Life Cycle Management of Motors and Generators - Are you · PDF file ·...

Life Cycle Management of Motorsand Generators

Deni JuharsyahService Representative for Motors & Generators

West Java & Sumatera RegionsDiscrete Motion & Automation Division

[email protected]: +6221 2559 5514Mobile: +6281 1155 0508

Tangerang - Indonesia

Global presenceGlobal service products, local service centers

Service Partner

Service Center

© ABB GroupJune 5, 2015 | Slide 4


ABB Machines Service in Indonesia

§ Part of global ABB Machines Service network

§ Established in 1987

§ Workshops located in Tangerang, Surabaya, Balikpapan;

§ Hazardous motor certification for workshops and engineers.

§ Certified by ISO 9000 series since 1996

§ Certified ISO 14001 and OSHAS 18001 (since Dec 2003);

§ Member of Electrical Apparatus & Service Association (EASA)


Testing facilities

Test bench with 350 kVAwith voltage 0–6600 volts,

ac/dc;

Surge comparison testup to 30 kV with

computerized software

RSO

Dynamometer for load test upto 300 hp.

Vibration analyzer andbalancer (VibXpert II)

High VoltageInsulation

Resistance

MACHsense LEAPEMPATH

Shaft align laseralignment

In order to achieve high quality service, ourworkshop has

Receptionat the plant

Mounting,alignment, andcommissioning

Motor operationat costumer

plant

TroubleshootingDiagnostic:- Technical- Economic

Dismounting

Transport

Overhaul &repair

Modernization

Spare parts

RotableManagement

Replacementof the M&G

M&G operationat customer

plant

PredictiveMaintenance

SystematicPreventive

Maintenance

ProactiveMaintenance

Life Cycle Management


Upgrade andModernization PeriodWarranty Period

Overhaul

PreventiveMaintenance

Aging + TEAM(Thermal, Electrical, Ambient, Mechanical) Repair

Optimized Maintenance Line

Time

Maintenance Period

Replacement & Recycle Period

Value tocustomerthroughmaintenance

Life Cycle Curve

ReactiveMaintenance

Continuous Maintenance & Spares Holding

Condition Monitoring

Asset Monitoring

Predictive

Proactive

Installation &Commissioning

Troubleshoot

Training for Skill Improvement

CaseStudy

Case Study – Preventive vs Predictive



2014 EASA Research - Method


2014 EASA Research – Maintenance Budget

75%respondents

have same orhigher budget in

past 3 years


2014 EASA Research – Maintenance Strategy

More than 55%respondentsexperienced

that PredictiveMaintenance

has lessbudget spend

and timedevoted

Cost Ilustration

PM

PdM

How if you havehundreds of

motor ?

Design Life Time : 25 years

Maintenance Type EventCost / Event (USD) Total Cost (USD)

10 HP 100 HP 300 HP 600 HP 10 HP 100 HP 300 HP 600 HP

Overhaul 8 280 1,100 3,500 9,300 2,240 8,800 28,000 74,400

Corrective Action 4 480 2,050 7,050 20,900 1,920 8,200 28,200 83,600

Total 4,160 17,000 56,200 158,000 235,360

ABB MachSense-P 50 250 250 250 250 12,500 12,500 12,500 12,500

Corrective Action 25 45 180 700 2,000 1,125 4,500 17,500 50,000

Total 13,625 17,000 30,000 62,500 123,125

How if youcalculate all

related cost ?The ice berg


Maintenance scheduling basedon actual condition requires

reliable condition monitoring anddiagnostic services

MaintenanceCondition based predictive maintenance

ABB LifeExpectancyAnalysis Program(ABB LEAP) –Offline• Assesses the condition ofthe stator windinginsulation in motors andgenerators >= 4 kV

ABB MACHsense P– Online Portable• Offers a comprehensiveanalysis ofelectromagnetic andmechanical faults inmotors like rotor windingdefects, installationproblems and bearingdefects

ABB MACHsense R- Online remoteservice• Continuously monitors keyparameters related to thecondition of the cage rotor,bearings of motors andgenerators, temperatureissues.

Benefitsfor

customers

OptimumTotal Cost

ofOwnership

Comfortin

knowingcondition

Minimizeunplanned

andplanned

downtime

Extendmotors andgenerators

lifetime

Reduceoperating

risks

Performedby trainedpersonnel

ABB Life Expectancy Analysis ProgramCondition and lifetime assessment ofstator winding

§ Customer presentation, Motors and Generators Service


ABB LEAP measurements

§ Can be applied on motors and generators from anymanufacturer

§ Time for data collection approximately 4 hours withmotor/generator stopped (off-line tests)

§ Not necessary to open covers/machine for data collection§ Only need access to the terminal boxes§ Non destructive tests

General information


ABB Life Expectancy Analysis Program (ABB LEAP)Levels

PremiumLarge synchronousmotor and generatorabove 710 frame size

AdvancedLarge synchronousmotor and generatorabove 710 framesize

StandardAll AC motors andgenerators

1. Condition assessmentand life expectancy with80% confidence

2. Machine stopped but notdismantled

3. During short stoppage(few days)

1. Condition assessmentand life expectancy with85% confidence

2. Machine stopped andpartially dismantled (endcovers removed)

3. During minor overhaul (1week stoppage)

1. Condition assessment andlife expectancy with 90%confidence

2. Machine stopped and fullydismantled (rotor removedfrom stator)

3. During major overhaul (3week stoppage)


ABB Life Expectancy Analysis Program (ABB LEAP)Tests carried out in each level

Test Standard Advanced PremiumPolarization Depolarization Current Analysis (PDCA) • • •

Tan Delta and Capacitance Analysis • • •

Non-Linear Insulation Behaviour Analysis • • •

Partial Discharge Analysis • • •

Visual inspection of end winding • •

Visual inspection of stator and rotor •

ELCID •

Endoscopic test •

RSO •

Natural frequency •

Wedge tightness •

FEM •


ABB Life Expectancy Analysis Program

Provides condition assessment of statorwinding§ Helps make short term maintenance

plan

Provides remaining lifetime of statorwinding§ Helps make long term maintenance

plan

Provides recommendation§ What maintenance needs to be done§ When maintenance needs to be done§ What winding areas to attend§ When to perform rewinding or buy new

stator

Reports

Reference List


ABB MACHsense-POnline condition monitoring ofcomplete shaft line


ABB MACHsense-P

§ ABB MACHsense-P is unique diagnostic tool to assess condition of:§ Motor§ Gearbox (if any)§ Load (pump, fan, compressor)

§ Portable equipment is used to take periodic measurements with equipmentin running condition

§ Service performed by ABB local service centers§ Main benefit

§ Enables correct maintenance at correct time§ Evaluates performance of motor in given environment§ Provides report with specific maintenance plans

Overview


ABB MACHsense-PMeasurements and deliverables

Electric motor

Measurements§ Current§ Voltage§ Vibration

Deliverables§ Rotor§ Bearings§ Installation§ Power quality

Measurements§ Vibration

Deliverables§ Gear wear§ Gear looseness§ Misalignment§ Tooth faults§ Shaft faults§ Bearings

Gearbox

Load (pump, fan, compressor)

Measurements§ Vibration

Deliverables§ Misalignment§ Looseness§ Bearings§ Cavitation§ Flow turbulence§ Blade faults


ABB MACHsense-P1. Motor analysis

Key functions Main benefits

§ Vibration and electrical data (current andvoltage) are analyzed by same software

§ Covers both mechanical and electricalproblems in motor

§ Uses specific motor related algorithms § Increases reliability of analysis(automated slip calculation, loadnormalization, etc.)

§ Uses multiple analysis tools(simultaneous measurement ofcurrent/voltage, torque analysis,vibration, etc.)

§ Helps specify source of fault

Vibration

Stator current

Stator voltage


ABB MACHsense-P2. Gearbox and load analysis

Key functions Main benefits

§ Time synchronous averaging of vibrationsignal

§ Provides exact determination of gearfaults such as tooth damage, gear wear,and others

§ Time synchronous averaging of vibrationsignal without additional RPMmeasuring hardware

§ No need to stop equipment to pastereflecting tape (for speed measurement)

§ Combining data from different sources § Helps combine signals from multiplesensors to determine probability of faultin each subsystem of drivetrain (motor –gearbox - load)

Vibration


Without a properinstallation and

commissioning noamount of maintenancewill achieve the desired

performance

Installation and Commissioning

Benefitsfor

customers

Carry outby skilledpersonnel

Safe andcontrolledstart-up

Clearlydefined

procedures

Standardreporting &parameters

Warrantyprotection

Reduction ininstallation andcommissioning

time

TEAM as aging effectThe majority of all rotor and stator failures are caused by combination of TEAM

Act alone or in combination leading to general weakening and ultimately failure

Thermal Electrical Ambient Mechanical

Operatingcondition such asoverload, etc

Starting conditionssuch as long start,stalking, repeatedstarts

Inadequatecooling, fouling ofcoolers of filters

Terminal voltage

Harmonics

Transient, voltagepeaks in network,switching surge

Phase unbalance

Contaminated air,dust, chemicals

Humidity

High temperature

Corrosion

Vibration due tomisalignment,unbalance, airgaps, installation

Repeated startscausing torsionaleffect and fatique


Investing in preventing offailure, rather than living with

its consequences, such as lossof production can make the

company manage to retain itslong-term competitiveness

MaintenanceTime based preventive maintenance

Benefitsfor

customers

Resourcescan be

deployedmore

effectivelyProvenconcept

with clearprogram:

L1-L4

Predefinedmaintenance

kits

Scheduledaccording to

plannedproduction

stops

Reduced oreliminated lossof production

andenvironmental /safety issues

Reduce theoverall cost

ofmaintenance

Warrantyprotection

Recommended Maintenance Program


The faster a faultcan be repaired, the

smaller theconsequences

On site and workshop repair

Benefitsfor

customers

ABB Branchoffice will

enabling of fastresponse ofCustomer

inquiry

Access totechnical

documentationfor ABB motorsand generators

Standardizedrepair with ISO& HazardousArea Certified

Supported byABB’s world

wide network &EASA

30 yearsexperiences

with high qualityof work

Range of repairdepending ofthe situation

and exactfinancial and

operation needs


Spare-parts

Benefitsfor

customers

Access tooriginal spare-

parts

Expert supportin part and

capital sparesidentification

Minimizeddown-time in

case of failure

Ensure motorand generator

availability

Single source /ABB Validatedsupplier (ISO

Standard)

On line system– Business

OnLine

Having spare parts atthe customer site mayreduce the downtime

significantly whensomething breaks


Replacement

• New standardmotors/generatorswith adaptations

• New standardmotor/generatorwith specificelectrical and/ormechanical design(e.g.: foot print)

• Upgrading orrebuilding of oldmotors/generators

When partsmight not be

availableanymore or

repaircannot bedone at

reasonablecosts,

replacementis the onlysolution

Benefitsfor

customers

Reductionin lifecyclecosts

Increase ofreliability,availabilityand safety

Selectionbased on

energycalculations

possible

Access tolatest

technology

Expertsupport in

selecting anddesigning

replacement

Access tooriginal ABBdrawing andspecification


Engineering and consulting

Advisory services from expertsfor life cycle management of

motors and generators

Energy efficiency and reliabilityappraisals show the savings thatcan be achieved by replacing an

existing product with a moreefficient and reliable unit

Transient mitigation servicescheck the susceptibility of your

network to transients which coulddamage the stator windings of

motors

Other solutions are available fordealing with specific problems

that may arise at the site.

Benefitsfor

customers

Maximizedavailability

andreliability

Extendedlifetime through

use of mostappropriate

maintenancepractices

Minimizedunplanneddowntime

Controlledrisks and

costsassociated

withmaintenance

Access tosolutionsbased on

patented andspecializedtechnology

Single sourcefor consultingservices and

implementationof solutions


Technical support and Emergency field serviceresources

• Fast andcompetent

• Escalation to worldleading experts

Technicalsupport through

world widenetwork of

service centers

• Selection ofguaranteed on-siteresponse time

Field engineersavailable on

call out

Benefitsfor

customers

Quickidentification

of the problem

Direct serviceactions to

prevent failureand minimize

consequences

To helpminimize yourdowntime andbring back on

line

Possibility tooptimize in

housemaintenance

staff.


Training

Benefitsfor

customers

Employeeconfidence and

motivation

Employeecompetence in

maintenance andfirst-line trouble

shooting

Createcompetent

employee toreduce risk of

down-time

Ability tointerpret alarmwarnings and

undertakeappropriate

actions to avoidfailures

Gives ability toCustomer tointeract with

expert technicalsupport

•Generalmotor andgeneratorawareness

•Maintenanceand service

Providedtrainings to

ABB’scustomersand end

users

•Low voltagerewinding

•ConditionMonitoring

Can betailored to

suitcustomers

needs


One or more servicescombined to achievebest possible solution

for each customer

Service contract – customized solutions

Benefitsfor

customers

Tailor madeservicesbased oncondition,

importance &needs

Cost-effectivedelivery

under onesingle

contract

Cut theadministration

process ofservice order

Fastresponseof delivery

servicerequest

Access toABB ServIs

formaintenanceplan & history

/ record

Full supportof technicalconsulting &engineering

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