Download Motor Management Basics - Tango™ Information 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
© 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.