18 EEE 308T ENERGY MANAGEMENT SYSTEM AND SCADA
UNIT 2
Session 1
Power Supply for and EMS for a motor driven system.
Effect of unbalanced voltages on the performance of a 3-phase IM.
Power Supply for and EMS for a motor driven system.
Ten “Key Elements” that are crucial to success of a motor driven energy management program
are:
1. Secure Top Management Commitment
2. Appoint an Energy Coordinator
3. Obtain Employee Cooperation
4. Conduct Energy Surveys
● For motor driven systems, ‘The Plan Electrical Distribution System’ must be
clearly known.
● Problems associated with over and under voltages, unbalanced voltages, trouble
shooting poor contacts, voltage drop survey and monitoring insulation leakage are
to be keenly monitored and cleared asap.
5. Organize Energy Data
● Taking Field Measurements
● Acquiring Motor Nameplate Data
● Load-Time Profiles
● Measuring Operating Values
● Safety Issues in Data Gathering
● Power Factor Measurements
● Purchasing Motor Testing Instruments
6. Analyze Survey Results
Motor Load and Efficiency Estimation Techniques
Input Power and Line Current Measurements
Varying Load Levels
Computerized Load and Efficiency Estimation Techniques
7. Set Conservation Goals
● Energy, Demand, and currency Savings Analysis
● Assessing Economic Feasibility
8. Develop an OrganizationWide Energy Management Plan
● Motor Improvement Planning
● Upon Failure Alternatives: Repair the Motor, Replace with a New Motor,
● Without an Existing Motor Failure: Leave the Present Situation As Is, Replace
Operating Motor with a New Energy-Efficient Motor
● Motor Resizing.
9. Implement Engineering Changes
10. Monitor and Evaluate Results
Effect of unbalanced voltages on the performance of a 3-phase IM.
Unbalanced voltages are assumed here as having dissimilar voltage levels.
This would affect the torque and speed of the motor, as unbalanced voltages would create
asymmetric(means that magnetic flux due to a section would not be equal to the other sections at
other instants of time, the peak flux would be different due to different voltages) rotating
magnetic field, thus affecting the rotation of the motor.
Some of the major effects of unbalanced supply are:
1.1 Heating due to negative seq currents.
1.2. Reduction of Torque , Torque pulsations
1.3. Shaft voltage which might lead to bearing failure
1.4. Vibration and noise
1.5 Reduced efficiency , pf
2. You can model:
2.1 The 6 coupled stator/ rotor equations and Torque equation directly
and solve using differential equation solver. Computationally costly.
2.2 . Use transformations e.g dq0 etc , more elegant and intuitive.
2.3 Model source (e.g Invertor ) either as ideal source with harmonics or
include switching modes in 2.1 or 2.2
Session 2
Glossary of frequently occurring motor terms
Design, load and torque of motor
Glossary of frequently occurring motor terms
[Link]
Design, load and torque of motor
Design: Already covered in machines course.
● Output equation
● Specific loadings
● Stator design
● Rotor (cage and slip-ring) design
● Bars and end rings design
● Enclosure design
● Performance design
● Efficiency calculations.
Load and Torque of Motor
● Need of various torques: Tdev, Tshaft, Tin, Tout and Tload.
● Load types: Various loads such as industrial load, inductive load etc., and the respective
performance analysis of motors.
Session 3
Power Factor of Motor
Benefits of Power Factor Corrections
PF of motors
Power factor is a measure of how effectively you are using electricity. Various types of
power are at work to provide us with electrical energy. Here is what each one is doing.
Working Power – the “true” or “real” power used in all electrical appliances to perform
the work of heating, lighting, motion, etc. We express this as kW or kilowatts. Common types of
resistive loads are electric heating and lighting.
An inductive load, like a motor, compressor or ballast, also requires Reactive Power to
generate and sustain a magnetic field in order to operate. We call this non-working power
kVAR’s, or kilovolt-amperes-reactive.
Every home and business has both resistive and inductive loads. The ratio between these
two types of loads becomes important as you add more inductive equipment. Working power and
reactive power make up Apparent Power, which is called kVA, kilovolt-amperes. We determine
apparent power using the formula, kVA2 = kV*A.
Going one step further, Power Factor (PF) is the ratio of working power to apparent
power, or the formula PF = kW / kVA. A high PF benefits both the customer and utility, while a
low PF indicates poor utilization of electrical power.
Here is an example.
A steel stamping operation runs at 100 kW (Working Power) and the Apparent Power
meter records 125 kVA. To find the PF, divide 100 kW by 125 kVA to yield a PF of 80%. This
means that only 80% of the incoming current does useful work and 20% is wasted through
heating up the conductors. Because Laurens Electric must supply both the kW and kVA needs of
all customers, the higher the PF is, the more efficient our distribution system becomes.
Improving the PF can maximize current-carrying capacity, improve voltage to equipment, reduce
power losses, and lower electric bills.
The simplest way to improve power factor is to add PF correction capacitors to the
electrical system. PF correction capacitors act as reactive current generators. They help offset the
non-working power used by inductive loads, thereby improving the power factor. The interaction
between PF capacitors and specialized equipment, such as variable speed drives, requires a well
designed system.
PF correction capacitors can switch on every day when the inductive equipment starts.
Switching a capacitor on can produce a very brief “over-voltage” condition. If a customer has
problems with variable speed drives turning themselves off due to “over-voltage” at roughly the
same time every day, investigate the switching control sequence. If a customer complains about
fuses blowing on some but not all, of their capacitors, check for harmonic currents.
Correction of power factor with capacitors
Description:
Power factor is the relationship (phase) of current and voltage in AC electrical
distribution systems. Under ideal conditions current and voltage are “in phase” and the power
factor is “100%.” If inductive loads (motors) are present, power factor less than 100% (typically
80 to 90% can occur).
Low power factor, electrically speaking, causes heavier current to flow in power
distribution lines in order to deliver a given number of kilowatts top an electrical load.
The Effects?
The power distribution system in the building, or between buildings, can be overloaded
by excess (useless) current.
Generating and power distribution systems owned by Laurens Electric have their capacity
measured in KVA (kilo amps).
KVA = VOLTS X AMPS X 1.73 (three phase System) / 1,000
With unity power factor (100%), it would take 2,000 KVA of generating and distribution network
capacity to deliver 2,000 KW. If the power factor dropped to 85%, however, 2, 353 KVA of
capacity would be needed. Thus we see that lower power factor has an averse effect on
generating and distribution capacity.
Low power factor overloads generating, distribution, and networks with excess KVA.
If you own a large building, you should consider correcting poor power factor for either or both
of these reasons:
● To reduce the possibility of additional power factor charges in event that Laurens Electric
starts billing for PF corrections and
● To restore the (KVA) capacity of overloaded feeders within the building or building
complex.
There are several methods of correcting lower power factor. Commonly used are:capacity.
Capacitor Banks
The most practical and economical power factor correction device is the capacitor. It
improves the power factor because the effects of capacitance are exactly opposite those of
inductance.
The var of KVAR rating of a capacitor shows how much reactive power the capacitor will
supply. Since this kind of reactive power cancels out the reactive power caused by inductance,
each kilovar of capacitance decreases the net reactive power demand by the same amount. A 15
KVAR capacitor, for example, will cancel out 15 KVA of inductive reactive power.
Capacitors can be installed at any point in the electrical system and will improve the
power factor between the point of application and the power source. However, the power factor
between the load and the capacitor will remain unchanged. Capacitors are usually added at each
piece of offending equipment, ahead of groups of motors (ahead of motor control centers or
distribution panels) or at main services.
Switched Capacitors
Plants equipped with very large, intermitted inductive loads, such as large motors,
compressors etc., may require switched capacitors; that is, capacitors are connected to individual
motors or groups of motors. Therefore, they are only in action when the motor load is turned on.
Or, capacity may be switched on and off at the substation, depending on measured power factor.
The switching feature is only required if the capacitors needed are so large that they cause an
undesirable leading power factor during times when large motors are turned off.
For more information, read the “Reducing Power Factor Cost” Fact sheet (pdf) published
by the U.S. Department of Energy. Note: Adobe Acrobat Reader is required to view and print pdf
files.
Benefits of Power Factor Corrections
There are numerous benefits to be gained through power factor correction. These benefits
range from reduced demand charges on your power system to increased load carrying
capabilities in your existing circuits and overall reduced power system loses. And the benefits of
power factor correction aren’t just limited to the balance sheet; there are also huge environmental
benefits associated with power factor correction, which means your company is reducing it’s
carbon footprint and helping the environment.
1. REDUCED DEMAND CHARGES
Most electric utility companies charge for maximum metered demand based on either the
highest registered demand in kilowatts (KW meter), or a percentage of the highest registered
demand in KVA (KVA meter), whichever is greater. If the power factor is low, the percentage of
the measured KVA will be significantly greater than the KW demand. Improving the power
factor through power factor correction will therefore lower the demand charge, helping to reduce
your electricity bill.
2. INCREASED LOAD CARRYING CAPABILITIES IN EXISTING CIRCUITS
Loads drawing reactive power also demand reactive current. Installing power factor
correction capacitors at the end of existing circuits near the inductive loads reduces the current
carried by each circuit. The reduction in current flow resulting from improved power factor may
allow the circuit to carry new loads, saving the cost of upgrading the distribution network when
extra capacity is required for additional machinery or equipment, saving your company
thousands of dollars in unnecessary upgrade costs. In addition, the reduced current flow reduces
resistive losses in the circuit.
3. IMPROVED VOLTAGE
A lower power factor causes a higher current flow for a given load. As the line current
increases, the voltage drop in the conductor increases, which may result in a lower voltage at the
equipment. With an improved power factor, the voltage drop in the conductor is reduced,
improving the voltage at the equipment.
4. REDUCED POWER SYSTEM LOSSES
Although the financial return from conductor loss reduction alone is seldom sufficient to
justify the installation of capacitors, it is sometimes an attractive additional benefit; especially in
older plants with long feeders or in field pumping operations. System conductor losses are
proportional to the current squared and, since the current is reduced in direct proportion to the
power factor improvement, the losses are inversely proportional to the square of the power
factor.
5. REDUCED CARBON FOOTPRINT
By reducing your power system’s demand charge through power factor correction, your
company is putting less strain on the electricity grid, therefore reducing its carbon footprint. Over
time, this lowered demand on the electricity grid can account for hundreds of tons of reduced
carbon production, all thanks to the improvement of your power system’s electrical efficiency via
power factor correction.
Session 4
Electric Motor Design at varying loads
Determining electric motor operating loads
Electric Motor Design at varying loads
Saving money with energy efficient motors
It is very important that you consider the type of load that is being put on each electric
motor, as this can affect the opportunity for energy saving.
The three main electric motor load types are:
● Variable-torque loads - eg fans and pumps where the speed varies. With this type of
load, reducing the speed of the motor by even a small amount can save a lot of energy.
● Constant-torque loads - eg conveyors, screw and reciprocating compressors, and
crushers. With these loads, the amount of power consumed is in direct proportion to the
useful work done. So halving the speed will halve the energy consumed.
● Constant-power loads - eg machine tools and centre winders. With these loads, the
power is constant so there will rarely be energy savings when the speed is reduced.
Using a variable-speed drive (VSD)
For variable torque loads in particular, using a VSD in conjunction with a suitable motor
allows you to get a better match between the speed of the motor, the speed of the machine it is
driving, and the requirements of the process. A VSD converts the incoming electrical supply
from a fixed frequency to a variable frequency output. This frequency variation allows the VSD
to control the speed of the motor.
You can achieve significant energy and cost savings by using a VSD in certain
applications, particularly those that use variable torque such as fans and pumps. For example,
you could save up to 50 per cent of the energy used by a fan or pump if you reduce the speed by
20 per cent.
Discussion
How is sizing of electric motors done for a motor running at variable load to achieve
maximum efficiency?
Motors frequently need to be operated under varying load conditions due to process
requirements. Mostly a motor is selected based on the highest anticipated load. But the
highest load can occur only for a short period of time. Instead a motor can be selected with a
rating slightly lower than the peak anticipated load which can operate at overload for a short
period of time. Example: For a particular load cycle, the average load is around 69kW with
peak load(180kW) occurring for a few seconds. For this load cycle, it won't be cost efficient if
we select a motor with rated power around 180kW.
Session 5
Power Meter to Measure Unit Operation
Selection of Equipment for Power Measurement and Surveys
Power Meter to Measure Unit Operation
What is a Power Meter?
A Power Meter is one of the most useful and simple instruments to measure electrical
power when no deeper analysis of the measured data is required. It measures the voltage (V) and
current (A) and derives from these the most important power results. Power meters are perfect
for technicians and engineers performing simple tasks like stand-by power measurements.
The most important features are fast, accurate and easy power measurements as well as simple
operation on an instrument alike base unit.
Typical Applications for a Power Meter
A power meter is easy to use, accurate and is the preferred instrument for cost
effective power measurement solutions for a wide range of applications, such as: Production line
testing of electric devices, evaluation of large current equipment, battery or DC driven device
evaluation, quality assurance, efficiency measurement for industrial motors, rotating machinery
and calibration labs, for installation and maintenance tasks and partly for R&D. It is also used to
measure GRID power.
The Working Principles of a Power Meter
Power meters are typically equipped with 1, 3 or 6 measurement channels. They can
measure all parameters in alternating current (AC) or direct current (DC) systems like apparent
power, active and reactive power, Current, Voltage, Frequency, Power factor, Apparent energy,
active and reactive energy.
Conventional power meters are push button style instruments, being the same for
decades. Whereas state of the art power meters are equipped with modern and intuitive user
interfaces. Even more advanced systems can be connected via web app to a laptop or smart
phone. This simplifies the operation and even remote monitoring is possible over any distance.
Electronic power meters allow numerous functions such as multi-rate tariffs, remote
reading, load switching, and energy management thanks to time-of-use registration, etc. These
new meters contain a mains-powered memory where power consumption data is stored. Of
course, a power outage can lead to loss of information, but the presence of primary Li cells for
memory backup avoids this inconvenience. In this case, the pulse currents do not exceed few
mAs.
Selection of Equipment for Power Measurement
Choosing the right power meter involves considering many factors. Whether it is for
tenant submetering, submetering a commercial building, power monitoring for energy
management, or another application, a power meter should meet certain specifications. Although
each individual application will have its own requirements, there are several common factors to
evaluate. When exploring options for a power meter, it is important to know the:
● Application
● Mounting Requirements
● Type of Current Transformers
● Communication Setup
● Field Configuration
● Total Install Cost
This is not a comprehensive list of specs for selecting a power meter for your
application.
Power quality is assessed based on a number of power quality parameters. Today’s
instruments usually handle the most common parameters such as voltage, current, power,
harmonics, voltage dips, flicker and transients. Often it is difficult to say in advance what type of
disturbance gives rise to a fault condition. The more different types of disturbances an instrument
handles, the more likely it is that one can identify the disturbance, or alternatively to exclude
certain types of disturbances.
Session 6
Slip Measurement of Motor
Amperage Readings
Slip Measurement of Motor
What is a slip?
Slip % or slip is the name given for the ratio of rotor speed and synchronous speed (stator
rotating magnetic field). It is expressed in percentage (%).
Slip % = n slip / n sync * 100
nslip = Slip speed
nsynch = stator speed (synchronous speed), that is (Ns)
So measuring slip is nothing but measuring the relative motion of the motor.
*Rotor speed (Nr) - rotatory speed of the motor.
What is a slip speed (n slip)?
Slip speed is nothing but differentiation between synchronous speed (stator speed) and rotor
speed nr.
nslip =nsync - nrotor
nslip = Slip speed (Nslip)
nsyn = stator speed, Ns, called as (synchronous speed
nr= rotor speed, (Nr)
Slip measurement method
There are three common methods used by engineers and electricians for measuring the slip of the
motors.
1. Tachometer method.
2. Galvanometer method.
3. Stroboscopic method.
Concept of tachometer method
We have already seen, that slip is the differentiation value between rotor speed and stator speed
(synchronous speed).
The device tachometer helps us to find the Rotor speed (Nr) which is the rotatory speed of the
motor.
The formula Ns=120 f / P helps us to identify synchronous speed (Ns).
So Slip = (NS – Nr) / Ns.
Concept of galvanometer method
A galvanometer is a measuring device connected suitably to the circuit to measure the
magnitude and direction of the current. Slip measurement with a galvanometer is very simple.
Slip can be measured by following some of the constant rules.
Consider an electrical motor, for instance, an induction motor. Now follow these steps to
measure slip.
Steps to measure rotor frequency & stator frequency
1. Connect the Null type Galvanometer to the brushes of the induction motor,
2. Due to relative speed, some EMF is induced across the shaft of the induction motor.
3. This induced EMF is applied to the galvanometer through brushes.
4. Count the galvanometer vibration cycles (Movement of a needle) for one second time.
5. This count gives the value of Rotor EMF frequency fr and Since fs is generally known,
∵ fr= S*fs
fr = Rotor Frequency (obtained by galvanometer)
f = Supply Frequency (Mentioned in the nameplate detail)
After taking these two reading, we need to substitute these values in the formula
S= fr/f
Concept of Stroboscopic method.
Using the Stroboscope.
Amperage Readings
Amperage Readings (Amps) are the measurement of amperes (the strength of an
electrical current) flowing in the circuit. Without trying to get too far down the rabbit hole of
visualizations, imagine that current would be the amount of ft. lbs of torque that your impact
wrench is needing to putout to break a bolt free from its current position. If it takes all 1800 lbs
of nut busting torque to set that bolt free, the amps are the foot lbs in this example (1800), if it
only took 400 ft. lbs, then those 400 are the amps, it just took less amps or ft lbs (in this example)
to get that bolt moving…. Amps are the driving force behind the electrical value known as
Volts… in the case of an electric motor, amps are the “pushing force” that are needed to turn that
electric motor… initially pushing a completely stopped motor will take more amps (known as
inrush), then eventually once those amps get that motor spinning there are less required to keep it
moving so that value is known as (operating amperage).
Every electrical component on a vehicle has a known good voltage and operating
spectrum for inrush and operation. Being able to see the amps value on a standard meter is great
(especially with min and max functionalities enabled), but being able to see the rise and drop as
well as the live status of the amperage flow of a circuit or component gives you a true and literal
picture of its operating health and status. Amperage measurements are also key to understanding
battery drain and finding drivability issues. By utilizing the N2 with an amp clamp at the battery
terminal it is possible to watch and dive into a whole deeper level of the use of amperes as the
vehicle is in operation. Amperage testing is essential, just like you are in all automotive testing
today, especially when visually displayed in such a way the allows for the analysis of inrush,
operational values and time to create the ability to see the true health of a circuit and or
component.
Session 7
Amperage readings of electric Motor
Electric Motor Efficiency
Amperage readings of electric Motor
An AC motor uses alternating current to power it, and AC current changes directional
flow 50 times a second. Three electrical windings on the outer part of the motor enable the
central rotor to turn, otherwise they would simply vibrate moving backwards and forwards as the
current alters direction. The amount of energy drawn to drive the motor is measured in amperes
and is known as current. The greater the amperes the motor requires, the more powerful the
motor. Don't confuse amperes and voltage, or assume that low voltage means low amperes.
Step 1
Read the amperage draw your AC motor requires, if it's operating according to the
manufacturer's specification. The amperes are on the label on the AC motor.
Step 2
Set your multimeter to measure amperes. Set it to the correct ampere range for the AC motor
you're checking. For example, if the motor draws 20 amperes, set your multimeter to read
between 10 and 30 amperes.
Step 3
Put on rubber gloves to protect you from an accidental electric shock. Run your AC motor,
otherwise you can't check the amperage draw.
Step 4
Locate the terminals on the AC motor. The positive terminal is labeled "+" and the negative "-."
The wires connected to the AC motor are colored red for positive and black for negative.
Step 5
Place the metal sensor on the end of the black wire from the multimeter onto the negative
terminal of the AC motor, keeping your hands clear of all moving parts. Place the metal sensor
on the end of the red wire from the multimeter onto the positive terminal of the multimeter.
Read the multimeter display and then immediately remove the sensors from the AC
motor. Turn off the motor. If the ampere reading is within the range you set on your multimeter,
the AC motor is drawing the correct amperage. If it's below the range, get your motor checked as
it may require maintenance such as new brushes. The amperes won't exceed the top figure in the
range as the motor is unable to draw more amperage than set by the manufacturer.
Electric Motor Efficiency
Self Study
Session 8
Comparing motors based on efficiency
Sensitivity of load to motor RPM
Comparing motors based on efficiency
Motor efficiency is the ratio of the mechanical power output to the electrical power input,
usually expressed as a percentage. Energy-efficient motors use less energy than standard motors
to perform the same amount of work. Improved energy efficiency in electric motors has been
achieved through various design improvements:
20% to 60% more copper in windings∙
35% more electrical steel in the cores∙
Thinner lamination∙ Higher quality electrical steel∙
More efficient rotor bar design∙
Reduced windage, friction, and stray load losses∙
Reduced resistance (I2R) losses through a longer core∙
Optimized air gap between the rotor and stator∙
Closer machining tolerances ∙
Efficiency Classes of Motors In the European Union, industrial the electric motors used
in the industrial field typically consume 60% to 70% of the total absorbed electrical energy. In
the commercial sector, this percentage is up to 35%. For these reasons, laws or protocols, such as
the EPAC in the U.S. and the European Union and the CEMEP committee agreement in Europe,
have been promulgated to define the efficiency classes of motors. The European CEMEP
protocol defines the following efficiency classes of industrial IMs:
• Eff1 class: High efficiency motors
• Eff2 class: Energy efficiency motors
• Eff3 class: Standard efficiency motors (those currently in production).
These standards also play an important role in induction motor classification according to
efficiency levels. In the European Union and the U.S laws have been set to define the efficiency
class of induction motors. Table below shows the requirement limits for the efficiency.
These limits are determined through testing according to a particular standard (IEC in this
case). Previously in Europe, low voltage three-phase motors have been graded and marketed in
three efficiency classes – EFF3, EFF2 and EFF1 – based on a voluntary agreement between
motor manufacturers and the European Commission. Unfortunately, other countries have also
developed their own national systems, which are very different from the European system. That
was the reason for the European motor manufacturers to develop an energy efficiency standard
for the International Electrotechnical Commission (IEC).
The new international standard defines efficiency classes IE1, IE2 and IE3 for
three-phase motors. The efficiency classes for induction motors according to the new
classification are shown in the below Table.
Sensitivity of load to motor RPM
Torque is the turning force through a radius - with the units Nm in the SI-system and the
units lb ft in the imperial system. Torque is the measure of load in induction motors.
The torque developed by an asynchronous induction motor varies when the motor
accelerates from zero to maximum operating speed.
Locked Rotor or Starting Torque
The Locked Rotor Torque or Starting Torque is the torque an electrical motor develops
when starting at zero speed.
A high Starting Torque is more important for application or machines hard to start - like
positive displacement pumps, cranes etc. A lower Starting Torque can be accepted for centrifugal
fans or pumps where the start load is low or close to zero.
Pull-up Torque
The Pull-up Torque is the minimum torque developed by an electrical motor when it
runs from zero to full-load speed (before it reaches the break-down torque point).
When a motor starts and begins to accelerate the torque in general will decrease until it
reach a low point at a certain speed - the pull-up torque - before the torque increases until it reach
the highest torque at a higher speed - the break-down torque - point.
The pull-up torque may be critical for applications that needs power to go through some
temporary barriers achieving working conditions.
Break-down Torque
The Break-down Torque is the highest torque available before the torque decreases
when the machine continues to accelerate to working conditions.
Full-load (Rated) Torque or Braking Torque
The Full-load Torque is the torque required to produce the rated power of an electrical
motor at full-load speed.
Accelerating Torque
Accelerating Torque = Available Motor Torque - Load Torque
Torque Speed Characteristic is the curve plotted between the torque and the speed of the
induction motor. We have already discussed the torque of the induction motor in the
topic Torque Equation of an Induction motor. The equation of the torque is given as shown
below:
At the maximum torque, the speed of the rotor is expressed by the equation shown
below:
The curve below shows the Torque Speed Characteristic:
The maximum torque is independent of the rotor resistance. But the exact location of the
maximum torque Ʈmax is dependent on it. The greater, the value of the R2, the greater is the value
of the slip at which maximum torque occurs. As the rotor resistance increases, the pullout speed
of the motor decreases. In this condition, the maximum torque remains constant.
Session 9
Motor Performance Management Process (MPMP)
How to start MPMP?
Motor Performance Management Process (MPMP)
Electrical motor management is often associated with motor maintenance, but involves
much more. It concerns multiple electrical, mechanical and maintenance challenges for
end-users, designers and equipment manufacturers. Associating extensive offer portfolio,
competencies and know-how, MPMP helps for a sustainable motor integration in the electrical
system and the industrial process.
A motor performance management package is a system in which appropriate tools are
used to improve motor reliability, reduce cost of repair and replacement, manage spares
inventory and ensure appropriate preventative and predictive maintenances are carried out.
In other words, MPM is a total focus on motors.
The MPM program makes the motors visible. The preventative and predictive tasks are
monitored to detect developing problems. In many facilities, the vibration data is collected and
never analyzed because of staff reductions, loss of knowledge and its low priority until
something fails. The MPM program must look at the data and find the motors that are in distress.
The problems must be documented to establish credibility so operations is given a real reason to
get a planned replacement into service with minimal production disruption.
What goes into an MPM program?
A number of standard procedures conducted regularly cause a steady improvement in
performance and overall equipment efficiency:
● Improving repair specifications to give high quality with minimum cost;
● Precision aligning motors upon installation;
● Reducing wear and tear through preventive maintenance;
● Using predictive measurement data to replace critical motors on planned schedule before they
cause downtime;
● Doing root cause analysis on critical motors that fail and feedback the results to reduce future
failures.
The key word in MPM is "management," but an equally important word is "focus." The
MPM team is concerned just with the motors and checks everything on a regular basis without
distractions.
An MPM program uses a small, dedicated team of expert engineers and technicians
focused only on motors to achieve the following goals:
● Extend motor life (environment, lubrication, loading);
● Predict failure in time to schedule required actions (vibration, infrared and ultrasonic emission
testing, data management, etc.);
● Replace motors with ones that are correctly sized, suitable for the operating conditions and
correctly installed (alignment, grounding and safety, etc.);
● Reduce the costs of repairs by actively working with repair shops to ensure quality,
specifications, scope of work and pricing are optimized.
A solid set of tools to cover oil analysis, machine alignment, vibration analysis, thermography,
electrical signature analysis and ultrasonic emissions is crucial, as is the experience to use them.
How to start MPMP?
The MPMP mainly focuses on:
● Expert services for motor applications
● Advanced motor control
● Motor protection and control
● Power quality