Motor Management Basics What Needs to be Managed Motor Life Cycle Measuring Motor Reliability Managing Condition Information Data Mining for the big Reliability

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


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?


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


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


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.


Types of MTBF Location Equipment Tag

ID Manufacture Model or Design Overhaul

Vender

HP Frame Size Voltage Bearing Type


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


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.


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


Vibration

Tango | Condition Manager ProgramIntegrate, Organize, and Communicate Predictive Maintenance

Results


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/


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.


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!


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


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


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


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:


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.
