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MAP ********

a solution to life assessment of large motors

omsaiempl@gmail.comanilscoob@gmail.com

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The deterioration of large motors isnormal, and this process begins as soonas motor is installed.

If deterioration is not checked, it can

cause electrical failures and malfunctions.

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In addition a TEAM of stresses

further contributes to the deteriorationprocess.

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TTTThermalhermalhermalhermal EEEElectricallectricallectricallectrical

StressStressStressStress

MMMMechanicalechanicalechanicalechanical AAAAmbientmbientmbientmbient

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The purpose of a good maintenanceprogram shall be• to discover the potential reasons of

deterioration• take remedial measures for correctionto avoid catastrophic failures.

The other important purpose of maintenance program is to maximizereliability and availability, improveoperational efficiency and productivity.

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MAP****

is the answer

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MAP****

proactive action and solutionto ensure availability and reliability of motors

improve operational efficiency and productivityto ensure trouble free running of the plant

inspection and maintenance processduring the lifetime of a motorplanned during either operation or outage

linked to motor planned outageensuring minimum downtime of the plantassessing the healthiness of the motor

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MAP1111

MAP2222

*

MAP 4444 MAP 3333

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MAP1111

MAP2222

****

MAP 4444 MAP 3333

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MAP 1111 concept

During operation of the motor

Data collection + online tests

After 8,000 hours of operation

Takes 1-2 days

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MAP 1111 deliverable

Thermal life by Arrhenius Equation

Thermal life b N-Y method

Schedule for MAP 1111 , MAP 2222 & MAP 3333

Optional on-line assessment

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MAP1111

MAP2222

****

MAP 4444 MAP 3333

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MAP 2222 concept

During outage with cables removed

Offline ins ection and testin

After 16,000 hours of operation

Takes 2-3 days

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MAP 2222 deliverable

Condition assessment by diagnostic test

Residual life b D- and B-method

May include MAP 1111 deliverables

Schedule for MAP 3333 , MAP 4444 & MAP 1111

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MAP1111

MAP2222

****

MAP 4444 MAP 3333

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MAP 3333 concept

During outage with end-covers removed

Ins ection to extent ossible

After 32,000 hours of operation

Takes 3-5 days

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MAP 3333 deliverable

Visual examination

Residual life b FEM method

May include MAP 1111 & MAP 2222

Schedule for MAP 4444 , MAP 1111 & MAP 2222

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MAP1111

MAP2222

1111

MAP 4444 MAP 3333

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MAP 4444 concept

During outage with rotor threaded out

Ins ection and testin

After 64,000 hours of operation

Takes 10-12 days

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MAP 4444 deliverable

Condition Index and Health Index

Residual life b FEM method

May includeMay include MAP 1111 ,, MAP 2222 & & MAP 3333

Schedule forSchedule for MAP 1111 ,, MAP 2222 & & MAP 3333

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ConceptLife Cycle Concept

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ContinuousUpgrading/

Replacement

Overhaul

Maintenance

Optimized Maintenance LineValue to Customer through Maintenance

}

Life Cycle ConceptLife Cycle Concept

Upgrade andModernization PeriodWarranty Period

AgingRepair

Time

Maintenance Period

Replacement & Recycle Period

Customer Project Lifecycle

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ConceptConfidence Level

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Stress

Stresscalculatedfrom MAP 2

StrengthCalculatedfrom MAP 2

StrengthCalculatedfrom MAP 3

Stresscalculated

from MAP 1

StrengthCalculated

from MAP1

Stresscalculatedfrom MAP 4

from MAP3

StrengthCalculatedfrom MAP 4

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h / s t r e s s

Strength

uncertainty

S t r e n

g

Time

Stress

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ConceptStator Winding Failures

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Failure statisticsFailure statistics

37%3%5%

11%Bearing

Detection during Normal Operation

33%

5%

6%Rotor Shaft/coupling

Brushes/slipring

External devices

Not specified

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Failure statisticsFailure statistics

7%

4%10%

Bearing

Winding

Detection during maintenance or test

8%2%

8%

61%

Rotor

Shaft/coupling

Brushes/slipring

External devices

Not specified

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Failure Statistics ConclusionFailure Statistics Conclusion

• Bearings fail frequently

• Windings also share a significant failure rate

in maintenance (8.3%) as against thetotal failure of 33% in normal operation

• This indicates poor insulation problemsdetection technique

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THANK YOU

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