It is standard to see the “frame” size on every electric motor nameplate, but do you understand what that frame means in regard to the mounting of the motor? Many have been in the situation where you needed a specific frame only to realize it was made with a special shaft or has a mounting flange, but no one knew how to find this information!
When you think about the processes you have in place at your facility that are designed to keep the operation running, the first thing that comes to mind is most likely the PM schedule. You go around monthly or so and check filters, oil levels, temperatures and other detectable signs of easy to remedy issues that are bound to arise. Beyond that, maybe you have a quarterly vibration route and are collecting data on the health of your machines. Usually, this data is worth the cost of the program when it is able to predict an impending failure that can then be repaired before it breaks down catastrophically. This is a solid cost savings and can be easily justified.
If you are involved in the repair of electric motors, chances are you have heard about a core loss test (or core test, core loop test, core flux test, etc.) being performed on your motor. This article serves to provide a basic understanding of what a core loss test is and why it matters.
Are you replacing your failed motor with the best motor for your application and environment? The easy part of replacing your motor is matching the frame size, horsepower, RPM, and voltage, but it may not always be wise to just replace the motor with a motor matching the same enclosure that you have always had.
It is important to consider what enclosure is best for the environment that the motor is going to be installed in. You certainly wouldn’t want to continue on with a mistake that was made when the original motor was selected. Often times equipment OEM’s select a motor based on cost and not what's in the best interest of the longevity of service.
In recent years, companies have entered the transition from reactive maintenance, to planned maintenance, and into the most efficient method found in predictive maintenance. While the first two methods have dominated in the past, they have been found to be costly, inefficient in time, and sometimes result in over-maintenance of machines.
In predictive maintenance, machine downtime, cost for spare parts, and overtime are all held to a minimum. With all of these benefits, you may be asking - “What is the best implementation of predictive maintenance in my workplace?"
One of the most effective ways of predictive services is Vibration Analysis.
We received a phone call from a motor repair shop that had a power plant client that was under a unit wide shutdown due to a breakdown on a 1000 HP 394 RPM 4000v GE Vertical Solid Shaft Pump Motor. With a replacement motor 9 months out, and a completely destroyed, practically unrepairable original motor, they were asking - "Can you help?"
Lucky for this customer, we had a potential surplus motor in our inventory. Would this work? Below you will see some of the steps and comparisons that were taken to perform this evaluation.
When it comes time to purchase an electric motor, whether its an AC Induction Motor, AC Synchronous Motor, AC Wound Rotor Motor, or even a DC Motor, you have many options to consider. What brand should you buy? Who should you buy it from? How do you get something that fits? How do you get the best deal?
How often do you consider a surplus motor as a viable option? There are many perks to purchasing a surplus motor but you also have to be careful when you purchase them to make sure you are getting what you expect.
Let me start by saying that we love sensors and gadgets! In fact we are selling and installing sensors daily. The available IIoT (Industrial Internet of Things) technologies for reliability and predictive maintenance have never been greater. The tools available today have saved hundreds of millions of dollars in lost downtime and repair costs. Some of these technologies boast that they call tell you of an impending failure down to the week/day of that imminent failure.
So... you are looking to purchase a new electric motor and you are trying to get an idea of what the cost will be. That's a pretty loaded question. Think of an automobile - you can get a pickup truck, a sedan, a coupe, or even a semi truck. What is it exactly that you need? Obviously a semi truck is going to cost a lot more than a standard family sedan.
Time is money. When an electric motor is out for repair it can take days, weeks, or months to get it back. What should your expectation be? What are they even doing with the motor while its gone, why does it take this long? We feel a better question to ask is:
Does a quick repair lead to the best (long-term) motor reliability?