1. Motor Management Basics What Needs to be Managed Motor Life Cycle Measuring Motor Reliability Managing Condition Information Data Mining for the big Reliability Picture Improving Motor Reliability © 2001 24/7 Systems, Inc.

2. What needs to be Managed Location Failure History Condition Info Repair Procedures Inspection and test Documents Measurements and Observations Failure Analysis Reliability Assessment Equipment Purchase Info Design Info Manuals and drawings Failure History Installation History Repair Details Repair Documents Suitable Replacements Reliability Assessment © 2001 24/7 Systems, Inc.

3. Industrial Motor Life Cycle Path Is Motor Repair Practical? Scrap NO YES Motor Installation Motor Failure Motor Removed From Service Motor Sent For Repair Shop Ships Motor Shop Repairs Motor YES NONO Plant Receives Motor Buy Replacement? (New ID) Stores For every Blue Box event TANGO provides practical Motor Management tools ® Repair Quote Approved? Motor Purchased Calculate MTBF Cost of Failure Failure Root Cause Failure Progression © 2001 24/7 Systems, Inc.

4. To improve motor life, you must be able to measure it How do you measure motor life? © 2001 24/7 Systems, Inc.

5. Motor Life Measurements Time till failure - MTBF Mean Time Between Failures Cost of failure - Cost of each repair Life cycle cost - Cradle to Grave cost Cause of Failure - Apparent failure vs. root cause of failure © 2001 24/7 Systems, Inc.

6. How Long Should a Motor Live? AC Motor100,000 hours11.4 years DC Motor50,000 hours5.7 years Source Bloch, Heinz P. and Fred K. Geiter 1994, Practical Machinery Management for Process Plants Vol. 2: Machinery Failure Analysis and Troubleshooting 2 nd Edition, Gulf Publishing Co. Houston, TX © 2001 24/7 Systems, Inc.

7. What is a Motor Failure? A motor failure occurs when the motor is unable to perform its required function. Typical failure modes: Bearings Shorted / open windings These are apparent failure modes. © 2001 24/7 Systems, Inc.

8. Types of MTBF Location Equipment Tag ID Manufacture Model or Design Overhaul Vender HP Frame Size Voltage Bearing Type © 2001 24/7 Systems, Inc.

9. Root Cause of Failure 1.Lubrication 1.Old lubrication 2.Lack of lubrication 3.Excessive lubrication 2.Contamination 1.Internal moisture 2.Dirty cooling passages 3.Dirty windings 3. Fatigue / Wear 1. Shorted windings 2. Broken parts 4. Environment 1. Lighting 2. Power 3. High ambient temperature 5. Process 1. Excessive starts 2. Overloads © 2001 24/7 Systems, Inc.

10. Condition Monitoring vs. Reliability Improvement Condition Monitoring Prevents process failures by detecting faults and removing motor before failure in service. Reduces/eliminates catastrophic failures and process down time Reliability Improvement Reduce and eliminate future failures Time between failure (MTBF) is increased, reducing cost of maintenance and life cycle cost Both technologies must be applied aggressively to achieve a wining maintenance strategy. © 2001 24/7 Systems, Inc.

11. Motor Condition Management Manage Motor Condition 1.Create a “no failures in service” mandate for critical motor. 2.Integrate all condition information 3.Communicate in a highly visible manner 4.Easily capture condition entries, documentation of failures in service, and motor down 5.Link condition information to failure analysis 6.Require validation and closure of condition calls 7.Maintain a History of Condition Results © 2001 24/7 Systems, Inc.

12. Integrating & Communicating Condition Information Several predictive technologies apply to motor including: This information is coming from different analysis packages with different databases, different analysts, and different reporting methods often to different people in the operating areas. Tango allows all the predictive technologies to be compiled into a single integrated view of a given piece of a motor’s condition. This allows proactive scheduling of motor repairs and helps prevent failures in service. Current and voltage analysis Megger readings Thickness Lubrication analysis Process Ultrasonics MCSA PdMA analysis Vibration Flux analysis Thermography © 2001 24/7 Systems, Inc.

15. Data Mining The Developers of Tango cannot develop reports which answer every question a user may have. Data Mining was developed to allow users to investigate their data and interact with it to provide answers and solutions unique to the plant and user. © 2001 24/7 Systems, Inc.

16. What Exactly is Data Mining? Data mining is a way of finding relationships and patterns in data. Examples:  MTBF by Equipment and Location  High cost equipment and Locations  Cause of failure for equipment and locations  Failures by design, vendor, equipment type  You can’t improve what you can’t measure! © 2001 24/7 Systems, Inc.

17. What does Data Mining Offer? A way to partition information into meaningful chunks What are my causes of failures? When did I have the most failures Allows you to sub-divide into smaller chunks Helps you make sense of your information Which vendor sells the best product? What failure mode occurs most often What failure mode occurs most quickly © 2001 24/7 Systems, Inc.

18. Standard Data Mining Tools Tango’s Data Mining uses OLAP to provide a standardized Data Mining database Many commercial Data Mining tools exist for operators on OLAP databases © 2001 24/7 Systems, Inc.

19. What Issues Affect Reliability ? A.Poor performance by: 1.Equipment – lemons 2.Locations 3.Manufactures 4.Overhaul vendors 5.Equipment Design Groups (models) B.Root cause of failures Systematic mitigation of root causes C.Cost of repair Allows justification of expenditure to extend life Focus on areas of high return © 2001 24/7 Systems, Inc.

20. Reliability Improvement Identify which motors are failing rapidly and repetitively Identify equipment groups and location groups with high Repair cost Identify root cause of failure. Aggressively eliminate root causes In large plants with thousands of critical motors, failure may occur rapidly and repetitively, but no one realizes there is a reliability problem. Tango’s main function is to solve this problem by: © 2001 24/7 Systems, Inc.

21. Savings From Motor Management Decrease in cost of repairs & replacement motor Increased process availability – more production. Reduced maintenance labor & overtime. Increased safety from reduced failures in service and emergency replacements. © 2001 24/7 Systems, Inc.