Six Steps to Motor Management

Jim TaylorDirector of Operations

Machinery Management Solutions, Inc.

jim.taylor@machineryhealthcare.com

www.machineryhealthcare.com

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

Example100 HP motor Purchase price of $3519Efficiency of 94.1% at rated load5¢/kwhOperating two shifts, five days per weekConsumes $14,920 worth of electricity each year.

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

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 Step Motor Management Plan

4. Develop a purchasing specification

5. Develop a repair specification

6. Develop a planned maintenance program

Goal 1 - Minimize Cost Of Operation Of The Motors

Step 1: Create A Motor Inventory And A Motor Tracking Program

Identify inefficient motors for replacementProper sizing of motorsVariable Frequency drive?Timing Immediate When it fails

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

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

Step 4: Develop A Purchasing Specification

For each motor, predetermine correct size, type and efficiency requirements

Predetermine vendor & mfg/model number

Determine stocking policy

Step 5: Develop A Repair Specification

Improper repair can reduce efficiency

Find a repair shop who will work with you and respect your specification

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

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?

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.

 Goal 2 – Maintain Reliability Of Motors

Preventive Maintenance

PM tasks & period Only do PM's that make a positive impact

on reliability

Major Causes Of Motor Failure

HeatDirtMoistureVibrationVoltage irregularities

Goal 3 – Receive Early Warning Of Motor Failure

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

Managing Equipment Failures

Goal

Managed

Avoided

Surprise Managed

Avoided

Surprise

Predictive Maintenance

Thermal imaging Vibration monitoring Power monitoring Motor circuit analysis Motor current signature analysis Others – both on-line and off-line

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

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