Premature Failure of Large Horsepower Motors: Created By Improper Field Connections, During Installation, and Commissioning

The commissioning phase is the final stage of a project before production. This phase is where all the pieces of the puzzle have to come together. The objective of commissioning is to demonstrate to the end user that the goals and objectives specified in the project scope have met the requirements. This article focuses on premature failures of large motors in the oil and gas industries due to improper field installation, connections, and commissioning. Large horsepower (HP) motors are a key part of most projects and require great attention to detail. Motors require relay protection, writing specifications, vetting suppliers, and testing protocols. The goal is to get the desired life expectancy with trouble-free service from the motor and the driven equipment. It is clear that good installation is a key to success. Incorrect installation of field connections and modifications can shorten the life of the motor and instrumentation and in some cases lead to premature failures. This applies to a new installation as well as retrofits with an adjustable-speed drive (ASD). This article discusses multiple premature motor failures resulting from improper installations and offers possible protocols that might have prevented equipment failure and downtime.