Post on 06-Apr-2018
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8/3/2019 Motor Assessment Process
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MAP ********
a solution to life assessment of large motors
omsaiempl@gmail.comanilscoob@gmail.com
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The deterioration of large motors isnormal, and this process begins as soonas motor is installed.
If deterioration is not checked, it can
cause electrical failures and malfunctions.
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In addition a TEAM of stresses
further contributes to the deteriorationprocess.
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TTTThermalhermalhermalhermal EEEElectricallectricallectricallectrical
StressStressStressStress
MMMMechanicalechanicalechanicalechanical AAAAmbientmbientmbientmbient
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The purpose of a good maintenanceprogram shall be• to discover the potential reasons of
deterioration• take remedial measures for correctionto avoid catastrophic failures.
The other important purpose of maintenance program is to maximizereliability and availability, improveoperational efficiency and productivity.
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MAP****
is the answer
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MAP****
proactive action and solutionto ensure availability and reliability of motors
improve operational efficiency and productivityto ensure trouble free running of the plant
inspection and maintenance processduring the lifetime of a motorplanned during either operation or outage
linked to motor planned outageensuring minimum downtime of the plantassessing the healthiness of the motor
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MAP1111
MAP2222
*
MAP 4444 MAP 3333
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MAP1111
MAP2222
****
MAP 4444 MAP 3333
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MAP 1111 concept
During operation of the motor
Data collection + online tests
After 8,000 hours of operation
Takes 1-2 days
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MAP 1111 deliverable
Thermal life by Arrhenius Equation
Thermal life b N-Y method
Schedule for MAP 1111 , MAP 2222 & MAP 3333
Optional on-line assessment
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MAP1111
MAP2222
****
MAP 4444 MAP 3333
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MAP 2222 concept
During outage with cables removed
Offline ins ection and testin
After 16,000 hours of operation
Takes 2-3 days
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MAP 2222 deliverable
Condition assessment by diagnostic test
Residual life b D- and B-method
May include MAP 1111 deliverables
Schedule for MAP 3333 , MAP 4444 & MAP 1111
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MAP1111
MAP2222
****
MAP 4444 MAP 3333
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MAP 3333 concept
During outage with end-covers removed
Ins ection to extent ossible
After 32,000 hours of operation
Takes 3-5 days
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MAP 3333 deliverable
Visual examination
Residual life b FEM method
May include MAP 1111 & MAP 2222
Schedule for MAP 4444 , MAP 1111 & MAP 2222
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MAP1111
MAP2222
1111
MAP 4444 MAP 3333
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MAP 4444 concept
During outage with rotor threaded out
Ins ection and testin
After 64,000 hours of operation
Takes 10-12 days
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MAP 4444 deliverable
Condition Index and Health Index
Residual life b FEM method
May includeMay include MAP 1111 ,, MAP 2222 & & MAP 3333
Schedule forSchedule for MAP 1111 ,, MAP 2222 & & MAP 3333
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ConceptLife Cycle Concept
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ContinuousUpgrading/
Replacement
Overhaul
Maintenance
Optimized Maintenance LineValue to Customer through Maintenance
}
Life Cycle ConceptLife Cycle Concept
Upgrade andModernization PeriodWarranty Period
AgingRepair
Time
Maintenance Period
Replacement & Recycle Period
Customer Project Lifecycle
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ConceptConfidence Level
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Stress
Stresscalculatedfrom MAP 2
StrengthCalculatedfrom MAP 2
StrengthCalculatedfrom MAP 3
Stresscalculated
from MAP 1
StrengthCalculated
from MAP1
Stresscalculatedfrom MAP 4
from MAP3
StrengthCalculatedfrom MAP 4
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h / s t r e s s
Strength
uncertainty
S t r e n
g
Time
Stress
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ConceptStator Winding Failures
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Failure statisticsFailure statistics
37%3%5%
11%Bearing
Detection during Normal Operation
33%
5%
6%Rotor Shaft/coupling
Brushes/slipring
External devices
Not specified
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Failure statisticsFailure statistics
7%
4%10%
Bearing
Winding
Detection during maintenance or test
8%2%
8%
61%
Rotor
Shaft/coupling
Brushes/slipring
External devices
Not specified
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Failure Statistics ConclusionFailure Statistics Conclusion
• Bearings fail frequently
• Windings also share a significant failure rate
in maintenance (8.3%) as against thetotal failure of 33% in normal operation
• This indicates poor insulation problemsdetection technique
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THANK YOU
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