum levels to ensure proper dissipation of heat. 4. For large sized machines periodic maintenance should be scheduled as per manufacturer's recommendations. 5. Designing of the machine is to be done to ensure proper ventilation of all parts of the machine and to prevent generation of local hotspots

Being an LNG plant engineer for Shell, here is something from my experience. -Really big and critical motors come with RTD to know the temperature of each phase of the motor windings. These are connected up to the Integrated Automation System, where the temperature Alarm and Trip points are set as per manufacturer setpoints. - Motors also have over current trips, high current cause of over heating. - Undervoltage trip, lower grid voltage the motor takes more current to compensate. - Article mentions rotor temperature, doubt that's right. We do condition based maintenance, where motor parameters are recorded, like temperature, Amps, Vibration taken and a trend observed to assess deterioration in condition.

Here's some additional information: Unsing thermocouples as they are an inexpensive why to temperature monitoring. These sensors can provide real-time data and early warning signals. Remote Monitoring: In modern systems, consider implementing remote monitoring solutions. These systems can provide real-time temperature data and alerts, enabling prompt responses to temperature anomalies even from a distance.

Proper Sizing and Selection Ensure that the electrical machine is appropriately sized and selected for its intended application. Undersized machines are more likely to overheat during operation Temperature Monitoring Install temperature sensors or thermocouples to monitor the temperature of critical components within the machine. Implement a control system that can shut down the machine or reduce its load if temperatures exceed safe limits Electrical Insulation Ensure that electrical insulation materials are in good condition. Damaged or deteriorated insulation can lead to electrical faults and overheating Balanced Loads Voltage Regulation Use of Thermal Protection Devices Insulation and Enclosures Monitor Operating Conditions

En sencillas palabras la manera más eficiente de controlar el correcto funcionamiento de las máquinas e equipos es realizar de forma periódica y controlada una rutina de mantenimiento de los mismos para verificar el estado y el correcto funcionamiento de forma tal que si existiera una variable esta podría ser controlada y atendida en su debido tiempo por el departamento correspondiente.

I think if there is a well designed sys. and equipment , should not have overheating that damages machine except faults or change in environment conditions , but to prevent overheating we can do some simple(off line and hot line) routine check and services like cleaning body of machine for better transfer of operating temperature, check the bearings for abnormal sound and their relevant lubricating , check the current in coupled and uncoupled conditions

As an LNG Plant engineer for Shell, this is what we followed. Daily rounds of your equipment, just a feel of the motors by hand for temperature/vibration is the best early indicators. Cause you will immediately recognize a change. Condition based maintenance - Where every 3 months various performance data are taken from the motor and what it drives a pump/compressor etc -These include, Vibration reading which assess bearing condition, alignment, pipe strain, soft foot etc. -Current drawn, which also asses wear in bearings if goes up. And if it drops condition of pump impeller is bad eg. - Motor Temperature on the outside. - Pump/Comp parameters A trend is recorded and monitored to assess deterioration and issue maintenance when required.

I agree that to prevent overheating and damage in electrical machines, regular maintenance is crucial. Some alternative solutions are: Predictive maintenance: Use of sensors and data to predict maintenance, reduces the risk of unexpected failures. Temperature monitoring: Continuously monitor machine temperature using sensor and receive alerts before reaching dangerous levels. Thermal insulation: Thermal insulation materials applied to sensitive machine components reduce heat transfer and minimize overheating. Operator training: Regular training helps to recognize signs of any abnormality. Remote monitoring and control: IoT technology enables monitoring and control of machines remotely, allowing for immediate shutdowns and adjustments.

In addition to consider the deratings due to altitude and ambeint temperature, while selecting the equipment or machine 15-20% of rated values should be considered as safe margin. It is of good practice, to follow NEMA regulations and manufacturer recommendations in regards to duty cycle's of equipment or machines (standby/emergency duty, primary duty or continuous duty)

Also, relative humidity of the installation area should be considered. Moisture and condensates from humid air may burn your electrical system due to short circuit.

maneiras de evitar superaquecimento e danos em máquinas elétricas é escolher a máquina certa para sua aplica??o e ambiente. Você deve considerar os requisitos de potência, velocidade, torque e eficiência de sua carga e selecionar uma máquina que possa atendê-los sem sobrecarga ou superaquecimento e dimensionar um equipamento sempre com trabalho mínimo do equipamento assim contribuindo com a vida útil do equipamento

I agree. Selecting the right machine is vital. Consider deratings, motor type, and application-specific controls. Choose a location accessible for maintenance. Typically, specialists or manufacturers provide custom designs. Review for cost, efficiency, load, and request revisions before procurement. Follow the datasheet for correct connections to ensure performance and safety.

One critical step not mentioned in this protection device paragraph is knowing how to choose the suitable device and how to program the programmable protective devices. Just because 2 fuses, say, 100A fuses, does not make them equally suitable. Some breakers have settings; you must know what setpoint to choose and why.

Some faults are due to poor grounding. Implementing a proper grounding and isolation techniques will minimise the risk of electrical faults that could lead to overheating.

A lot of the contactors we use have a lot of these protections in-built. Over current, Under voltage, over frequency. Some big motors I worked with would have an interlock to prevent 2 consequent starts. A safety delay of 60mins to permit the windings to cool down before the next start. As you know starting current is usually higher. Some control panels located out on site in hot conditions, have a mini AC for the panel booth. With temperature alarms for early warnings of failure. Transformers are usually located in Switchboard rooms that are air conditioned.

In the control panel, protection measures are standard. It is important to adapt them according to the clients' needs. Monitoring and control are enhanced by timely warning of faults and the BMS.

The first is the correct choice of the machine, which corresponds to the load, working conditions and utilization level. The electrical protection should be chosen according to the size and importance of the machine. Proper selection of the power cable is also important, and in addition to the appropriate section, it must be suitable for the environment in which the machine is located. Regular maintenance is one of the most important factors. A very common problem occurs at the connection box, especially if the machine works in an aggressive atmosphere. If there is a suspicion of overheating of the entire machine or one of its parts, it is very useful to use a thermographic camera to identify and prevent potential issues.

That is great for a frequently occurring problem within electrical machines, The preventive measures in chronological order are 1- proper selection of the machine to be adequate for the load / process / ambient conditions with a safe margin 2- Ensure proper ventilation around the machine /equipment… consider any additions or engineering modifications within the work place that could adversely impact the air circulation 3- During design the machine ( depending on its size) shall be equipped with the necessary monitoring and protective devices ( for example thermocouples or RTD,overload / over current protective relays, may include protection to limit the number of motor starts) 4- During operation the machine shall be continuously

Preventing electrical machine overheating is crucial for: 1. Safety: Averts fires and injuries. 2. Reliability: Reduces downtime and failures. 3. Efficiency: Maintains optimal energy use. 4. Cost Savings: Cuts repair and replacement expenses. 5. Performance: Ensures machines meet capacity. 6. Compliance: Avoids legal and financial penalties. 7. Environmental Impact: Lowers energy consumption and pollution. 8.Data Integrity: Protects critical data systems. 9.Quality Assurance: Upholds product and process quality. 10.Operational Continuity: Prevents costly interruptions. Proactive measures like maintenance and monitoring are essential.

Monitoring the Voltage and Current Harmonics with the power meter can be an excellent way to determine what Harmonics are contributing to the distortion and size Harmonic Filters to correct the high harmonic conditions before they cause damage and overheating to equipment. Negative Sequence voltage harmonics contribute to overheating in motors. Even an increase of 10 degrees can reduce the life of a motor by 50%.

A current monitoring system is a good way to give you early warnings that bearings, windings or a motor brake may be beginning to fail.