2. What’s the impact of machinery vibrations to
your Business Operation?
• How much it cost your company
for a major breakdown?
• As vibration increases, motor load
(average amps) also increases.
Refer to formula below.
• How much power wastage you
spent in your electricity bill/month?
• According to International Energy
Consultants as cited in Joint
Foreign Chambers (2010)
Philippines is the 2nd highest in
terms of electricity prices among
Asian countries.
Copyright ALPS 2013
3. Can these be prevented?
Damaged input bevel gear teeth of Cooling Tower Damaged electric induction motor
Yes, it can be prevented?
Copyright ALPS 2013
Copyright ALPS 2013
4. Our Approach
ECG for Doctors Vibration Analysis for Engineer
Machine
talks
ECG is used to diagnose heart problems while
Vibration analysis is for rotating machine and
structural problems.
Copyright ALPS 2013
Copyright ALPS 2013
5. Who are we?
ALPS MSI was established in 1996. Specialized in:
• Advanced diagnostic maintenance/vibration
analysis/energy audit of electric motors & its drive
systems;
• Laser alignment;
• Power savings through computerized motor rewinding,
balance supply voltage, etc;
• System improvements through precision maintenance of
motors, pumps, blowers/fans, & gearboxes. Distributor of
Elos Fixturlaser AB products based in Sweden.
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6. Company and Individual
Certifications:
• Professional Electrical Engineer, Registered Mechanical
Engineer and Registered Electrical Engineer
• Vibration Institute Category II Vibration Specialist
• Certificate of Attendance Vibration Institute Category III
Vibration Specialist.
• Certified Condition Monitoring Engineer Level I and II by
FIS, Germany.
• Member, Electrical Apparatus Service Association of
USA
• Certified Laser Alignment Specialist, Fixturlaser AB
Sweden
• Airborne Ultrasound Specialist Level I
• Highly skilled rewinders and journeymen (mechanical &
electrical)
Copyright ALPS 2013
7. Key Success Factors
• Effective implementation of condition
monitoring program;
• Quality workmanship and control in the
repair of equipment;
• Implementation of lubrication program;
and
• “Design out” ongoing reliability problems.
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8. Major Assets
• Facility Area: 560 sq. m.
• Lifting equipment: 5 Tons
• 3-Tonner Boom Truck
• 500HP Temperature
controlled electric oven
• 150HP Temperature
controlled electric oven
• Safe chemical treatment
for removing burnt winding
and paints.
• Professional bearing tools
Fixturlaser XA Alignment System Computerize Motor Rewinding
• 50-tonner hydraulic puller
01dB Vibration Analyzer Motor Circuit Analyzer (Offline) Balancing Instrument
Copyright ALPS 2013
9. Key Services Provided
Condition Monitoring
Helps identify the root cause and health condition
of motor and it’s drive system prior to breakdown.
This saves you money as we all know that emergency
breakdown is expensive.
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10. Condition Monitoring
Program Design, Commissioning, Training, and Remote Support
Monitoring route is set-up after Client had provided list of equipment
and classify its criticality.
Conduct commissioning for newly installed or repaired equipment as
part of the quality control program.
Conduct training on vibration analysis, alignment, bearing
maintenance, and motor maintenance.
Remote support for in-depth vibration analysis.
Program Audit, Benchmarking, and Optimization
Quarterly audit of the program in terms of equipment health status,
benchmarking, and optimization.
How to optimize the program? Example, if equipment health is
stable in that monitoring route, the program maybe channel to other
productive monitoring.
Vibration Monitoring, Infrared Thermography (Optional), Motor Circuit
Analysis (yearly)
A minimum of two(2) years contract.
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11. Scope of Works
• Onsite support of two vibration technicians for plant vibration
measurement and monitoring
• Yearly monitoring of Motor Condition using SAMATIC 6000R to
reduce if not prevent motor breakdown
• Monitor results; route adherence, asset health, & other key metrics
• Provide regular data review & interpretation onsite or remote
• Provide regular reporting & communication
• Identify and coordinate additional resources for troubleshooting,
fault diagnostic, & reliability improvement initiatives
• Provide additional hands-on support for data acquisition and fault
diagnostics, when required.
• Engineering Manager or VP Operations to attend bi-monthly
meeting on-site for two days per meeting (if client required).
Note:
• Client preferred Scope of Works is also considered.
Copyright ALPS 2013
12. Case 1: San Miguel Yamamura
Asia Corp
Unbalance
Overall amplitude after correction
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13. Client Inputs
• Total list of equipment to be enrolled for
condition monitoring and classify its
criticality to your operation.
ALPS MSI will establish the condition
monitoring route, how much manhours
needed, and proper costing.
• Motor inventory and its specification.
This will help us establish
preventive/corrective maintenance pricing on
per call basis.
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14. Benefits
• Minimized if not eliminate emergency
breakdown & overtime increase
production time;
• Just-in-time (JIT) delivery of spare parts &
materials needed for the repair reduce
inventory.
• Safety of equipment and personnel
eliminate catastrophic failure.
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22. Case 3: Water Utility
Motor Efficiency: 94.5% @ 75% load.
Electricity rate = Php 11.5/kwh
Operating hours = 4680
Calculated electricity consumption is,
Php 12,814,286 per annum
Electricity Consumption = (kW/motor efficiency) x rate x operating hours x motor load%
Whereas, motor load% = (Ave. current x ave. supply voltage) x 100%
(nameplate full-load current x voltage)
The actual motor load % = (425 x 445)/440 x 460) x 100%
= 93.44% a reduction of motor efficiency by 2%
Electricity consumption@ 93.44% load = Php 16,310,289
Power wastage (Php) = Elect. consumption@ 75%-Elect. consumption @ 93.44%
= (Php 3,496,003)
Copyright ALPS 2013
23. Factors that influence
Motor Load %
Vibration analysis and laser alignment had
identified factors that influence motor load,
%:
Misalignment
Vibrations
Bearing problems
Supply voltage
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24. Existing Maintenance
Practices
• When vibration is felt at the control room,
pump is inspected on the following:
a. Impeller condition
b. Bearing condition
c. Any unusual observation in the pump.
• Straight-edge and one dial indicator are
used to align motor – pump shafts.
• Untimely re-greasing of bearings
Copyright ALPS 2013
25. Why Motor Load Increased?
• Definitely, it’s difficult to
establish without using
high technology
instruments or tools,
and the experience on
motor maintenance.
• What are the
instrument they
invested?
a) Vibration analyzer:
01dB Movipack
b) Laser alignment
Fixturlaser Shaft 50
Copyright ALPS 2013
27. Key Services Provided
Computerize Motor Rewinding
Motor power losses is included in your
electricity bill & unknowingly you spent more
money for your operating cost than the
rewinding price we offered
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28. Motor Power Losses
• What’s the impact of increase motor
power losses to your electricity bill?
Power loss is an energy waste consumed by
a motor and included in your electricity bill;
Increase your operating cost; and
Reduce motor reliability and uptime.
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29. How it affects your electricity
bill?
• Prior a motor got burnt,
power exceeds its rated
capacity (kW/HP);
• In the process of coil
forming, turns/coil and POOR INTERLAMINAR
coil span definitely altered INSULATION
resulting to increase
motor power losses.
• Said power losses is
included in your electricity
bill & unknowingly you
spent more money to
your operating cost than
pay the rewinding price This motor rewound by other vendor & was
we offered. burned in less than a year.
Client: Petrol Refinery
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30. Motor Power Losses are caused by:
• 40%: Stator Winding Loss
Turns/coil, Coil span;
Cross-over of wires; and
Poor quality of rewinding
materials. Such as magnet wires
& insulation materials.
• 20%: Rotor Loss
Damage rotor, bearing quality,
improper bearing installation, or
rotor unbalance.
• 20%: Stator Core Loss
Poor workmanship, and
Quality of interlaminar
insulation.
• 20%: Stray Load Loss
Misalignment and
Poor motor ventilation
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31. Turns/coil affects CMA
• Unequal turn/coil affects “circular
mil/amperage” resulting to increase power
losses.
CMA – Circular
mil/Amperage
AGD – Air
Gap Density
Copyright ALPS 2013
32. Inappropriate coil span and/or
cross-over of wires leads to power
losses.
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33. Why Computerized Motor
Rewinding
• ALPS MSI is the only rewinding shops
in the Philippines that utilize
computerize motor rewinding machine.
Redesign/Restore AC Motor
Winding Data
Repair of AC/DC Motors,
Replacement/Restore Defective
Components
Motor Rewinding using
Computerized Motor Rewinding
Machine
• Benefits
Automatic Wire Guidance in a
manner that assures perfect layer
winding, Guaranteed no
crossovers;
Automatic Wire Tensioning; and
Ease of Coil insertion into slots
Warranty: due to zero crossovers, a major
time savings with consistent high
a) One year if you align the motor quality of coils.
b) Two years if we align the motor
Copyright ALPS 2013
34. Coil Span Preparation
SAMATIC Adjustable Concentric Wizard Jig
Coil span is adjusted based on stator diameter
and total number of slots.
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35. Workmanship Comparison
POOR INTERLAMINAR
INSULATION
Competitor DE- Motor burned in less than ALPS MSI pulled out the said motor from
one year due to cross-over & insufficient Competitor – DE as per instruction by client
phase-to-phase insulation. and rewind it.
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36. Key Services Provided
Predictive & Preventive Maintenance, Repair &
Maintenance
This is a complete package where you outsource
your maintenance to us while you focus on your own core business
–
Producing A Product.
Copyright ALPS 2013
37. Key Success Factors
• Effective implementation of condition
monitoring program;
• Quality workmanship and control in the
repair of equipment;
• Implementation of lubrication program;
and
• “Design out” ongoing reliability problems.
Copyright ALPS 2013
38. Predictive & Preventive Maintenance,
Repair & Maintenance
Two years minimum maintenance contract with the
following Scope of Works
• Condition Monitoring
• Vibration Analysis
• Computerize Motor Rewinding/Motor repair
• Bearing Maintenance & implementation of
lubrication program.
• Repair & Maintenance of Pumps, Blowers/Fans,
& Gearboxes
• Laser Alignment, and
• Onsite Dynamic Balancing.
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39. Benefits
• Warranty
For a period of two years from the date of the repair,
ALPS warrant that all design, equipment, materials,
and workmanship shall be free of any and all defects
and shall be in conformity with the requirements of
this specification.
• Reduce your maintenance cost
• Increase productivity of your personnel focus on
your core business – producing your product.
• Increase equipment reliability & uptime
• Peace of mind
Copyright ALPS 2013
40. Client Inputs
• Total list of equipment to be enrolled for
condition monitoring and classify its
criticality to your operation.
ALPS MSI will establish the condition
monitoring route, how much manhours
needed, and proper costing.
• Motor inventory and its specification.
This will help ALPS MSI establish preventive
& corrective maintenance pricing @ special
discount as compared to per call basis.
Copyright ALPS 2013
42. Energy Saving Business
• Phase 1 - Energy Audit of Electric Motors and its Drive-
Systems with the goal of energy efficiency improvement.
Conduct energy audit (kW, V, I, & PF) on electric motors &
vibration analysis for the whole system.
Identify other areas that will help generate power independently
Submission of Findings, Analysis, Recommendation, and
Feasibility Study.
• Phase 2 – Source out financing from banks or investors
through the assistance of International Copper
Association SEA or CTIPFAN
• Phase 3 – Project Implementation by new entity.
• Phase 4 – Monitoring the Success of the Project
Copyright ALPS 2013
43. Client Inputs
• Inventory of electric motors and its drive
systems.
• Tools and instruments used for
maintenance
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44. Products
Fixturlaser XA Alignment System On-line Protection System/Vibration
01dB Vibration Analyzer
Copyright
Cooling tower FRP Fan Blades ALPS 2013
48. Equipment Reliability
Cooling Tower
Proposal to diagnose mechanical
problems:
• Safety issue is major concern in
the measurement of vibration.
• Install on-line condition monitoring
device (upper right picture) with BNC
permanent sensors to the On-line condition monitoring mounted
bearings of gearbox, motor, and in a stable/safe wall, wired toward sensor.
cooling blower.
• Use 01dB Vibration Analyzer
(lower right picture) using its BNC
cable and plug to on-line condition
monitoring device. Problems that
can be diagnose: gear meshing,
bearings, misalignment,
unbalance, bent shaft, etc.
• ALPS MSI supply these
instrument inclusive of 5 days on-
site training with one year
technical support through remote
analysis. Copyright ALPS 2013
49. Equipment Reliability
Cooling Tower
Proposal for corrective
maintenance
• Always use Fixturlaser
XA for every alignment.
• Use Fixturlaser XA’ digital
spirit level to check & Fixturlaser XA Alignment System
correct blade pitch angle.
• Use professional bearing
tools to replace and
mount a bearing.
YDT 150 Bearing heater
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50. Thank You Very Much for Your Time
ALPS Maintaineering Services, Inc
Isateram Bldg., Magsaysay Road Ext., Brgy San Antonio,
San Pedro, Laguna 4023
Tel 806 3851 / 808 7495 Fax 808 2425
Email: alps@pldtdsl.net / may.delgado@alpsmsi.com
Website: http://www.alpsmsi.com/
Copyright ALPS 2013
