Six steps to motor management webcast
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Six steps to motor management webcast
- 1. Six Steps to Motor Management Jim Taylor Director of Operations Machinery Management Solutions, Inc. jim.taylor@machineryhealthcare.com www.machineryhealthcare.com
- 2. Why A Motor Management Program Running costs for life can be >10 times purchase price >60% of a company's total energy costs. Can reduce required energy by 10 to 25% by Proper sizing Use of high efficacy motors
- 3. Example 100 HP motor Purchase price of $3519 Efficiency of 94.1% at rated load 5¢/kwh Operating two shifts, five days per week Consumes $14,920 worth of electricity each year.
- 4. Goals Of Motor Management 1. Minimize Cost Of Operation Of The Motors (LCC) 2. Maintain Reliability Of The Motors 3. Receive Early Warning Of Motor Failure
- 5. 6 Step Motor Management Plan 1. Create a motor inventory and a motor tracking program 2. Develop guidelines for repair/replace decisions 3. Prepare for motor failure by creating a spares inventory for critical applications
- 6. 6 Step Motor Management Plan 4. Develop a purchasing specification 5. Develop a repair specification 6. Develop a planned maintenance program
- 7. Goal 1 - Minimize Cost Of Operation Of The Motors
- 8. Step 1: Create A Motor Inventory And A Motor Tracking Program Identify inefficient motors for replacement Proper sizing of motors Variable Frequency drive? Timing Immediate When it fails
- 9. Step 2: Develop Guidelines For Repair/Replace Decisions Don’t wait until you’re under fire to prepare! Upon failure, will motor be repaired or replaced? Criteria for repair vs. replace
- 10. Step 3: Prepare For Motor Failure By Creating A Spares Inventory For Critical Applications In-house Vendor stocked Optimized spares inventory Storage Control procedures Inventory control Storage conditions
- 11. Step 4: Develop A Purchasing Specification For each motor, predetermine correct size, type and efficiency requirements Predetermine vendor & mfg/model number Determine stocking policy
- 12. Step 5: Develop A Repair Specification Improper repair can reduce efficiency Find a repair shop who will work with you and respect your specification
- 13. Step 6: Develop A Planned Maintenance Program Maintain reliability of the motors Receive early warning of motor failure See first webcast in this series, Uptime Magazine, Dec ’05 and Plant Services Dec ’05 for methods to develop
- 14. Summary of Machine Healthcare Analysis 1.First ask, what are the possible failures? 2.Next ask, which of these failures are significant? 3.Next ask, how can we avoid these failures?
- 15. Summary of Machine Healthcare Analysis 4. Then ask, when we can’t avoid failure, how can we get an early warning? 5. Then, tailor a suite of tests to detect those early warning signs. 6. Finally, collect the results of the tests at one decision point.
- 16. Goal 2 – Maintain Reliability Of Motors
- 17. Preventive Maintenance PM tasks & period Only do PM's that make a positive impact on reliability
- 18. Major Causes Of Motor Failure Heat Dirt Moisture Vibration Voltage irregularities
- 19. Goal 3 – Receive Early Warning Of Motor Failure
- 20. Purpose of doing PdM Tell Maintenance when damage has progressed enough to be confirmed but not enough to cause secondary damage All equipment deteriorates Can never completely eliminate failure
- 21. Managing Equipment Failures Goal Managed Avoided Surprise Managed Avoided Surprise
- 22. Predictive Maintenance Thermal imaging Vibration monitoring Power monitoring Motor circuit analysis Motor current signature analysis Others – both on-line and off-line
- 23. Goals Of Motor Management 1. Minimize Cost of operation of the motors (LCC) 2. Maintain Reliability of the motors 3. Receive early warning of motor failure
- 24. 6 Step Motor Management Plan 1. Create a motor inventory and a motor tracking program 2. Develop guidelines for repair/replace decisions 3. Prepare for motor failure by creating a spares inventory for critical applications 4. Develop a purchasing specification 5. Develop a repair specification 6. Develop a planned maintenance program
Editor's Notes
- Good morning everybody. I’m Jim Taylor. This morning I hope to give you a tool you can find immediate use for. A way to decide how to manage your motors to reduce costs and increase reliability and availability. What I’d like to explore today is a way that you can get the most effective operation of your motors while maintaining their health and reliability. We’re going to look at some of the steps that you should take to have an effective motor management program. Next slide
- You may wonder why we should worry about a formal program for managing motors. After all, they’re reliable and relatively inexpensive. But let’s take a look at some of the impacts that the motors have on a usage of electric power. The average electric motor in industry can use many times Its purchase price electric power over time. look at the amount of money we spend on electricity and where it goes. in most plants more than 60% of that power goes to run electric motors. If we can increase the efficiency the motors we use, make sure they’re properly sized for the application, and if appropriate, install a variable frequency drive, we should be able to reduce the amount of power we use by a significant amount. Let’s look at a specific example Next slide
- Let’s take the case of 100 HP squirrel cage induction motor that costs $3,519.00 when new. If this motor has an efficiency of 94.1% rated load, and it’s properly sized for the application, we can figure out how much it cost to run. Assume electricity costs 5¢ per kilowatt hour (I wish) . If our motor operates for two shifts, five days a week Is going to use almost $15,000.00 worth of electricity every year. Now assume that this motors going to have a service life of twenty years. If we do the math , that comes out to nearly $300,000.00 in operating costs over the life of the motor. What this means is that if we can increase the efficiency of our motors the by only fractions of a percent, we can have significant savings. Of course these numbers will vary with motor size and type, operating profile, and your electric charges. Next slide
- So let’s look at goals that we probably want for a motor management program. I think there are three things that we want to have as goals. The first of these is we want to minimize in the operating cost of a motors. In other words, minimize the lifecycle cost of the motor. The lifecycle cost includes not only the initial purchase price of the motor, but all maintenance actions that are done on the motor and all power that is used to run the motor. So we want to make sure the motor is appropriate for its use, that it’s of sufficient efficiency, and that we maintain it in the most cost effective manner . I think our second goal should be to maintain the reliability in the installed motor base. Just as you want a good exercise program and a good diet for your own health, we need to have a good preventive maintenance program in our motors. If we can address those issues cause motors to deteriorate and fail, we should be able to get maximum useful life from a motor. Once we got a good preventive maintenance program in place, we want think about getting an alert when the motor is starting to deteriorate. This is where good condition assessment program comes in. So our three goals should be to: minimize the life cycle costs of the motor maintain the reliability of the motor and receive early warning when the motor is starting to fail. Next slide
- I recommended we follow a sex step process to develop a motor management plan. The first step of the process Is to create an inventory of all motors in our plant. We want record things like horsepower, RPM, voltage, full power amps, frame size, and other things that give a complete picture of the motor. Don’t forget about the driven machinery. Driven machinery has different characteristics; they require a different type of motor to match. So we want to make sure the installed motor Is properly sized and the proper type for the application. Then we can use that inventory to make decisions on future replacement or repair of those motors. Having put together a good inventory of motors, we want to develop some guidelines for deciding whether to repair or replace those motors when they fail. When the motor actually fails, the alligators will be hungry and we won’t have time to make the analysis. So if we developed an up front criteria, we can quickly come to the proper decision on what action to take. The third step is to look at our motor inventory and determine which ones are the most critical motors. we want set up spares plan for those critical applications. Next slide
- The fourth step is developing a purchasing specification for buying new motors . Should we buy a standard motor or should we buy a high efficiency motor. We can go a step further and identify specific manufacturer and model numbers for each application when it comes time to replace that motor. Next we want a develop a repair specification. The repair specification will make sure that when we do repair a motor, its efficiency is not reduced in the repair process. And finally we want to develop a good planed maintenance system, that includes both preventive and predictive tasks, to maintain the health of our motors . Next slide
- Let’s take a look at the first goal. We want to minimize the cost of operations of the motors. This means that we want to have a motor that’s properly sized in the application it also means that we want to have a high efficiency mother in the application. And we only want to do that maintenance that has significant impact on the motors reliability. Next slide
- Our first step is going to be to create a motor inventory and a plan to make sure that inventory remains up to date. Our objective with this inventory is to identify all motors in our plant. Then we can decide which motors are inefficient or improperly sized or should be should have a variable frequency drive. Knowing this will put us in a position to make decisions on what action to take. At this point, our actions will be either immediate motor replacement, or wait until the motor fails. At that time, we’ll either repair it or replace it according to the repair criteria. As we create an inventory, we want to capture motor horsepower, RPM, full load amps , and all the other nameplate data . We also want to record the application of the motor. a fan has a different torque curve than a winder. We need to know that to select the correct type of motor. We also need to develop some method to track motors. A motor may be moved from location to location. Or it may be replaced, sent out for repair, or some other disposition. We want some way, that is institutionalized, to keep our database up to date . The more automatic this is the better . You can probably find some way to use workorder input, stockroom input, and or purchasing input to update the database. Once we got our database of motors developed, then we can go through it and look at the individual motors to decide what action we’re going to take. Next slide Next slide
- Once we have our inventory, we can start developing some guidelines for repair or replace decisions . You don’t want to wait until the mothers has failed because if you do you will be under a lot of pressure to get back on line as quickly as possible. You won’t have time to sit down and work through the analysis of whether it’s appropriate to replace it with a high efficiency motor or to send it out for repair. As part of this process, you want set up some criteria that will help you make that repair or replace decision. For example, if the motor is of reasonable efficiency and damage is limited to the winding, then repair it. If damage extends to the core, replace it. When you’ve made the decision for each individual motor, make that information available so that when the motor does fail it is readily available. Next slide
- Would be nice if we can predict all failures of motors. But we can’t. So we need to develop a spares stock for the most critical motors. This inventory can be either maintained in house or maintained by the vendor. Or some combination of both. If we’re going to maintain the inventory in house , we need to consider and address inventory control, the storage conditions of the motor, and maintenance of stored motors. Next slide
- We also need to develop a purchasing specification. The purchasing specification tells us, for each voter in the database, what its replacement is. It will specify size, type and efficiency requirements for the replacement motor. If you wish, you can go ahead and add specific manufacturer and model numbers in the specification . The purchasing specification, along with the previous step, will help you and your vendors determine the stocking policy for individual motors . Next slide
- As important as a purchasing specification is a repair specification. If a motor is repaired, especially if rewound, it may be returned with a lower efficiency. If the repair shop uses a different water size, or winding configuration, the efficiency of the motor can be reduced by several percent . We need to develop, probably together with the repair shop, a specification for repair that ensures the efficiency doesn’t decrease. A good repair shop should be glad to work with you on this. Expect that the individual repairs are probably going to cost more little more. But you’ll more than make up the cost difference in the energy savings . Next slide
- And finally step six, which addresses goals two and three, is developing a planned maintenance system for the motors. There are a number of ways that you can develop such a system. For example, use manufactures recommendations , general practice , reliability centered maintenance , and others. Last February, during the first of this series webcasts, we talked about a way to develop a predictive maintenance system for your equipment. You can also check Uptime Magazine December, 2005, and Plant Services Magazine December 2005 for more information . Let’s quickly review the steps in the process. Next slide
- The first thing we want to do Is ask, what are the possible failures. When we talk about failures here, we mean functional failures of the machine. How does it fail to meet the function that was put in the system for in the first place . The next step Is to ask which of these failures of significant. In other words rank them based on how often they fail and How severe is the impact of failure. Step three is to ask how can we avoid these failures in the first place. From this step may come either design or operation changes or preventive maintenance actions that can be taken to maintain the help of the machine. Next slide
- If we can’t avoid failure altogether, we ask how can we get an early warning of the failure. What are the symptoms that the machine is going to exhibit that we can measure or detect that will give an early warning. Once we have the answer to that question, we can tailor a suite of tests that will detect those early warning signs. And then finally, we want to collect all this information at one decision point. Think of this decision point as the personal trainer for that machine. Probably a planner, possibly a maintenance technician or supervisor. Next slide
- that brings us to goal number two, maintain the reliability of our motors. To do this we need to identify those things that will cause the motor to deteriorate. our healthcare analysis should have helped us to do that. Once we know what causes the motor to deteriorate, we can develop actions to counter those factors. Next slide
- We want to develop a series of preventive maintenance tasks that will help maintain the machine. Each of these tasks will have a certain periodicity attached to it. Coming up with the task Is not too different. Coming up with a periodicity is more difficult. If you have an understanding of or feeling for how fast or how frequently a condition occurs, you can use that as a judgment on how often to do that task. For example If you have electric motor in a very dirty environment, you want clean that motor much more frequently than you would a motor running in a clean environment. And don’t get carried away with preventive maintenance tasks. there a lot of tasks we can do but often they don’t have much on the reliability of the machine. Look at your tasks very closely and ask the question “is this really going to maintain the health of my machine?” If the answer is no, don’t do it. Next slide
- These are probably the most common causes of motor failure. It’s certainly not an inclusive list; others that will cause motor failures too. But let’s take a look at this list. Heat is a major enemy of motors. the insulation In the motor is very sensitive to heat and if it’s overheated it can deteriorate rapidly. so we want to do everything we can to keep our motors running cool. That leads to the next one on the list. if there is dirt buildup on a motor in the cooling fins or the cooling fan or on any filters, that can cause overheating of the motor. We need to take actions to keep her motors clean. moisture is also detrimental to motors. not only can it cause corrosion, it can also get Into the inside of the motor, especially when shut down, and cause shorts and deterioration of internal components. We need to keep the moisture out . This means if we have heaters on the motor that operate when the motor is shutdown we need to make sure they are operating properly. if we don’t have heaters on a motor that may be shut down for extended periods in an moist environment, condensation can occur inside of it. we should consider installing heaters. Vibration is a symptom of many different problems. It can alert you to Imbalance, misalignment, and electrical problems, among others. Any vibration can cause the bearings to wear out faster. So We want to keep the vibration of the motor as low as possible. This means that we need to have a good shaft alignment program, keep our motors and driven equipment balanced, and a good lubrication program to minimize vibration. Voltage irregularities as the source of many motor problems doesn’t get a lot of attention. But it should. If I have a 1% imbalance In the voltage supplied to the motor terminals, I can have as much as six to 10% imbalance in the current that the motor draws. That imbalance current causes internal heating in the motor, loss of efficiency, and possibly improper operation. so we need to maintain our power system in good condition. This means that we have balance load on all phases, we have a good transformer maintenance program, and we keep connections and terminals in good shape. Next slide
- A third goal Is to find a way to get an early warning of motor failure. This is a condition assessment program or a predictive maintenance program. We’ll make periodic tests and measurement of the motor system to spot failure symptoms early. Next slide
- Reason we do predictive maintenance is we’d like to be able to tell maintenance when damage has started to occur in the machine. We have to be careful when we make our recommendation that we don’t cry wolf too many times. We also don’t want to wait too long when we get an indication so we have significant secondary damage. So we want a measure that is reliable enough to confirm that damage is occurring as early as possible. Ideally in, we’re going to have more than one test . If the machine is deteriorating, these tests should correlate and give us confidence that we’re really seeing a deterioration. Likewise, If they don’t confirm each other, we know we need to do some additional testing and investigation to see what the true problem is . Next slide in
- This is really our objective in predictive maintenance. As you can see in the left hand chart surprise failures are the norm in a lot of plants. If we implement a good predictive manes program, we should be able to move from the left hand chart to the right hand chart, or surprise failures are small percentage. we’ve been able to avoid some of the failures altogether by taking some action, and we’ve been able to manage the remaining failures to avoid major production losses, secondary casualties and other damage. next slide
- There are quite a few different condition assessment technologies that can be applied to motors. Thermography or infrared imaging is very effective on motors. It can detect problems with terminals, find overheating in the motor itself, and monitor other conditions that affect the motor. Vibration, as we said before, is a symptom of many different problems in motors. It can alert you to Imbalance, misalignment, electrical problems, among others. All these can lead to motor deterioration . So we’ll need a good vibration monitoring program in place to watch for these. We said voltage irregularity is a source of many motor problems. So we need to monitor the power system. There are a number of good power quality monitors on the market that will help you monitor the power system to insure voltage and current balance, minimize total harmonic distortion, and measure other problem areas in the power system . Motor circuit analysis is an offline system in that makes measurements of the electrical end of the motor. It can detect problems with the windings and connections in the motor . Motor current signature analysis is similar to vibration analysis. But instead of using an accelerometer we can use a clamp on current probe to measure the current. We can then identify features in the spectrum and relate them to problems in the motor . And there are many other tests that you can use both online and offline for your motor’s . Next slide
- So in summary, a good motor management program probably has three goals. The first goal is to minimize the lifecycle cost of the motor. Because the utility cost to operate the motor over its lifetime will be many times the purchase price of the motor, it makes sense to install properly sized high efficiency motors. The second goal is to maintain the reliability or the health of the currently installed mothers. this involves developing preventive maintenance tasks that counter deteriorating influences on the motor . And finally, the third goal is to receive an early warning when the motor stars to deteriorate. If we can react to an early warning we can take action to avoid catastrophic failure or a major production downtime . Next slide
- To accomplish these three goals, I recommend a six step plan. Step one Is to create an accurate inventory of your installed motor base. Along with creating the Inventory you want a program in place that will keep the Inventory up to date. Step two is to develop guidelines that will tell you, when you’re under fire because a motorist failed, whether to replace It or repair it. And if you are going to replace it, It will tell you what to replace it with. Step three is to create an inventory of motors, either in house or at the vendor, for when the critical motors do fail. Step four is to develop a purchasing specification for each motor so that when it comes time to replace that motor we Already know exactly what its replacement is. Step five in is to develop our repair specification, so when we send a motor out for repair the repair shop knows exactly what we want. Then the motor will be repaired properly so that we maintain the efficiency of the motor. And finally, step six Is to develop a planed maintenance program. This planed maintenance program is a combination of preventive and predictive tasks that we will take with respect to the motor . Thank you for attention. I hope you got some useful information from this, something you can take back and put to use right away. I’d be happy to answer any questions either now or later on the reliabilityweb.com forum.