MAP

* ** ** ** *
motor assessment process motor assessment process
a solution to life assessment of large motors
omsaiempl@gmail.com anilscoob@gmail.com
The deterioration of large motors is
normal, and this process begins as soon
as motor is installed.
If deterioration is not checked, it can
cause electrical failures and malfunctions. cause electrical failures and malfunctions.
In addition a TEAM of stresses
further contributes to the deterioration
process.
T TT Thermal hermal hermal hermal
E EE Electrical lectrical lectrical lectrical
Stress Stress Stress Stress
M MM Mechanical echanical echanical echanical A AA Ambient mbient mbient mbient
Stress Stress Stress Stress
The purpose of a good maintenance
program shall be
• to discover the potential reasons of
deterioration
• take remedial measures for correction
to avoid catastrophic failures.
The other important purpose of
maintenance program is to maximize
reliability and availability, improve
operational efficiency and productivity.
MAP
* ** *
is the answer is the answer
MAP
* ** *
proactive action and solution
to ensure availability and reliability of motors
improve operational efficiency and productivity
to ensure trouble free running of the plant
inspection and maintenance process
during the lifetime of a motor
planned during either operation or outage
linked to motor planned outage
ensuring minimum downtime of the plant
assessing the healthiness of the motor
MAP
1 11 1
MAP
2 22 2
MAP
*
MAP
4 44 4
MAP
3 33 3
MAP
*
MAP
1 11 1
MAP
2 22 2
MAP
* ** *
MAP
4 44 4
MAP
3 33 3
MAP
* ** *
MAP
1 11 1
concept
During operation of the motor
Data collection (+ online tests) Data collection (+ online tests)
After 8,000 hours of operation
Takes 1-2 days
MAP
1 11 1
deliverable
Thermal life by Arrhenius Equation
Thermal life by N-Y method Thermal life by N-Y method
Schedule for MAP
1 11 1
, MAP
2 22 2
& MAP
3 33 3
Optional on-line assessment
MAP
1 11 1
MAP
2 22 2
MAP
* ** *
MAP
4 44 4
MAP
3 33 3
MAP
* ** *
MAP
2 22 2
concept
During outage with cables removed
Offline inspection and testing Offline inspection and testing
After 16,000 hours of operation
Takes 2-3 days
MAP
2 22 2
deliverable
Condition assessment by diagnostic test
Residual life by D- and B-method Residual life by D- and B-method
May include MAP
1 11 1
deliverables
Schedule for MAP
3 33 3
, MAP
4 44 4
& MAP
1 11 1
MAP
1 11 1
MAP
2 22 2
MAP
* ** *
MAP
4 44 4
MAP
3 33 3
MAP
* ** *
MAP
3 33 3
concept
During outage with end-covers removed
Inspection to extent possible Inspection to extent possible
After 32,000 hours of operation
Takes 3-5 days
MAP
3 33 3
deliverable
Visual examination
Residual life by FEM method Residual life by FEM method
May include MAP
1 11 1
& MAP
2 22 2
Schedule for MAP
4 44 4
, MAP
1 11 1
& MAP
2 22 2
MAP
1 11 1
MAP
2 22 2
MAP
1 11 1
MAP
4 44 4
MAP
3 33 3
MAP
1 11 1
MAP
4 44 4
concept
During outage with rotor threaded out
Inspection and testing Inspection and testing
After 64,000 hours of operation
Takes 10-12 days
MAP
4 44 4
deliverable
Condition Index and Health Index
Residual life by FEM method Residual life by FEM method
May include May include MAP
1 11 1, ,
MAP
2 22 2
& & MAP
3 33 3
Schedule for Schedule for MAP
1 11 1
, , MAP
2 22 2
& & MAP
3 33 3
Concept
Life Cycle Concept
Continuous
Upgrading/
Replacement
Overhaul
Maintenance
Aging
Optimized Maintenance Line
Value to Customer
through Maintenance
}
Life Cycle Concept Life Cycle Concept
Upgrade and
Modernization Period
Warranty Period
Aging
Repair
Time
Maintenance Period
Replacement & Recycle Period
Customer Project Lifecycle
Concept
Confidence Level
Stress
calculated
Stress
calculated
from MAP
2
Strength
Calculated
from MAP
2
Strength
Calculated
from MAP
3
Stress
calculated
from MAP
1
Strength
Calculated
from MAP
1
Stress
calculated
from MAP
4
calculated
from MAP
3
Strength
Calculated
from MAP
4
S
t
r
e
n
g
t
h
/
s
t
r
e
s
s
Strength
uncertainty
S
t
r
e
n
g
t
h
/
s
t
r
e
s
s
Time
Stress
Concept
Stator Winding Failures
Failure statistics Failure statistics
37%
3%
5%
11%
Bearing
Winding
Detection during Normal Operation
37%
33%
5%
6%
3%
Winding
Rotor
Shaft/coupling
Brushes/slipring
External devices
Not specif ied
Failure statistics Failure statistics
7%
4%
10%
Bearing
Winding
Detection during maintenance or test
8%
2%
8%
61%
Rotor
Shaft/coupling
Brushes/slipring
External devices
Not specified
Failure Statistics Conclusion Failure Statistics Conclusion
• Bearings fail frequently
• Windings also share a significant failure rate
• Very few winding failures are detected • Very few winding failures are detected
in maintenance (8.3%) as against the
total failure of 33%in normal operation
• This indicates poor insulation problems
detection technique
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