More Up Time / Less Costs through Motor Management Presented By: George Flolo
What is EASA? Electrical Apparatus Service Association Trade association serving the electrical and mechanical apparatus sales, service and repair industry Founded in 1933 Over 2,000 member firm locations worldwide; approximately 1500 in the U.S. Supports its members with industry research, engineering services, and education Establish industry standards and practices
What am I going to Cover? Why Motor Management is Important That Motor Management can be very basic and very elaborate That Motor Management will not be the same for Everyone That Motor Management requires a Team with different interests and knowledge
What is Motor Management? A set of ongoing policies and practices that help facilities proactively plan and effectively manage their motor population reducing equipment downtime and energy costs.
Motor Management is One of the Few Decisions that is a. Win for Maintenance/Production Uptime Win for Business as a whole Profit through Uptime and reduced Utility Costs Win for Service Centers Sales Opportunities for Repair and Replace Win for Utilities Helps meets regulatory requirements and improves equipment utilization Win for MAC less carbon consumed.
The Dreaded 3:00 am Call Sound (OLE2)
What Happened? A motor failed which shut down the system. With no plan in place the repair/replace decision was based on availability & secondarily first cost. This decision will have a long-term impact possibly 15 years or more. Is there a better way?
Yes there is a solution and. You re it!
Proof Positive 150hp, 1775 rpm ODP motor driving climate control blower on roof. Pharmaceutical facility production area cannot operate without the blower. Failure occurs shortly after midnight. Extensive mechanical damage and winding failure.
Proof Positive Replacement option immediately considered: 2 hour site search for spare, 6 hours until vendor contacted for replacement motor, 24 hours until new motor installed,????????- total downtime costs.
Proof Positive Spare motor Facility had initially declined opportunity to purchase spare. Spare NEMA Premium TEFC for outdoor location motor is purchased. Some motor management steps applied.
Proof Positive (Some First Easy Steps) Next Steps Institute repair/replace policy. Purchasing and repair policy based on life-cycle costing. Demand best practice repairs. Have a critical Motor Inventory.
Understanding a motor s true costs Annual energy costs are often 5 x s the initial purchase price. Energy is often 95% of total lifetime operating costs. Assumes 100 hp motor, 94.5% efficiency, 6,300 hours/year, 18-year life, 7.5 /kwh
Understanding the benefits of planning ahead Consider motors as an asset class, not as individual commodity items. Develop policies based on proactive planning and life-cycle costing to minimize downtime and operating costs. Make these policies routine practice.
Managing a plan is easier than managing a crisis
Another Proof Positive Packaging plant conveyor gearmotor failure. 25hp, 1150 rpm TEFC motor integrally mounted to gearbox No spare OEM Special special Shaft Service center/distributor evaluates motor Rewind and machine work needed Gearbox to be overhauled
Proof Positive Replacement option - New gearmotor delivery > 2 months - OEM special. Repair is the viable option. Unit returned within 30 hours of receipt. Total downtime 1 ½ days. Alternative for replacement spare. Service center/distributor determines NEMA Premium motor can be retrofitted to gearbox.
Proof Positive (Continued) Survey of 4 critical units showed all are identical One spare can reduce future downtime and costs. Plant management partners with service center/distributor to survey all critical equipment. NEMA Premium preference for spares. Duplicate units identified to reduce spares.
Proof Positive Next Steps Work with service/center distributor to complete motor survey Establish repair/replace policy based on life-cycle costing Purchase spares Demand best practice repairs Institute predictive & preventive maintenance program Review the applications to see if Variable Speed Drives or soft start makes sense
Planning Allows You to: Go from PANIC to PROACTIVE planning REPLACE IMMEDIATELY WITH NEMA PREMIUM MOTOR REPAIR ON FAILURE FOLLOWING BEST- PRACTICE PROCEDUES and cost effective DECISION making. REPLACE ON FAILURE WITH NEMA Premium MOTOR
Proactive Planning
Developing a Plan Available at www.motorsmatter.org
Use 1-2-3 to Demonstrate Value
Tools from EASA/MDM/..
Key Market Resources
Get Started Today Log onto MDM s web site, www.motorsmatter.org and download the Motor Planning Kit. Log onto www.easa.com and Download the Motor Repair Best Practices.
In Summary.. The building blocks of a motor management plan.
Motor Management is a TEAM EFFORT and a Win -Win Win -Win - Win Happening.
The Relaxed 9 am Phone Call Sound (OLE2)
Thanks for Listening George Flolo geflolo@flolo.com