Resatech

Reducing Rotating Machines Lifecycle Costs – a Concerted Effort

Rotating machines are versatile and exist in almost every power conversion operation in the plant. Yet they are sensitive to misuse and poor maintenance

Rotating electrical machines are among the most complex and expensive items in the modern power plant. Their purchasing and reconditioning account to a large portion of the capital investment for the plants. Their reliability is however hampered by high number of inexplicable failures which often result in exorbitant cost of repair and replacement in addition to loss of enormous production revenue. Curbing these failures calls for an in-depth study of various failure modes and their implications as observed from each asset individually. The absence of relevant historical data pertaining to the actual operational details of the machine while in service as well as the unavailability of data trends relating to other variables which have direct influence on the overall machine performance make it difficult, if not impossible to administer appropriate counter measures in an effort to restrain the upsurge in premature failures and minimise the overall lifecycle costs of rotating electrical machines.

Underlying Facts

Rotating electrical machines fail.
Cost of replacement, reconditioning and maintenance continue to increase.
Loss of production due to failure is even costlier.
**** High failure rate needs to be restrained ****
Failure prevention entails understanding failure modes.
Failure root cause analysis is a complex process
Data needed to facilitate FRCA is often insufficient or non-existent – most failure mechanisms are catastrophic.
Attempts to mount irrefutable warranty claims are often futile.
Inexplicable failure of REM continues unabated.
**** An urgent solution is needed ****

Need for Intervention

The necessary material required to develop effective maintenance programs to better safeguard these assets is often available and quite easily accessible however, it needs to be constantly collected, systematically organised, well managed and meticulously analysed to provide the evidence required and augment the calls for intensified continuous improvement initiatives. Contrary to popular belief, the installation of insulation health monitoring systems does not prevent failure of rotating machines but provides critical information regarding the health of the insulation system in time to enable power plant and asset managers to better plan for condition-based maintenance. A couple of questions need to be answered to develop an airtight program to reduce lifecycle costs of rotating machines.

Primary Challenges

High population of rotating machines in plants.
Unavailability of competent plant personnel specializing in rotating electrical machines
Lack of time and suitable resources (technology and expertise) in the plants to deliver this service effectively.
Absence of proper infrastructure to enable plants to handle this service effectively (adequately equipped workshops and high voltage laboratories).
High cost of permanent monitoring and diagnostic technologies.

Reliability Solution - SARP

Develop a Smart Asset Reliability Program – (SARP) to manage lifecycle processes of all motors enrolled in the program.
Create a Digital Asset Health File – (DAHF) for each motor enrolled in the program.
Failure Root Cause Analysis conducted by competent people.
Management of the reconditioning process including establishment of strategic hold points and witnessing of functionality tests at the repairer.
Conduct OLPD tests and mechanical inspections regularly while the machine is in service.
Trending and analysis of the motor operating condition.
Issue periodic reports and suggest necessary interventions.
Update digital asset health file (DAHF).

SARP– Fundamental Aspects

Drastic reduction in MV motor premature failures.
Reduction in non-conformance and warranty claims.
Improved asset reliability.
Extended asset life.
Reduction in the overall maintenance costs.
Identification and management of potential failure risks – online periodic/continuous monitoring.
Development of asset registry (Digital Asset Health File - DAHF) - Computation of lifecycle costs i.e. purchasing, maintenance, condition assessment and monitoring costs.
Good business practice – better decision making.
Determine asset’s residual life – Lifex studies.
Better planning and control – finance.

Envisaged Program Outputs

Operational excellence is every executive decision-maker’s desire in every industrial establishment across the globe. Realizing efficiencies depends on the alignment of needs and requirements with the existing capabilities and resources. Therefore, a complete understanding of medium voltage assets, their capabilities, lifecycle, performance, condition assessment, maintenance requirements, reliability, external factors and their influence on the asset’s operation, etc. should be easily accessible to key role players so that questions relating to operational efficiencies could be answered.

These critical aspects are fully encompassed in our innovative asset management strategy to facilitate a smooth process of ensuring continuous improvement, achievement of corporate objectives and maximization of return on investment in the most cost-effective manner possible. Our Smart Asset Reliability Program (SARP) is designed to help modern industrial power plant owners better identify risks and determine needs for optimization while achieving their projected targets in the smartest manner possible.

Total Quality Management