Up Time Magazine- August/September 2008

Motor Purchase Motor In-Service Motor Removed from Service Motor Storage No Problem? Yes aspect of a well-designed condition monitoring program is the use of the right technologies for the application. Selection of PdM techniques and frequency of data collection is beyond the scope of this paper, but suffice it to say that RCM principles should apply when developing a good PdM/CM Program. Similarly, a good Preventive Maintenance Program should be developed and, more importantly, executed. As with PdM, the RCM principle should be utilized when developing a PM program. No ment distributors may prove invaluable in keeping the right motors in stock, freeing up capital. If this is a corporation, consider a shared inventory. • Make sure motors are stored in the right conditions. Factors to consider – temperature, humidity, floor vibration, access and maintenance. As with in-service motors, spares need to be regularly maintained. The maintenance tasks may include RTG measurement, visual inspection, shaft rotation and space heater operation. • Perform inventory reliability verification. When starting a Motor Management & Reliability Program, it may be necessary to test the spares motors. In many cases, the spares are not maintained and the storage environment adversely affects the motors’ condition. Motors that do not pass the test should be sent for reconditioning before being placed back in inventory. Repair Shop Yes Repair/ Replace? Scrap Support Services Motors, like any equipment that ages and wears, require repairs and overhauls. It is important that the plant Motor Management & Reliability Program addresses these issues: • Selection of repair facilities (motor shops) – The price should be only one of the parameters. The shop should follow the repair specification and provide quality, timely repairs; warranties; and information about repairs and causes of failure. • Development of motor repair specifications and their implementation so that all repairs are performed to the same standards to ensure consistency • Repair/replacement policy • Selection of new motor suppliers From the motor reliability standpoint, it does not matter if the repairs are completed inhouse or by outside shops. What is important is that the above criteria are followed and implemented. Figure 1 - Motor Management Process • • • • Reduce motor inventory Improve equipment uptime Optimize return on maintenance cost Address motor safety aspects Having defined the goals of the Motor Management & Reliability Program, the program criteria can be determined. Figure 2 shows the required elements of a successful Motor Management & Reliability Program. Consulting and Engineering Services A Motor Management & Reliability Program is not only about maintenance and spare parts. To provide real benefits to the bottom line of the business, there are a few additional aspects of modern asset management that should be included, such as the ability to objectively and systematically review and assess motor management processes, as well as motor conditions. These aspects form part of a toolbox for continuous improvement and should be performed on a regular basis to ensure the program is on track and delivering the necessary benefits. Additionally, they identify the areas for improvement by taking guesswork out of the decision process. These values are delivered through Motor Management Review and Motor Condition Assessment modules. It could be safely assumed that during plant constructions, the proper motors are selected for each application. However, over time, processes change. There are improvements in manufacturing, and usually plant output changes. Often, variable speed drives are added without analyzing the installed motors for a proper application fit. These changes lead to the need for consulting services, specifically application engineering. This service ensures the motors are right for the application and will provide long and reliable service. One of the goals of a Motor Management & Reliability Program is to increase motor reliability and decrease total cost of ownership. This is accomplished through a module called Reliability Improvement. The main activities include: On-Site (Plant) Services This is the basic, fundamental function of any maintenance organization and can either be performed in-house or contracted out. What is important, however, is that the work is performed to the right standards. This includes Condition Monitoring – traditional services such as vibration monitoring of bearings, oil analysis for sleeve bearing, infrared thermography and electrical tests – insulation resistance to ground measurement (RTG), motor circuit analysis, power quality, etc. The important Inventory Management On-Site Motor Service Condition Monitoring 24-Hour Emergency Response Inventory ties up capital and affects business performance. Too many spares equals too Motor Managament Program many wasted resources. Inventory Support Consulting & Information Not enough spares Management Services Engineering Management means uptime and Services production output are Overhaul, Inventory Motor negatively affected. So, System Design Repair & Optimization & Management & Interface from the business point Rewind Reduction Review of view, it is extremely Inventory Motor Motor Motor important to: Reliability Condition Information Upgrade Verification Storage & Maintenance Shared Inventory Assessment Application Engineering Reliability Improvement Management Preventive Replacement & Corrective Motor Supply Maintenance Program Management Figure 2 - Motor Management & Reliability Program Elements www.uptimemagazine.com • Optimize inventory. Make sure factors such as motor criticality, cost, lead time, repair possibilities, environment and safety are taken into account. Equip- 45 http://www.uptimemagazine.com

Table of Contents Feed for the Digital Edition of Up Time Magazine- August/September 2008

Up Time Magazine- August/September 2008 Contents Upfront Upclose Information Technology Lubrication Infrared Maintenance Management Motor Testing Precision Maintenance Reliability Ultrasound Vibration Upgrade

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