Course Details

Objective

By the end of this course, participants will be able to:

1. Understand the operational and performance characteristics of motors used in the oil and gas industry.
2. Recognize the key indicators that signal when a motor requires a major overhaul.
3. Conduct detailed motor diagnostics and troubleshooting to identify potential issues.
4. Safely disassemble, inspect, and reassemble motors during an overhaul.
5. Implement preventive maintenance strategies to extend the lifespan of motors and minimize downtime.
6. Understand the importance of lubrication, cooling, and insulation in motor care.

Content

Day 1: Introduction to Motor Maintenance and Overhaul Principles

• • Overview of Electric Motors in the Oil and Gas Industry:
    • Role of motors in oil and gas operations (pumps, compressors, blowers, etc.).
    • Types of electric motors used (AC, DC, synchronous, induction).
    • Key motor specifications and operating conditions.
  • Basic Motor Maintenance Principles:
    • Importance of regular motor maintenance for reliability and efficiency.
    • Key performance indicators (KPIs) for motor health.
    • Routine inspections and monitoring methods (vibration analysis, thermography, etc.).
  • Major Overhaul vs. Routine Maintenance:
    • Understanding the difference between minor and major overhauls.
    • Indicators for when a motor needs a major overhaul (performance degradation, wear and tear).
    • Key components of a motor that require overhaul (bearings, stator, rotor, windings).
  • Safety and Risk Management in Motor Overhaul:
    • Safety protocols for handling electric motors.
    • Electrical hazards and lock-out/tag-out (LOTO) procedures.
    • Risk assessment techniques for motor maintenance activities.

Day 2: Motor Diagnostics and Troubleshooting

• • Diagnostic Tools and Techniques:
    • Visual inspection (corrosion, physical damage).
    • Electrical testing (insulation resistance, continuity tests).
    • Vibration analysis, thermal imaging, and ultrasonic testing.
  • Troubleshooting Common Motor Issues:
    • Faults in motor windings, bearings, and insulation.
    • Identifying electrical imbalances and motor misalignment.
    • Motor overheating and related causes.
  • Root Cause Analysis (RCA):
    • Understanding the cause of motor failures.
    • Techniques for root cause analysis in motor maintenance.
    • Corrective actions and preventive measures.
    • Case studies of motor failures and hands-on troubleshooting exercises.

Day 3: Motor Disassembly and Inspection

• • Motor Disassembly Process:
    • Step-by-step procedure for safely disassembling a motor.
    • Tools and equipment needed for disassembly.
    • Documenting motor components and their condition during disassembly.
  • Inspection of Key Motor Components:
    • Checking stator, rotor, and windings for wear.
    • Bearing condition and lubrication assessment.
    • Inspecting shaft, commutator, and brushes (for DC motors).
  • Motor Cleaning and Preparation:
    • Cleaning methods for stators, rotors, and bearings.
    • Removing debris, dirt, and moisture.
    • Preparing components for reassembly.

Day 4: Motor Reassembly and Testing

• • Reassembly Process:
    • Step-by-step guide to reassembling the motor after inspection and repairs.
    • Importance of torque settings, alignment, and fitting.
    • Replacing damaged components (bearings, seals, windings).
  • Winding and Insulation Repair Techniques:
    • Repairing or replacing damaged windings.
    • Insulation resistance testing and improvement.
    • Techniques for maintaining motor performance after reassembly.
  • Motor Testing Post-Overhaul:
    • Initial power-up testing and running-in procedures.
    • Vibration, temperature, and noise checks.
    • Electrical testing (voltage, current, resistance).
  • Performance Verification:
    • Final checks on motor alignment and operating conditions.
    • Verifying the motor meets original specifications.

Day 5: Preventive Maintenance and Long-Term Motor Care

• • Preventive Maintenance Strategies:
    • Developing a preventive maintenance schedule for motors.
    • Key tasks and intervals (lubrication, cleaning, insulation testing).
    • Implementing condition-based monitoring and predictive maintenance tools.
  • Lubrication and Cooling Systems:
    • Best practices for motor lubrication.
    • Assessing the motor cooling system.
    • Importance of regular maintenance for cooling fans and air filters.
  • Motor Life Extension and Optimization:
    • Maximizing the lifespan of motors through proactive maintenance.
    • Techniques for motor optimization (efficiency improvements, load balancing).
    • Evaluating the cost-benefit of major overhauls versus replacement.
  • Final Case Studies and Troubleshooting Exercise:
    • Real-life case studies of successful motor overhauls.
    • Troubleshooting session with real motor issues.
    • Final Q&A session and course wrap-up.

NOTE:

Pre-& Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day reviews, and assessments will be carried out.

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Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences.  Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work& Practical Exercises
• 20% Videos& General Discussions