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A NOVEL APPROACH TO ELECTRIC MOTOR SYSTEM MAINTENANCE AND MANAGEMENT FOR IMPROVED INDUSTRIAL AND COMMERCIAL UPTIME AND ENERGY COSTS 2nd Edition Book 2 of the MotorDoc™ Series

by Howard W. Penrose, Ph.D. Old Saybrook, CT

Disclaimer: Use of the information contained within this study does not imply or infer warranty or guaranties in any form.

MotorDoc™ E-Book 2nd Book of the MotorDoc™Series

©1997, 2001 Howard W. Penrose, Ph.D.

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Motor Systems Management i

Abstract

A NOVEL APPROACH TO ELECTRIC MOTOR SYSTEM MAINTENANCE AND MANAGEMENT FOR IMPROVED INDUSTRIAL AND COMMERCIAL UPTIME AND ENERGY COSTS 2nd Edition

by Howard W. Penrose, Ph.D. SUCCESS by DESIGNPurpose of Study

With the ever increasing frequency of corporate re-engineering, electric motor system maintenance programs have decreased. This has resulted in billions of dollars of lost revenue through increased electrical costs, downtime, and waste in industrial and commercial companies. Modern management practices often do not take into

Motor Systems Management ii account theimportance of maintenance to equipment uptime and energy costs.

The purpose of a successful electric motor system maintenance and management program is to improve equipment readiness and uptime while reducing capital overhead. This program consists of particular maintenance and management tools designed to aid the maintenance engineer in electric motor systems and their care. These tools include:motor systems training; power quality, motor, and control improvements; reactive, preventive, predictive, and proactive maintenance systems and scheduling; electric motor systems management software; and the U.S. Department of Energy's Motor Challenge Program (now the Best Practices program).

Method

Research data was collected for the purposes of this study. The format for the collection of thedata was to separate it into four stages. These four stages included a maintenance system review, a case study of an active total motor systems management program, a review of the case study and development of Proactive Maintenance (PaM), and concludes with a Total Motor System Management Guidebook. The research conducted consisted of setting up a model company and

Motor Systems Management iiireviewing how different maintenance approaches would affect it. A study of the effects of a total motor system maintenance and management approach was studied on an actual company.

The conclusions found in these studies indicate the need for a guidebook for motor system maintenance and management and the development of a PaM program. In addition, further assessment of motor system life and theeffects of the actual and electrical environments is required in order to further assist in the development of decision making tools.

Motor Systems Management 1 Chapter 1 Introduction

Problems With Present Motor System Management Practices

Modern management practices often do not take into account the importance of motor systems maintenance and management requirements. Through effortsin cost control many industrial and commercial firms will reduce maintenance staffs, take least cost approaches to corrective actions, and sacrifice preventive maintenance programs. The result has been increased energy costs and downtime resulting from equipment not operating to full potential and failing unexpectedly. This problem results in billions of dollars of additional energy consumption andlost revenue.

Purpose of a Motor Systems Management Program

The purpose of a successful Electric Motor Systems Management Program is to improve equipment readiness and uptime while reducing capital overhead. This program consists of particular maintenance and management tools designed to aid the maintenance engineer in electric motor systems and their care. These tools include:

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