The below video is a 7 minute segment of a 30 minute long presentation given by Adam Smith and Jacob Bell of HECO PSG at the 2017 Reliability, Process, and Maintenance (RPM) Symposium. This presentation discusses three different maintenance philosophies: breakdown maintenance, preventive maintenance, and predictive maintenance.
It’s interesting how rarely this question is ever discussed. Can the electric motor shop that you use, run your motor or properly power it with full voltage? Or do they simply spin the motor up to full speed/volts, “for a moment”, but then have to reduce the voltage because their power supply can’t handle the load?
The below video is a 15 minute segment of an hour long presentation given by Todd Hatfield of HECO at the 2017 Reliability, Process, and Maintenance (RPM) Symposium. This presentation discusses common preventable causes of electric motor failures. This section of the presentation discusses bearing related failures as bearings account for about 51% of all electric motor failures.
During a recent plant survey we encountered several motors that were suspiciously missing the manufacturer’s data plate but miraculously had a data plate from the last repair vendor. These “vendor” data plates usually only have the vendors job number and of course their logo and contact phone number. This is an old trick that forces the customer to call the last vendor for a replacement motor or a motor repair.
We are all looking for ways to improve our maintenance practices and increase reliability in our industrial plants and facilities. We see articles and information all the time that talk about "cadillac" programs that people have put together and do a great job for them. Its true, some people take reliability to extreme measures and it pays off for them. However, it seems many people have limited budgets, limited staff, and a management team that is reluctant to try new things.
We cannot solve all of those issues, but what i can recommend are 8 ideas in which you can use to help improve your plant reliability. These can be very sophisticated, or very simple, dependent on how far you would like to go.
A common situation... 20 years ago someone decided that utilizing vibration analysis was a good idea in your plant. Maybe the idea came from a vendor or an internal Predictive Maintenance (PdM) guru. Either way you evaluated it and it just didnt make sense to have an internal team dedicated to this so you decided to outsource it.
How did you choose which company to use?
Was it a simple decision and go with the person who was bringing the idea to your plant? Did you develop a specification and go out for bid? How you made this determination is something to review down the road.
A dilemma every industrial facility comes to time and time again. An electric motor in your facility has an issue, it could be a vibration issue, bearing issue, or a variety of other items. Now is decision time... should you remove that motor from service and send it out to a motor repair shop or should you ask the motor repair shop to come to you and service the motor right where it sits?
As a motor repair facility and supplier of new motors you tend to get asked the question, do you offer storage for my spare electric motors? When deciding if you should move your spares you need to ask yourself a few questions about what you are currently doing in-house:
- Are these spares getting inventoried regularly?
- Are the shafts being spun regularly?
- Is the area clean of dust/debris?
- Are they stored in a temperature controlled environment?
- Are they stored seperate from a repair production area?
You should understand that every motor repair facility has their own practices and policies when it comes to charging an inspection fee.
What is an inspection fee?
It is a fee to cover the tear down, analysis, and testing of machinery to properly diagnose what has caused or could be causing the equipment to not work properly.
What does the fee cover?
It covers a portion of the cost for the professional skilled trades people to evaluate your equipment (such as):
You are the Maintenance Manager. You are tasked with keeping the plant running and having adequate replacement spares for critical equipment. It is critical to plant production that you know where every spare piece of equipment is located, that the piece is ready to go into service at a moment’s notice and that the piece of equipment was repaired to your specification during the last time that it was in for service. You don’t have time to physically go searching and certainly don’t want the embarrassment of not knowing where that spare 1000 hp or even 1 hp motor is in the event of an emergency breakdown situation. What could be even worse is knowing where the motor is, taking the time to install, wire, and align the motor only to find that it had not been stored properly and the motor will not run properly. But wait, it can be even worse. You stored the motor properly, you spun the shaft every quarter, kept it clean and dry, you even megged it semi-annually but the shop that repaired it the last time cut some corners, did not follow the specification and the motor is not going to be a viable option to get you out of this breakdown situation.