GAPS In Your Electric Motor Reliability Program. Hebert Libreros Regional Manager PdMA Corporation

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Calvin Pope
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1 GAPS In Your Electric Motor Reliability Program Hebert Libreros Regional Manager PdMA Corporation

2 Agenda Understanding the Challenge Defining the GAPS Reflection Closing the GAPS Summary

3 Understanding the Challenge Traditional tools won t be able to help us meet efficiency required to be competitive. Learning machinery requires large data. New generation with different habits. Expected to reduce U.S. economy per-capita GDP growth by an estimated 1.1 percent in this decade. Harvard University and Rand Corp.

4 Understanding the Challenge We are eliminating the need of the Experts from day to day operation. However, we continue to rely on them on a need basis. Example: we all have a digital camera, YET none of us is a photographer.

5 Understanding the Challenge At the same time, our workforce is becoming more knowledgeable (KPI s). Managers have to facilitate transition. Example: Just Look Around. Hint: Be nice to nerds. You might end up working for one someday. Often attributed to Bill Gates.

6 Understanding the Challenge - Summary of Motor Failures - Bearings 41% 12% Rotor 10% 37% Stator Rotor Stator Other Bearing 1985 EPRI/GE STUDY EL4286 Volume 1 Project Other

7 Defining the GAPS Three Keys of successful Motor Maintenance Quality Control Trending Troubleshooting

8 Fault Zones Power Quality Power Circuit F Stator Insulation Air Gap Rotor

9 Quality Assurance - Case Study #1

10 Quality Assurance - Case Study #1

11 Quality Assurance - Case Study #1

12 Quality Assurance - Case Study #1 Standard Test - Post Repair -

13 Quality Assurance - Case Study #1 A new replacement motor would cost $30,000

14 Quality Assurance - Case Study #2 Standard Test Name Plate - GE Volt FLA HP Z Frame # RPM

15 Quality Assurance - Case Study PdMA Corporation

16 Trending - Case Study - MCSA Name Plate Information Boiler Feed Pump 4160 V 309 FLA 2500 HP 3580 RPM 46 Bars 54 Slots

17 Trending - Case Study - MCSA 2008 x 2009 x 2010 x 2011 x PdMA Corporation

18 Trending - Case Study - Demod x 2009 x x x

19 Trending - Case Study - MCSA January 2012 We have a problem

20 Trending - Case Study - Demod January This demodulation capture represents nearly a 25 times increase over baseline

21 Trending - Case Study - Brainstorming What speed is the motor? Minimize load fluctuations Limit the starts & stops of the motor Increase testing frequency Let s compare to Pump #2

22 Trending - Case Study - Demod 0.1 COMPARISON Data taken from Boiler Feed Pump number 2 shows no rotor bar related anomalies

23 Trending - Case Study Damaged Rotor Rotor has multiple cracks and shows visible signs of rubbing damage

24 Trending - Case Study Damaged Stator Tooth

25 Troubleshooting - Case Study Insulation Persistent Drive Failure on 400 HP Baghouse Fan

26 Problem Description Four (4) Variable Frequency Drive failures within a short life span (all within 3 years) VFD s always replaced with new components at a cost of $45,000 each Electric Motor recently refurbished Frequent trips of the motor causing additional process problems

27 Troubleshooting - Case Study AC Induction General Electric 400 Horsepower 1780 RPM 509LL Frame 460 Volt 442 Amps

28 Troubleshooting - Case Study Data collected from local disconnect Quickly noticed the corrected Mohm value was only 145 All other data appeared to be within acceptable limits Standard Test

29 Troubleshooting - Case Study Polarization MCC Panel Final value less than 400 MegaOhm Erratic graph indicative of moisture and/or contamination

30 Troubleshooting - Case Study Data collected from motor leads Quickly noticed the corrected Mohm value increased from 145 to 1700 Indication of a problem within the conduit between disconnect and motor Standard Test

31 Troubleshooting - Case Study Final value increased to over Mohm Polarization Motor Leads Graph has more slope - less erratic

32 Troubleshooting - Case Study Answer Phase 1 Phase 2 Phase 3

33 Before/After Lead Change Corrected Mohm value close to when tested at motor Corrected Mohm value went from 145 to 1500 Resistive Imbalance at 0.00% Test Date 07/28/ /28/2003 Test Time 10:08:57 AM 03:03:13 PM Baseline Frequency Mohm Ph 1 to Gnd Charge Time Voltage Motor Temp Measured Mohm Corrected Mohm pf Ph 1 to Gnd ohm Ph 1 to ohm Ph 1 to ohm Ph 2 to mh Ph 1 to mh Ph 1 to mh Ph 2 to Avg. Inductance % Res. Imbalance % Ind. Imbalance $ Power Loss Test Location Motor Leads Bot Fuses LD MCE # HV HV User Notes Yes Yes

34 REFLECTION Humanity is now entering a period of radical transformation in which technology has the potential to significantly raise the basic standard of living for every man. Right now a Masai warrior with a cell phone has better mobile phone capabilities than the president of the United States did twenty-five years ago. And if he s on smart phone with access to Google, then he has better access to information than the president did just fifteen years ago. Imagina by Peter Diamandis Abundância - o Futuro É Melhor do Que Você

35 REALITY Maintenance budget has experienced a much needed rest from drive replacement costs. PdM technologies allows to quickly move from abstract to the concrete anticipating outcomes. For the first time our capabilities have begun to catch up with our ambitions.