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Motor Management Basics
What Needs to be Managed Motor Life Cycle Measuring Motor Reliability Managing Condition Information Data Mining for the big Reliability
Picture Improving Motor Reliability
© 2001 24/7 Systems, Inc.
What needs to be Managed
Location Failure History Condition Info Repair Procedures Inspection and test
Documents Measurements and
Observations Failure Analysis Reliability
Assessment
Equipment Purchase Info Design Info Manuals and drawings Failure History Installation History Repair Details Repair Documents Suitable Replacements Reliability Assessment
© 2001 24/7 Systems, Inc.
Industrial Motor Life Cycle Path
IsMotor Repair
Practical?
Scrap
NO
YES
MotorInstallation
MotorFailure
MotorRemoved From
Service
MotorSent ForRepair
ShopShipsMotor
ShopRepairsMotor
YES
NO
Plant Receives
Motor
Buy Replacement?
(New ID)
Stores
For every Blue Box event
TANGOprovides practical
Motor Management tools
®
Repair QuoteApproved?
MotorPurchased
Calculate MTBF
Cost of Failure Failure Root CauseFailure Progression© 2001 24/7 Systems, Inc.
To improve motor life, you must be able to measure it
How do you measure motor life?
© 2001 24/7 Systems, Inc.
Motor Life Measurements Time till failure - MTBF Mean Time
Between Failures
Cost of failure - Cost of each repair
Life cycle cost - Cradle to Grave cost
Cause of Failure - Apparent failure vs. root cause of failure
© 2001 24/7 Systems, Inc.
How Long Should a Motor Live? AC Motor 100,000 hours 11.4
years
DC Motor 50,000 hours5.7 years
Source Bloch, Heinz P. and Fred K. Geiter 1994, Practical Machinery Management for Process Plants Vol. 2: Machinery Failure Analysis and Troubleshooting 2nd Edition, Gulf Publishing Co. Houston, TX
© 2001 24/7 Systems, Inc.
What is a Motor Failure?
A motor failure occurs when the motor is unable to perform its required function.
Typical failure modes: Bearings Shorted / open windings
These are apparent failure modes.
© 2001 24/7 Systems, Inc.
Types of MTBF Location Equipment Tag
ID Manufacture Model or Design Overhaul
Vender
HP Frame Size Voltage Bearing Type
© 2001 24/7 Systems, Inc.
Root Cause of Failure
1. Lubrication1. Old lubrication2. Lack of lubrication3. Excessive
lubrication
2. Contamination1. Internal moisture2. Dirty cooling
passages3. Dirty windings
3. Fatigue / Wear1. Shorted windings2. Broken parts
4. Environment1. Lighting2. Power3. High ambient
temperature
5. Process1. Excessive starts2. Overloads
© 2001 24/7 Systems, Inc.
Condition Monitoring vs. Reliability Improvement
Condition Monitoring Prevents process
failures by detecting faults and removing motor before failure in service.
Reduces/eliminates catastrophic failures and process down time
Reliability Improvement Reduce and eliminate
future failures Time between failure
(MTBF) is increased, reducing cost of maintenance and life cycle cost
Both technologies must be applied aggressively to achieve a wining maintenance strategy.
© 2001 24/7 Systems, Inc.
Motor Condition Management
Manage Motor Condition
1. Create a “no failures in service” mandate for critical motor.
2. Integrate all condition information
3. Communicate in a highly visible manner
4. Easily capture condition entries, documentation of failures in service, and motor down
5. Link condition information to failure analysis
6. Require validation and closure of condition calls
7. Maintain a History of Condition Results© 2001 24/7 Systems, Inc.
Integrating & Communicating Condition Information
Several predictive technologies apply to motor including:
This information is coming from different analysis packages with different databases, different analysts, and different reporting methods often to different people in the operating areas.
Tango allows all the predictive technologies to be compiled into a single integrated view of a given piece of a motor’s condition. This allows proactive scheduling of motor repairs and helps prevent failures in service.
Current and voltage analysis
Megger readingsThickness
Lubrication analysisProcess
Ultrasonics MCSA PdMA analysisVibration Flux analysis Thermography
© 2001 24/7 Systems, Inc.
Vibration
Tango | Condition Manager ProgramIntegrate, Organize, and Communicate Predictive Maintenance
Results
© 2001 24/7 Systems, Inc.
Tango | Integrated Condition Report
Index to rank the severity of the problem and the number of technologies in red condition. Click the severity index to view the condition technology details supporting the Integrated Condition Report.
Color-coded severity indicators (red, yellow, blue, green).
Listing of equipment that is down and unavailable for production.
Pie chart provides an analysis of the num-ber of each machine’s severity in the user’s area.
When this button is acti-vated it indicates that plant maintenance has completed it’s work and the equipment needs condition validation from the technology analyst.
24/ 7 Systems, Inc. 1242 Topside Road
Louisville, TN 37777 Phone: (865) 681-0282
Fax: (865) 681-0532 Email: [email protected]
http:/ / www.tf7.com/
© 2001 24/7 Systems, Inc.
Data Mining
The Developers of Tango cannot develop reports which answer every question a user may have.
Data Mining was developed to allow users to investigate their data and interact with it to provide answers and solutions unique to the plant and user.
© 2001 24/7 Systems, Inc.
What Exactly is Data Mining?
Data mining is a way of finding relationships and patterns in data.
Examples:
MTBF by Equipment and Location
High cost equipment and Locations
Cause of failure for equipment and locations
Failures by design, vendor, equipment type
You can’t improve what you can’t measure!
© 2001 24/7 Systems, Inc.
What does Data Mining Offer? A way to partition information into
meaningful chunks What are my causes of failures? When did I have the most failures
Allows you to sub-divide into smaller chunks
Helps you make sense of your information Which vendor sells the best product? What failure mode occurs most often What failure mode occurs most quickly
© 2001 24/7 Systems, Inc.
Standard Data Mining Tools
Tango’s Data Mining uses OLAP to provide a standardized Data Mining database
Many commercial Data Mining tools exist for operators on OLAP databases
© 2001 24/7 Systems, Inc.
What Issues Affect Reliability ?A. Poor performance by:
1. Equipment – lemons2. Locations3. Manufactures4. Overhaul vendors5. Equipment Design Groups (models)
B. Root cause of failures• Systematic mitigation of root causes
C. Cost of repair• Allows justification of expenditure to extend life• Focus on areas of high return
© 2001 24/7 Systems, Inc.
Reliability Improvement
Identify which motors are failing rapidly and repetitively
Identify equipment groups and location groups with high Repair cost
Identify root cause of failure. Aggressively eliminate root causes
In large plants with thousands of critical motors, failure may occur rapidly and repetitively, but no one realizes there is a reliability problem.
Tango’s main function is to solve this problem by:
© 2001 24/7 Systems, Inc.
Savings From Motor Management
Decrease in cost of repairs & replacement motor
Increased process availability – more production.
Reduced maintenance labor & overtime.
Increased safety from reduced failures in service and emergency replacements.
© 2001 24/7 Systems, Inc.