Embed Size (px)
Citation preview
Copyright ALPS 2013
Condition Monitoring & Reporting for Onsite Support
ALPS MSI
Copyright ALPS 2013
What’s the impact of machinery vibrations to your Business Operation?
• How much it cost your company for a major breakdown?
• As vibration increases, motor load (average amps) also increases. Refer to formula below.
• How much power wastage you spent in your electricity bill/month?
• According to International Energy Consultants as cited in Joint Foreign Chambers (2010) Philippines is the 2nd highest in terms of electricity prices among Asian countries.
Copyright ALPS 2013Copyright ALPS 2013
Can these be prevented?
Damaged input bevel gear teeth of Cooling Tower Damaged electric induction motor
Yes, it can be prevented?
Copyright ALPS 2013Copyright ALPS 2013
Our ApproachECG for Doctors Vibration Analysis for Engineer
Machinetalks
ECG is used to diagnose heart problems while Vibration analysis is for rotating machine and structural problems.
Copyright ALPS 2013
Who are we?
ALPS MSI was established in 1996. Specialized in: • Advanced diagnostic maintenance/vibration
analysis/energy audit of electric motors & its drive systems;
• Laser alignment; • Power savings through computerized motor rewinding,
balance supply voltage, etc; • System improvements through precision maintenance of
motors, pumps, blowers/fans, & gearboxes. Distributor of Elos Fixturlaser AB products based in Sweden.
Copyright ALPS 2013
Company and Individual Certifications:
• Professional Electrical Engineer, Registered Mechanical Engineer and Registered Electrical Engineer
• Vibration Institute Category II Vibration Specialist• Certificate of Attendance Vibration Institute Category III
Vibration Specialist.• Certified Condition Monitoring Engineer Level I and II by
FIS, Germany.• Member, Electrical Apparatus Service Association of USA• Certified Laser Alignment Specialist, Fixturlaser AB
Sweden• Airborne Ultrasound Specialist Level I• Highly skilled rewinders and journeymen (mechanical &
electrical)
Copyright ALPS 2013
Key Success Factors
• Effective implementation of condition monitoring program;
• Quality workmanship and control in the repair of equipment;
• Implementation of lubrication program; and
• “Design out” ongoing reliability problems.
Copyright ALPS 2013
Major Assets
Fixturlaser XA Alignment System Computerize Motor Rewinding
01dB Vibration Analyzer Motor Circuit Analyzer (Offline) Balancing Instrument
• Facility Area: 560 sq. m.• Lifting equipment: 5 Tons• 3-Tonner Boom Truck• 500HP Temperature controlled electric oven• 150HP Temperature controlled electric oven• Safe chemical treatment for removing burnt winding and paints.• Professional bearing tools• 50-tonner hydraulic puller
Copyright ALPS 2013
Key Services ProvidedCondition Monitoring
Helps identify the root cause and health condition of motor and it’s drive system prior to breakdown.
This saves you money as we all know that emergency breakdown is expensive.
Copyright ALPS 2013
Condition Monitoring
Program Design, Commissioning, Training, and Remote SupportMonitoring route is set-up after Client had provided list of equipment
and classify its criticality.Conduct commissioning for newly installed or repaired equipment as
part of the quality control program.Conduct training on vibration analysis, alignment, bearing
maintenance, and motor maintenance.Remote support for in-depth vibration analysis.
Program Audit, Benchmarking, and OptimizationQuarterly audit of the program in terms of equipment health status,
benchmarking, and optimization.How to optimize the program? Example, if equipment health is
stable in that monitoring route, the program maybe channel to other productive monitoring.
Vibration Monitoring, Infrared Thermography (Optional), Motor Circuit Analysis (yearly)
A minimum of two(2) years contract.
Copyright ALPS 2013
Scope of Works
• Onsite support of two vibration technicians for plant vibration measurement and monitoring
• Yearly monitoring of Motor Condition using SAMATIC 6000R to reduce if not prevent motor breakdown
• Monitor results; route adherence, asset health, & other key metrics• Provide regular data review & interpretation onsite or remote• Provide regular reporting & communication• Identify and coordinate additional resources for troubleshooting,
fault diagnostic, & reliability improvement initiatives• Provide additional hands-on support for data acquisition and fault
diagnostics, when required.• Engineering Manager or VP Operations to attend bi-monthly
meeting on-site for two days per meeting (if client required).Note:• Client preferred Scope of Works is also considered.
Copyright ALPS 2013
Case 1: San Miguel Yamamura Asia Corp
Unbalance
Overall amplitude after correction
Copyright ALPS 2013
Client Inputs
• Total list of equipment to be enrolled for condition monitoring and classify its criticality to your operation. ALPS MSI will establish the condition
monitoring route, how much manhours needed, and proper costing.
• Motor inventory and its specification. This will help us establish
preventive/corrective maintenance pricing on per call basis.
Copyright ALPS 2013
Benefits
• Minimized if not eliminate emergency breakdown & overtime increase production time;
• Just-in-time (JIT) delivery of spare parts & materials needed for the repair reduce inventory.
• Safety of equipment and personnel eliminate catastrophic failure.
Copyright ALPS 2013
Key Services Provided
Advanced Vibration Diagnostics & Vibration Control
“Design out” ongoing reliability problems.
Copyright ALPS 2013
Case 2: Liquigaz Pump 3A Before: SAT 23/07/2011 11:04:51
Vibration Problem:Unbalance
Copyright ALPS 2013
Case 2: Liquigaz Pump 3AAfter: SAT 22/09/2012 09:22:54
A reduction of unbalance from 5.38 to 1.76 mm/s RMS
Copyright ALPS 2013
Motor Condition Before
Motor Circuit Analysis
Grease contamination
Effect of grease contamination
Copyright ALPS 2013
Motor Condition After
Excellent results after recondition of motor
Copyright ALPS 2013
Benefits
The Benefits:•Increase equipment reliability & uptime•Reduce power losses electricity consumption•Peace of mind
Copyright ALPS 2013
Benefits ofReducing Motor Load
Copyright ALPS 2013
Case 3: Water Utility
Electricity Consumption = (kW/motor efficiency) x rate x operating hours x motor load%Whereas, motor load% = (Ave. current x ave. supply voltage) x 100% (nameplate full-load current x voltage)The actual motor load % = (425 x 445)/440 x 460) x 100% = 93.44% a reduction of motor efficiency by 2%Electricity consumption@ 93.44% load = Php 16,310,289Power wastage (Php) = Elect. consumption@ 75%-Elect. consumption @ 93.44% = (Php 3,496,003)
Motor Efficiency: 94.5% @ 75% load.Electricity rate = Php 11.5/kwhOperating hours = 4680Calculated electricity consumption is, Php 12,814,286 per annum
Copyright ALPS 2013
Factors that influence Motor Load %
Vibration analysis and laser alignment had identified factors that influence motor load,%:MisalignmentVibrationsBearing problemsSupply voltage
Copyright ALPS 2013
Existing Maintenance Practices
• When vibration is felt at the control room, pump is inspected on the following:
a. Impeller condition
b. Bearing condition
c. Any unusual observation in the pump.
• Straight-edge and one dial indicator are used to align motor – pump shafts.
• Untimely re-greasing of bearings
Copyright ALPS 2013
Why Motor Load Increased?
• Definitely, it’s difficult to establish without using high technology instruments or tools, and the experience on motor maintenance.
• What are the instrument they invested?
a) Vibration analyzer:01dB Movipack
b) Laser alignmentFixturlaser Shaft 50
Copyright ALPS 2013
Impact of misalignment
Misalignment & Unbalance IncreasesPower Consumption
Copyright ALPS 2013
Key Services ProvidedComputerize Motor Rewinding
Motor power losses is included in your electricity bill & unknowingly you spent more
money for your operating cost than the rewinding price we offered
Copyright ALPS 2013
Motor Power Losses
• What’s the impact of increase motor power losses to your electricity bill?Power loss is an energy waste consumed by
a motor and included in your electricity bill;Increase your operating cost; andReduce motor reliability and uptime.
Copyright ALPS 2013
• Prior a motor got burnt, power exceeds its rated capacity (kW/HP);
• In the process of coil forming, turns/coil and coil span definitely altered resulting to increase motor power losses.
• Said power losses is included in your electricity bill & unknowingly you spent more money to your operating cost than pay the rewinding price we offered.
How it affects your electricity bill?
This motor rewound by other vendor & was burned in less than a year.Client: Petrol Refinery
POOR INTERLAMINARINSULATION
Copyright ALPS 2013
Motor Power Losses are caused by:
• 40%: Stator Winding Loss Turns/coil, Coil span; Cross-over of wires; and Poor quality of rewinding
materials. Such as magnet wires & insulation materials.
• 20%: Rotor Loss Damage rotor, bearing quality,
improper bearing installation, or rotor unbalance.
• 20%: Stator Core Loss Poor workmanship, and Quality of interlaminar
insulation.• 20%: Stray Load Loss
Misalignment and Poor motor ventilation
Copyright ALPS 2013
• Unequal turn/coil affects “circular mil/amperage” resulting to increase power losses.
CMA – Circular mil/AmperageAGD – Air Gap Density
Turns/coil affects CMA
Copyright ALPS 2013
Inappropriate coil span and/or cross-over of wires leads to power
losses.
Copyright ALPS 2013
Why Computerized Motor Rewinding
• ALPS MSI is the only rewinding shops in the Philippines that utilize computerize motor rewinding machine. Redesign/Restore AC Motor
Winding Data Repair of AC/DC Motors,
Replacement/Restore Defective Components
Motor Rewinding using Computerized Motor Rewinding Machine
• Benefits Automatic Wire Guidance in a
manner that assures perfect layer winding, Guaranteed no crossovers;
Automatic Wire Tensioning; and Ease of Coil insertion into slots
due to zero crossovers, a major time savings with consistent high quality of coils.
Warranty:a) One year if you align the motorb) Two years if we align the motor
Copyright ALPS 2013
Coil Span Preparation
SAMATIC Adjustable Concentric Wizard JigCoil span is adjusted based on stator diameter and total number of slots.
Copyright ALPS 2013
Workmanship Comparison
Competitor DE- Motor burned in less than one year due to cross-over & insufficient phase-to-phase insulation.
ALPS MSI pulled out the said motor from Competitor – DE as per instruction by client and rewind it.
POOR INTERLAMINARINSULATION
Copyright ALPS 2013
Key Services Provided
Predictive & Preventive Maintenance, Repair & Maintenance
This is a complete package where you outsource your maintenance to us while you focus on your own core business
– Producing A Product.
Copyright ALPS 2013
Key Success Factors
• Effective implementation of condition monitoring program;
• Quality workmanship and control in the repair of equipment;
• Implementation of lubrication program; and
• “Design out” ongoing reliability problems.
Copyright ALPS 2013
Predictive & Preventive Maintenance, Repair & Maintenance
Two years minimum maintenance contract with the following Scope of Works
• Condition Monitoring• Vibration Analysis• Computerize Motor Rewinding/Motor repair• Bearing Maintenance & implementation of
lubrication program.• Repair & Maintenance of Pumps, Blowers/Fans,
& Gearboxes• Laser Alignment, and • Onsite Dynamic Balancing.
Copyright ALPS 2013
Benefits
• Warranty For a period of two years from the date of the repair,
ALPS warrant that all design, equipment, materials, and workmanship shall be free of any and all defects and shall be in conformity with the requirements of this specification.
• Reduce your maintenance cost• Increase productivity of your personnel focus on
your core business – producing your product.• Increase equipment reliability & uptime• Peace of mind
Copyright ALPS 2013
Client Inputs
• Total list of equipment to be enrolled for condition monitoring and classify its criticality to your operation. ALPS MSI will establish the condition
monitoring route, how much manhours needed, and proper costing.
• Motor inventory and its specification. This will help ALPS MSI establish preventive
& corrective maintenance pricing @ special discount as compared to per call basis.
Copyright ALPS 2013
Key Service Provided
Energy Saving Business
Copyright ALPS 2013
Energy Saving Business
• Phase 1 - Energy Audit of Electric Motors and its Drive-Systems with the goal of energy efficiency improvement. Conduct energy audit (kW, V, I, & PF) on electric motors &
vibration analysis for the whole system. Identify other areas that will help generate power independently Submission of Findings, Analysis, Recommendation, and
Feasibility Study.
• Phase 2 – Source out financing from banks or investors through the assistance of International Copper Association SEA or CTIPFAN
• Phase 3 – Project Implementation by new entity.• Phase 4 – Monitoring the Success of the Project
Copyright ALPS 2013
Client Inputs
• Inventory of electric motors and its drive systems.
• Tools and instruments used for maintenance
Copyright ALPS 2013
Products
On-line Protection System/Vibration
01dB Vibration Analyzer
Fixturlaser XA Alignment System
Cooling tower FRP Fan Blades
Copyright ALPS 2013
Cooling Tower
Reliability and Energy Savings
Copyright ALPS 2013
Cooling Tower Energy Savings
Project: Replacement Cooling Tower Fan Blades from Aluminum to FRPClient: Cypress Semiconductor
Copyright ALPS 2013
Wind Turbine Generator
Copyright ALPS 2013
Equipment ReliabilityCooling Tower
Proposal to diagnose mechanical problems:
• Safety issue is major concern in the measurement of vibration.
• Install on-line condition monitoring device (upper right picture) with permanent sensors to the bearings of gearbox, motor, and cooling blower.
• Use 01dB Vibration Analyzer (lower right picture) using its BNC cable and plug to on-line condition monitoring device. Problems that can be diagnose: gear meshing, bearings, misalignment, unbalance, bent shaft, etc.
• ALPS MSI supply these instrument inclusive of 5 days on-site training with one year technical support through remote analysis.
On-line condition monitoring mounted in a stable/safe wall, wired toward sensor.
BNC
Copyright ALPS 2013
Equipment ReliabilityCooling Tower
Proposal for corrective maintenance
• Always use Fixturlaser XA for every alignment.
• Use Fixturlaser XA’ digital spirit level to check & correct blade pitch angle.
• Use professional bearing tools to replace and mount a bearing.
YDT 150 Bearing heater
Fixturlaser XA Alignment System
Copyright ALPS 2013
Thank You Very Much for Your Time
ALPS Maintaineering Services, IncIsateram Bldg., Magsaysay Road Ext., Brgy San Antonio,
San Pedro, Laguna 4023Tel 806 3851 / 808 7495 Fax 808 2425
Email: [email protected] / [email protected]: http://www.alpsmsi.com/
