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 Motor Failure Calculate MTBF Motor Removed From Service Motor Installation Motor Purchased NO For every Blue Box event TANGO Plant Receives Motor ® Buy Replacement? (New ID) provides practical Motor Management tools Scrap Stores Is Motor Repair Practical? YES Motor Sent For Repair N O Shop Ships Motor Cost of Failure Repair Quote Approved? Shop Repairs Motor YES Failure Root Cause Failure 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 hours 5.7 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. Lubrication 1. Old lubrication 2. Lack of lubrication 3. Excessive lubrication 3. 1. 2. 4. 2. 3. 5. Shorted windings Broken parts Environment 1. 2. Contamination 1. Internal moisture 2. Dirty cooling passages 3. Dirty windings Fatigue / Wear Lighting Power High ambient temperature Process 1. 2. Excessive starts Overloads © 2001 24/7 Systems, Inc. Condition Monitoring vs. Reliability Improvement Condition Monitoring Reliability Improvement Prevents process Reduce and eliminate failures by detecting future failures faults and removing Time between failure motor before failure in (MTBF) is increased, service. reducing cost of Reduces/eliminates maintenance and life cycle catastrophic failures cost and process down time 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: Current and voltage analysis Megger readings Thickness Ultrasonics Vibration Lubrication analysis Process MCSA PdMA analysis Flux analysis Thermography 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 © 2001 24/7 Systems, Inc. service. Tango | Condition Manager Program Integrate, Organize, and Communicate Predictive Maintenance Results Oil E l ca tri c le Thermogra phy Vibration Electrical Ultr aso nic Pr oc es s © 2001 24/7 Systems, Inc. Tango | Integrated Condition Report Pie chart provides an analysis of the number of each machine’s severity in the user’s area. Color-coded severity indicators (red, yellow, blue, green). Listing of equipment that is down and unavailable for production. 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. When this button is activated 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. 2. 3. 4. 5. B. Equipment – lemons Locations Manufactures Overhaul vendors Equipment Design Groups (models) Root cause of failures • C. Systematic mitigation of root causes Cost of repair • • Allows justification of expenditure to extend life Focus on areas of high return © 2001 24/7 Systems, Inc. Reliability Improvement 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: 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 © 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.