Process Technology Equipment
Chapter 9 Motors and Engines
CHAPTER 9 Motors and Engines
Table of Contents
Contents
Page
Chapter Overview
2
Class Preparation Checklist
2
Chapter Objectives
2
Agenda
4
Lesson Plan
6
9.1 Purpose of Motors and Engines
9.2 Types of Motors and Engines
8
9
9.3 Components of Motors and Engines
10
9.4 Operating Principles of Electric Motors and
Engines
9.5 Potential Problems of Motors and Engines
9.6 Safety and Environmental Hazards
9.7 Process Technician’s Role in Operation and
Maintenance
9.8 Typical Procedures
12
16
18
20
21
Summary and Wrap-Up
24
Suggested Student Activities
24
End of Chapter Review Questions
25
Clicker Questions
Appendix
37
40
Process Technology Equipment
Chapter 9 Motors and Engines
Page 2
1.
Familiarize yourself with the chapter content.
2.
Bring cutaways or other hands-on teaching aids if available.
3.
Copy and distribute any fill-in-the-blank handouts for today’s content.
4.
Safety Minute prepared or assigned
5.
Review the PowerPoint slides associated with this chapter (if used) and
make sure that your computer is correctly set up to navigate the slide deck
smoothly.
6.
Request the appropriate A/V equipment (if needed) and make sure that
your computer is correctly synched with the projector to avoid any delays in
the classroom.
Chapter Objectives
9.1 Explain the purpose of motors and engines in the process industry (NAPTA Motors
& Engines).
9.2 Identify the common types and applications of motors and engines (NAPTA Motors
& Engines).
9.3 Identify the major components of typical motors and engines (NAPTA Motors &
Engines).
9.4 Explain the operating principles of motors and engines (NAPTA Motors & Engines).
9.5 Describe potential problems associated with motors and engines (NAPTA Motors &
Process Technology Equipment
Chapter 9 Motors and Engines
9.7 Describe the process technician’s role in operation and maintenance of motors and
engines (NAPTA Motors & Engines).
9.8 Identify typical procedures associated with motors and engines (NAPTA Motors &
Engines).
Process Technology Equipment
Chapter 9 Motors and Engines
Page 4
Class Agenda
Activity
Minutes
PPTs
1. Welcome to Class
1
1
2. Introduction and Agenda
1
2
3. Safety Minute
2
3
4. Objectives
0.5
4
5. Objectives (cont.)
0.5
5
6. Terms
1.5
6
7. Terms (cont.)
1.5
7
8. Motors and Engines
0.5
8
9. Purpose of Motors and Engines
1
9
10. Types of Motors and Engines
2
10
11. Selection of Electric Motors Versus Other
Drivers
0.5
11
12. Selection of Different Types of Engines
1
12
13. Uses of Engines in the Process Industries
1
13
14. Components of Motors and Engines — Motors
2
14
15. Major Components of Internal Combustion
Engines
2
15
16. Operating Principles of Electric Motors and
Engines — Motors
1
16
17. Load
0.5
17
18. Three-Phase Versus Single-Phase Motors
0.5
18
19. Operating Principles of Two- and Four-Cycle
Engines
0.5
19
20. Four-Cycle Internal Combustion Engines
2
20
21. Two-Cycle Internal Combustion Engines
1
21
22. Auxiliary Systems of Internal Combustion
Engines
0.5
22
23. Major Components of Combustion Gas Turbines
2
23
24. Operating Principles of a Combustion Gas
Turbine
2
24
25. Potential Problems of Motors and Engines
1
25
26. Mechanical Drivers and High Vibration
0.5
26
27. Misalignment and High Temperatures
0.5
27
28. Equipment Failure
1
28
29. Safety and Environmental Hazards
1
29
30. Safety Hazards When Working with Motors
1
30
31. Electrical Classification and Class
1
31
Process Technology Equipment
Chapter 9 Motors and Engines
Page 5
32. Group Designations and Divisions
1
32
33. Engines
0.5
33
34. Process Technician’s Role in Operation and
Maintenance
1
34
35. Motors
1
35
36. Engines
0.5
36
37. Monitoring, Lubrication, and Other Maintenance
Items
1
37
38. Typical Procedures
1
38
39. Start-up Procedures for Motors
1
39
40. Shutdown and Emergency Procedures for
Motors
0.5
40
41. Lockout/Tagout Procedures for Motors
1
41
42. Start-up Procedures for Engines
1
42
43. Engine in Service and Normal Operations
1
43
44. Shutdown Procedures for Engines
0.5
44
45. Lockout/Tagout and Emergency Procedures for
Engines
1
45
46. Summary and Wrap-Up
4
46
Process Technology Equipment
Chapter 9 Motors and Engines
Page 6
Chapter 9 Lesson Plan
Welcome Everyone to Class
Time: 1 minute
Resources: Slide 1
Introduction and Agenda
Time: 1 minute
Resources: Slide 2
Student Safety Minute
Time: 2 minutes
Resources: Slide 3
(Note to Instructor: Follow this procedure for the Safety Minute.)
• Announce who has responsibility for today’s Safety Minute.
• Have the student present the Safety Minute.
• Announce who is presenting the Safety Minute next class.
Objectives
Time: 0.5 minute
Resources: Slide 4
Objectives (cont.)
Process Technology Equipment
Chapter 9 Motors and Engines
Page 7
Time: 0.5 minute
Resources: Slide 5
Terms
Time: 1.5 minutes
Resources: Slide 6
Sample Instructor Script:
Turn to the terms page in today’s chapter in the textbook. I’ll call on some of you to take
turns reading the term and definition aloud and then using that term in a sentence. We’ll
begin with the following terms:
Terms (cont.)
Time: 1.5 minutes
Process Technology Equipment
Chapter 9 Motors and Engines
Page 8
Resources: Slide 7
Sample Instructor Script:
Other terms process technicians should be familiar with include the following:
Motors and Engines
Time: 0.5 minute
Resources: Slide 8
9.1 Purpose of Motors and Engines
Time: 1 minute
Resources: Slide 9
Process Technology Equipment
Chapter 9 Motors and Engines
Page 9
9.2 Types of Motors and Engines
Time: 2 minutes
Resources: Slide 10
Sample Instructor Script:
Electric motors use electricity for motive energy. Electric motors may use either AC or
DC electricity and may be single speed or variable speed.
DC motors are very useful for variable-speed applications because adjusting the voltage
can easily vary their speed. DC motors are also useful in applications that require very
high torque at start-up because series wound DC motors develop their greatest torque
at slow speeds. This makes them particularly good as starting motors for small diesel
engines and similar applications.
Engines are typically one of two types: internal combustion or external combustion.
9.2.1 Selection of Electric Motors Versus Other Drivers
Time: 0.5 minute
Process Technology Equipment
Chapter 9 Motors and Engines
Page 10
9.2.2 Selection of Different Types of Engines
Time: 1 minute
Resources: Slide 12
9.2.3 Uses of Engines in the Process Industries
Time: 1 minute
Resources: Slide 13
Sample Instructor Script:
9.3 Components of Motors and Engines — Motors
Time: 2 minutes
Resources: Slide 14
Process Technology Equipment
Chapter 9 Motors and Engines
Sample Instructor Script:
The shaft is a metal rotating component (spindle) that holds the rotor and all rotating
equipment in place.
The stator is a stationary part of the motor where the alternating current supplied to the
motor flows, creating a magnetic field using magnets and coiled wire.
9.3.1 Major Components of Internal Combustion Engines
Time: 2 minutes
Resources: Slide 15
Sample Instructor Script:
An internal combustion (or gasoline) engine has many components:
Process Technology Equipment
Chapter 9 Motors and Engines
Page 12
The exhaust port is a cavity or chamber that collects exhaust gases from the exhaust
valves and directs it to the exhaust system.
Exhaust valves are valves in the head at the end of each cylinder that open and direct
the exhaust from the cylinder to the exhaust port.
The oil pan/sump is a component that serves as a reservoir for the oil used to lubricate
internal combustion engine parts.
Pistons are components that move up and down or backward and forward inside a
cylinder. The pistons are usually equipped with seal and wear rings to isolate the
combustion chamber from lubricant oil.
9.4 Operating Principles of Electric Motors and Engines — Motors
Time: 1 minute
Resources: Slide 16
Process Technology Equipment
Chapter 9 Motors and Engines
Page 13
9.4.1 Load
Time: 0.5 minute
Resources: Slide 17
9.4.2 Three–Phase Versus Single–Phase Motors
Time: 0.5 minute
Resources: Slide 18
9.4.3 Operating Principles of Two– and Four–Cycle Engines
Time: 0.5 minute
Resources: Slide 19
Sample Instructor Script:
Gasoline and diesel engines function using similar four-stage engine cycles:
Process Technology Equipment
Chapter 9 Motors and Engines
Page 14
9.4.4 Four–Cycle Internal Combustion Engines
Time: 2 minutes
Resources: Slide 20
Sample Instructor Script:
The first stroke is the intake stroke. The second is the compression or ignition stroke.
During this second stroke, the piston compresses the gas in the cylinder. When a gas is
compressed, the temperature increases.
The remaining stages are essentially the same for either type of engine. In the third
stroke, the fuel burns and its energy is converted to a much higher pressure and
9.4.5 Two–Cycle Internal Combustion Engines
Time: 1 minute
Resources: Slide 21
Sample Instructor Script:
Two–cycle engines complete the same four processes as four–cycle engines do, but
they complete them in two strokes instead of four. A two–stroke engine fires on every
revolution of the crankshaft. It is typically more powerful than a four–stroke engine of
equivalent size.
9.4.6 Auxiliary Systems of Internal Combustion Engines
Process Technology Equipment
Chapter 9 Motors and Engines
Page 15
Time: 0.5 minute
Resources: Slide 22
Sample Instructor Script:
9.4.7 Major Components of Combustion Gas Turbines
Time: 2 minutes
Resources: Slide 23
Sample Instructor Script:
The major components of a combustion gas turbine include the following:
The nozzle, similar to blades, directs the flow of fluids to the turbine blades and causes
an increase in the velocity of the steam or gas.
Rotating blades are attached to the shaft of the turbine. The steam or gas contacting
the rotating blades causes the turbine to spin.
9.4.8 Operating Principles of a Combustion Gas Turbine
Time: 2 minutes
Process Technology Equipment
Chapter 9 Motors and Engines
Resources: Slide 24
Sample Instructor Script:
During the initial start-up of a gas turbine, the compressor is started by an external
starting mechanism. Once the turbine is operational, the external starting mechanism
can be removed from the compressor. The thermodynamic operating principle is called
the Brayton cycle.
In the first stage of the Brayton cycle, the hot compressed air enters the combustion
chamber, where fuel is added.
9.5 Potential Problems of Motors and Engines
Time: 1 minute
Resources: Slide 25
Sample Instructor Script:
Process Technology Equipment
Chapter 9 Motors and Engines
9.5.1 Mechanical Drivers and High Vibration
Time: 0.5 minute
Resources: Slide 26
Sample Instructor Script:
Time: 0.5 minute
Resources: Slide 27
Sample Instructor Script:
9.5.3 Equipment Failure
Time: 1 minute
Resources: Slide 28
Sample Instructor Script:
Process Technology Equipment
Chapter 9 Motors and Engines
9.6 Safety and Environmental Hazards
Time: 1 minute
Resources: Slide 29
Sample Instructor Script:
There are hazards associated with normal and abnormal motor and engine operations.
The hazards could affect the personal safety of the process technician, process safety,
9.6.1 Safety Hazards When Working with Motors
Time: 1 minute
Resources: Slide 30
Sample Instructor Script:
9.6.2 Electrical Classification and Class
Time: 1 minute
Resources: Slide 31
Sample Instructor Script:
Process Technology Equipment
Chapter 9 Motors and Engines
Page 19
9.6.3 Group Designations and Divisions
Time: 1 minute
Resources: Slide 32
Sample Instructor Script:
Another level of classification is the group designation. Group designations are used to
group the material by relatively similar hazardous characteristics. Groups are assigned
letters A through G. A thru D are used for Class I, E through G are used for Class II, and
Class III has no group designations.
9.6.4 Engines
Time: 0.5 minute
Resources: Slide 33
Sample Instructor Script:
Hazards associated with normal and abnormal engine operations can affect personal
safety, equipment, and environmental aspects of the process industries.
Process Technology Equipment
Chapter 9 Motors and Engines
9.7 Process Technician’s Role in Operation and Maintenance
Time: 1 minute
Resources: Slide 34
9.7.1 Motors
Time: 1 minute
Resources: Slide 35
Sample Instructor Script:
Process technicians must know how to maintain communications and partnerships with
maintenance personnel and coordinate preventive maintenance. Process technicians
also have specific roles with regard to the operation and maintenance of motors. These
roles include the monitoring of lubrication and the condition of seals, and proper
housekeeping.
9.7.2 Engines
Time: 0.5 minute
Resources: Slide 36