July 18, 2008
Ultra-Portable Vibration Monitoring and Analysis Equipment
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CTD-1010 - digital FFT Vibration Switch with 4-20 mA output. It has 2 relays, measures velocity RMS or displacement pk-pk. Alarm and shutdown levels, time delay and hold time are customizable and could be preset through up to 10 frequency bands.
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Find out more about Ultra-Portable Vibration Monitoring and Analysis Equipment
July 18, 2008
Motor Tip Discussion Continued
We have posted this exchange at MaintenanceForums.com to encourage additional discussion and to expand the learning from this information.
Please feel free to add your voice and experience to this discussion.
July 18, 2008
More Motor Tip Feedback
Original Tip: “Motor rewind shops will agree that seldom - if ever - is it feasible to rewind a motor more than once. This is due to the cumulative damage to the windings during failure.”
Feedback: The windings are replaced so no cumulative damage
Original Motor Tip: “One fact related to electric motor operations is that rewound motors operate less efficiently than new motors….”
Feedback: Efficiency should be almost the same as windings are replaced with the same as before - you may have a little more heat loss through the iron because the windings on smaller motors (1000 hp and less)are burnt out in ovens @ a high temperature.
Feedback provided by Lucy Malone
Catalyst Paper
Campbell River,B.C.
July 18, 2008
Even more Motor Tip Feedback
Original Tip: One fact related to electric motor operations is that rewound motors operate less efficiently than new motors.
Feedback: Only sometimes, if not done correctly, blanket statements are seldom all encompassing.
Original Tip: Worn motors can be “reconditioned”, that is reinsulated before any damage to the windings occurs
Feedback: Motors can be baked out, cleaned, revarnished, new lead wire installed.
Reinsulated implies much more.
Neil Gillespie
Electrical Engineer
July 18, 2008
Motor Tip Feedback
A recent article from the Reliabilityweb Maintenance Tips I received on July 17th, has gotten my blood boiling!
The author of the article made many statements in regards to motor maintenance, repair, rewinding and replacement that must be challenged, due to their blatant inaccuracy and falsehood!
In the article he states, quote (One fact related to electric motor operations is that rewound motors operate less efficiently than new motors.)Unquote. That statement is absolutely false! I direct your attention to the following publication from the Electrical Apparatus Service Association, Inc., EASA,
http://www.easa.com/indus/index.html
titled, “The Effect of Repair/Rewinding on Motor Efficiency”. I quote, (The 22 new motors studied were divided into four groups to accommodate the different test variables. The test results summarized below show no significant change in the efficiency of motors rewound using good practice repair procedures (within the range of accuracy of the IEEE 112B test method), and in several cases efficiency actually increased.) Unquote.
Later in the article the author states, quote (What they may be reluctant to admit is that rewound motors will operate less efficiently than new motors. Depending on who you talk to, estimates range from 50% to 90% efficiency for rewound motors versus new. Hence, it can be demonstrated that repaired motors will increase energy consumption.) Unquote. Once again, he is in error. I quote (The average efficiency change for each group also falls within the range of accuracy for the test method, (plus or minus 0.2%), showing that motors repaired/rewound following good practices maintained their original efficiency, and that in several instances efficiency actually improved.) unquote.
http://www.easa.com/indus/index.html
The author might want to do his homework before he submits another sales pitch disguised as an article. I would suggest the following, “A Guide to AC Motor Repair and Replacement”. He can find it here, http://www.easa.com/indus/index.html
Tip response provided by Stephen Powell
Service Manager
Turnupseed Electric Service, Inc.
Tulare CA
July 18, 2008
Editors Note
We published a tip in the July 17 issue that created a great deal of feedback. All of the feedback offered a 180 degree response to the original Motor Tip and attempt to correct what they state are mis-statements by the original tip author.
We accept responsibility for publishing the original tip from a new source who happened to be a supplier to this industry and we apologize for not vetting the information more carefully.
We appreciate all of those who emailed and we are sending Maintenance Tips hats and Stainless Steel. Diamond Plate Coffee Mugs as a small thank you. We hope the replies below go some distance to provide new information.
Respectful discussion is always encouraged throughout the Reliabilityweb.com network and we hope you can learn from our missteps. Additional comments are welcome.
Thank you for your patience and understanding.
Terry O
July 17, 2008
PdM-2008 Predictive Maintenance Technology Conference
PdM-2008
Predictive Maintenance Technology Conference
September 15-18, 2008
Qwest Center - Omaha Nebraska
Learn why best practice companies have a competitive edge because of machinery condition monitoring technologies like:
-Vibration Analysis
-Infrared Thermography
-Ultrasonic Detection
-Electric Motor Testing
-Oil Analysis
* 7 Preconference Certificate Workshops
* Over 45 Predictive Maintenance Case Studies for all levels including PdM beginner and PdM advanced
* Hand’s On Vibration Analysis Learning Lab
* PdM-2008 Expo with 70 Leading Predictive Maintenance Vendors
* 5 Post Conference Bonus Workshops included at no cost
* Association for Maintenance Professionals Breakthrough Benchmarking
* Co-located with LubricationWorld - 2 events - 1 price
* Meet Uptime Magazine’s PdM Program of the Year Winners for 2008
July 17, 2008
Motor Tip
A reader recently asked the question how could preventive maintenance be promoted to management on the basis of energy savings.
One fact related to electric motor operations is that rewound motors operate less efficiently than new motors.
By definition, a “burned out” motor has suffered from a mechanical failure. The winding insulation failed to contain the electric current - regardless of the cause (thermal breakdown, chemicals, vibration, voltage spikes, or moisture.)
Motor rewind shops will agree that seldom - if ever - is it feasible to rewind a motor more than once. This is due to the cumulative damage to the windings during failure.
Rewind shops will also admit that not all motors can be rewound, for the same reason. What they may be reluctant to admit is that rewound motors will operate less efficiently than new motors. Depending on who you talk to, estimates range from 50% to 90% efficiency for rewound motors versus new. Hence, it can be demonstrated that repaired motors will increase energy consumption.
This is avoidable by:
#1: Only replacing failed motors with new motors.
Or
#2: Monitoring motor condition and taking worn motors offline BEFORE they fail.
Worn motors can be “reconditioned”, that is reinsulated before any damage to the windings occurs. A reconditioned motor returns to like new efficiency and capacity.
In addition, the cost of reconditioning is usually less than half that of rewinding, and nearly 100% of worn motors can be reconditioned.
Of course, this is contingent on “catching” motors before they fail. What is required is lucky timing for a manual test or the use of automatic testing systems - like MEG-Alert.
So preventive maintenance CAN lead to lower operating costs, AND lower maintenance expenses, overall. Proactive maintenance will ALWAYS cost less than reactive, emergency repairs!
Reader tip by Randy Reek
MEG-Alert
Hot Springs Village Arkansas
Thanks Randy - your stainless steel, diamond plate, Reliabilityweb.com coffee mug is on the way
July 17, 2008
A Reliability Program Deserves a Reliability Roadmap
Many organizations have tried to implement a reliability program, but have failed to achieve the desired benefits. The lack of a reliability roadmap that integrates the elements of a reliability program is a main factor that leads to reliability program underperformance.
MRG has a proven approach to develop reliability a reliability roadmap
July 17, 2008
TPM Autonomous Maintenance Tip
Maintenance departments spent a lot of energy in designing their strategies to best maintain production equipment.
We often see that - in classic maintenance strategies - engineers and technicians only meet the equipment when it is already too late (breakdown) or when it is scheduled (PM/PdM).
A lot of breakdowns slip through our fingers because our classic approach is not sufficient to tackle all of them. If we take a closer look we will notice that the resistant amount of breakdowns is often due to “abnormal” conditions.
PM/PdM typically deals with “natural” predictable and accepted wear and not with “abnormal” wear. Abnormal wear can - for example - be caused by dirt contamination or wrong settings of the machine resulting in crashes and deformation of components, and in a later stage a breakdown. 80% percent of breakdowns are failures of mechanical components. Mechanical failures have a “life cycle”. Sometimes this is 5 minutes - sometimes it can take weeks or even months and years before a hidden cause of failure results in an actual breakdown.
Production operators spent the majority of their time on and around their equipment. While doing so they build up a sensory database and broaden their experience with their equipment’s behavior. They are best placed to detect abnormalities in a very early stage. Operators can thus be the eyes and ears for maintenance. You will be surprised how well they know their equipment and how valuable their input is.
Moving towards Maintenance Excellence is in the first place abandoning the statement “Production Makes Parts and Maintenance Makes Machines”
TPM/Autonomous Maintenance Programs enable your operators to participate in maintaining their equipment. Operators perform daily checks and cleaning tasks on their equipment and have regularly contact with maintenance technicians.
This will result in increased ownership, performance awareness and better relationship between maintenance and production. It is the only way to achieve “Zero Breakdowns”. There is only one goal for both of them: Overall Equipment Effectiveness (OEE).
Maintenance is often as seen as a department next to the production department – but – maintenance should be a part of the production department with shared objectives and common goals. The Voice Of The Customer comes in the first place. Always.
Reader tip provided by Chris Vanschooren
Supervisor Training and Team Implementation
Pfizer NV. Manufacturing
Puurs Antwerp
Belgium
Thanks Chris - your stainless steel, diamond plate, Reliabilityweb.com coffee mug is on the way!
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