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Title of the Best Practice

(Knowledge Acquisition Point)

Best Practices

Electric Discharge Detector

Aditya Cement Works, Shambhupura

1 | KAP | Best Practices | Title of the Best Practice

 To get the best results the EDD measurement is used to compare motors in the same running conditions over time.  EDD counts were more in that particular motor where as it was very less in other similar motors.  Higher EDD counts and deviation from base readings are discussed with maintenance team and suitable remedial actions taken to prevent break downs. electrical discharge occurs. Process*  Like all condition monitoring equipment used for predictive maintenance. Abstract* Monitoring Electric Discharge count in motor bearings by EDD pen. Over time this can cause electrical erosion.  Fluting in the bearing race ways noticed and this initiated to check the EDD count in motor bearings. to identify the Electrical erosion in bearing of VFD operated motors.  For example if you measure 25 motors using the EDD Pen and motors # 1 to # 24 show a reading between 1100 and 2400 but motor # 25 shows a reading of 10000 this means that motor # 25 is more likely to suffer the effects of electrical discharge currents. 2 | KAP | Best Practices | Title of the Best Practice .  Mechanical causes like misalignment and lack of lubrications were not there in the equipment. induces electrical currents that may increase until they find discharge paths to earth via the motor frame.  If a motor shows a reading significantly different then it is more likely to suffer from electrical erosion than the other bearings.Title of the Best Practice Attribute Description Title Electric Discharge Detection (EDD) in motor bearings. Problem In electric motors that are controlled by Variable Frequency Drives definition* (VFD).  Every measurement is made at the same distance and direction from the bearing in periodic interval. Applicability* Across Businesses Business Impact / Reduction in breakdowns due to premature bearing failure in VFD Benefits * operated motors. Approach *  Premature bearing failure happened in clinker cooler fan 2 FN 354.  EDD count found reduced and premature bearing failure not occurred afterwards.  The present EDD counts are compared with the base line made with previous data. we are using the EDD Pen used in a consistent way. The electric currents pass through the bearing and when the voltage reaches a level to overcome the lubricant film layer in the bearing. this means that the results are compared while motor is running at same speed and loads. In this case the bearing of motor # 25 should be checked at the first opportunity.  Damaged bearings are studied carefully and brainstorming done to identify the root cause.  Remedial measures taken to reduce EDD count. Electrical erosion can cause bearings to fail very prematurely causing motor failure and unplanned downtime.

22.5 Lacs 3 | KAP | Best Practices | Title of the Best Practice . 5. 4. EDD count was measured in Feb 11 for 10sec(DE : 3538 & NDE : 4937) 3. Remedial measures taken in motor and EDD counts found reduced in March 11(DE : 54 & NDE : 0). Approximate production loss of one breakdown ( Unit 2 – Kiln) = 6 hrs stoppage of kiln to replace the motor = 2250 MT of clinker (Considering average kiln out put of 9000 TPD) = 2250 MT of clinker * Rs 1000(Approx) = Rs. The bearings found damaged and fluting noticed in bearing inner race. By that the motor bearing premature failure avoided. Premature bearing failure happened in cooler fan 2 FN 354 motor.Title of the Best Practice EDD Pen Case Study of cooler fan 2FN 354 1. 2. EDD measurement Fluting in bearing Since the fan is one of the critical equipment in Pyro section this avoided the breakdown of kiln by identifying the fault in advance.

Title of the Best Practice 4 | KAP | Best Practices | Title of the Best Practice .

Safe to use since no rotating components are comes across. 3.Aditya Cement Works. Manager – Technical Services. Aditya Cement Works About Author* J.* . Chittorgarh. Fluting in bearings Note . No special training required 4. Project and Condition Monitoring.j@adityabirla. Contact details* jayaseelan. Jayaseelan UltraTech Cements Ltd Unit . Having 21 years of experience in the fields of Manufacturing. Hand held instrument and take less time to check.Title of the Best Practice Other applicability Same can be used to motor operated through VFD Uniqueness 1. 30 seconds or indefinite KPI Reduction in breakdowns due to premature motor bearing failure. Reference Being used in UltraTech Cements Ltd. Capable of detecting electrical discharges on a time base of 10 seconds.Mandatory fields 5 | KAP | Best Practices | Title of the Best Practice . 2. Rajasthan Mobile : 09887482037 Key words Electric discharge detector.