By Noah Bethel, CMRP
Vice President of Product Development
PdMA® Corporation
Efficiency is a hot topic. From news shows on TV to industrial plant management meetings, everyone from government officials to maintenance managers are trying to make daily processes run more efficiently. In the industrial manufacturing marketplace, that means they are, in large part, focused on improving motor efficiency and reliability, even as minor inefficiencies in this area significantly impact productivity, profitability, and sustainability.
Unfortunately, in their quest to optimize efficiency, many organizations make the mistake of taking too narrow a focus. It is critical for those wanting to streamline operations and maximize profits to address not just motor efficiency and reliability, but also their overall technology and resource efficiency. Organizations that implement electric motor fault zone analysis techniques and powerful motor efficiency strategies while leveraging the most advanced motor testing technology and resources are best positioned to achieve high efficiency and reliability, and maximum availability in their electrical motors.
Why efficiency is so critical in industrial manufacturing today
Manufacturing efficiency directly impacts a company’s ability to produce high-quality goods consistently and at a competitive cost, both of which are vital factors for success in a competitive marketplace. Companies where asset reliability is low often experience unplanned downtime, decreased operational efficiency, poor return on investment (ROI), reduced product quality and consistency, diminished workplace safety and compliance, and weakened production flexibility and responsiveness.
According to TWI Institute, “manufacturers can experience up to 800 hours of downtime annually, leading to substantial financial losses.” Siemens reports that the world’s largest manufacturers lose $1.5 trillion a year to production downtime and that those outages cost companies 50% more today than they did just five years ago. Simply put, companies that don’t take steps to address asset reliability, particularly the efficiency of their electric motors, put their very future at risk.
Unfortunately, an additional factor also contributes to poor efficiency in industrial manufacturing: a reduction in human resources. The COVID-19 pandemic caused a significant disruption in America’s labor force. The trade services industry, in particular, has not entirely recovered. This is compounded by the fact that a substantial proportion of America’s workforce is now aging into retirement. These factors have combined to leave manufacturing companies without the experienced workforce they need to effectively manage mechanical failures.
It’s not all “doom and gloom” regarding efficiency in manufacturing. The good news is that recent advances in artificial intelligence (AI), machine learning (ML), and testing technology enable forward-looking companies to overcome current challenges and improve efficiency. One example of the difference AI makes in motor efficiency is MCEMAX®, which utilizes a six-fault zone approach for analyzing electric motors. MCEMAX then provides comprehensive data for each specific fault zone, offering companies and AI the information needed to make key operational and maintenance decisions on their electrical motors to avoid expensive inefficiencies and downtime.
Another example is PdMAEYE®, which is a permanently installed motor testing technology that provides vital information 24 hours a day while the motor runs. With PdMAEYE, which is powered by PdMA’s MCEGold® software, companies are immediately warned of changes in the condition of critical motors so that appropriate action can be taken and costly downtime and other negative issues avoided.
The power of online motor testing was recently displayed when a technician heard a knocking noise in a large cooling tower induction motor at an electrical plant. The issue was whether the noise indicated a problem with the motor or the gearbox. With MCEMAX, the company was able to review demodulation data to quickly determine that the problem was in the gearbox. Catching the problem early allowed the company to perform the maintenance on a cooler day instead of having to shut down the plant in the heat of summer, resulting in tremendous savings.
In another instance, a pharmaceutical manufacturing facility tried to determine whether it needed to replace its electric motor or a variable frequency drive (VFD) in an exhaust fan. A quick three-minute fault zone analysis by PdMA determined that the problem was with the motor. The company then used the information PdMA provided to obtain a replacement motor from the fan manufacturer at no cost, as it was under warranty, and saved significant downtime and repair costs. While many companies benefit from the recent advances in motor testing technology, many others fail to embrace the full range of advantages the technology offers.
Asset reliability concerns
Manufacturing facilities need elevated efficiency and reliability, and maximum availability, as unplanned shutdowns can cause them to fall behind the competition. While most companies understand this, they often take a narrow approach. Companies focus on motor efficiency, which is critical, but they fail to also consider technology and resource efficiency.
By combining motor, technology, and resource efficiency, companies create a comprehensive approach that further reduces downtime and allows them to increase profits. To accomplish this, it’s essential for them to carefully consider a three-pronged approach. This approach incorporates the technology they employ, and the resources utilized, while maintaining a strong focus on motor efficiency that includes a full complement of electrical analysis covering from the insulation to the rotor.
Motor efficiency
Motor efficiency starts with ensuring specifications fall within application needs. For example, a high-efficiency motor running at very low loads can result in significant reductions in efficiency. New high-efficiency motors may only deviate 1% from no load to full load, but running a motor unloaded will still create system inefficiency. The most effective way to monitor this efficiency is through fault zone analysis. This comprehensive analysis process ensures that all elements of the electrical motor are being considered, so motor owners aren’t surprised by a less likely fault mode that causes a motor shutdown when they can least afford it. For instance, MCEMAX provides comprehensive data for six specific fault zones: Power Quality, Power Circuit, Insulation, Stator, Rotor, and Airgap.
This approach allows manufacturers to look at both motor and overall system efficiency, providing them with the information to make more informed decisions. Additional strategies companies can use to allocate testing resources more effectively to ensure motor health include installing motor test panels like the MTAP2®, which is designed to allow the safe testing of energized electric motors. Companies can also use a permanently installed data collection tool like PdMAEYE on all critical motors. PdMAEYE provides comprehensive data for all but Insulation in the six fault zones.
Technology efficiency
The most significant issue manufacturing companies face with technology efficiency is deciding whether to use portable technology or permanently installed technology. Each type has its pros and cons. Portable technology pros include offline and online motor testing, specialized insulation FZA warehouse motor testing, and no requirements for hardware installation or network IT. Some of the portable technology cons are energized equipment safety, equipment knowledge, site/asset location access, calibration requirements, personnel availability, and resource efficiency.
Permanently installed technology benefits are 24-hour online motor testing, specialized power quality FZA, and all in-rush tests captured. There are no electrical safety concerns or required site/location access or equipment knowledge post-installation. Personnel can be offsite, and calibration is not required. Permanently installed technology cons include no offline testing, cloud services and increased IT are required, and there is limited insulation FZA. By finding the right mix of portable and permanent testing, companies can unlock greater efficiency and higher profitability. Some general guidelines for choosing between portable and permanent testing technology include:
- Portable testing. Use this when field service or on-site diagnostics are needed and when commission or periodic inspections are performed.
- Permanently installed testing. Use this technology when motors are mission-critical and constantly in use, when continuous data collection is needed, and when automated alerts and predictive maintenance are valued.
Many organizations today are choosing a “best-of-both-worlds” hybrid strategy that puts permanent systems on high-value or high-risk motors and portable testing equipment on less critical or mobile assets.
Resource efficiency
Resource efficiency in electric motor testing refers to the optimal use of time, energy, labor, equipment, and materials to test motors effectively while minimizing waste and cost. It ensures companies gather the necessary performance and health data without overusing or misusing resources. Tips include:
- More tools. Use cutting-edge tools, like PdMA’s suite of products (MCEMAX, MCE®, EMAX®, MTAP2, MTAP3®, PdMAEYE, and Cloud Services), which are designed to work together optimally to deliver the information companies need to make critical decisions and increase plant reliability.
- Less effort. Improve labor efficiency through automation, smart diagnostics, and clear procedures, and train technicians to run tests correctly the first time to avoid retesting.
- Improved coordination. Align motor testing with preventive or predictive maintenance schedules to avoid redundant testing and downtime.
It is also crucial for manufacturing companies to understand that there are limitations to many current testing technologies. One common problem companies experience is not collecting data frequently enough to ensure the analyst can identify problems early. The solution to this challenge is to permanently install data collection on critical motors using tools like PdMAEYE and MTAP2.
Another common resource efficiency issue is having insufficient human resources to perform necessary reliability testing. The solution is to create a dedicated reliability department populated with an adequate number of mechanical and electrical specialists. If this is not possible or if companies want to save money and streamline operations, permanently installing data collection on critical motors can accommodate the reduced number of employees needed to monitor motor reliability.
Automated testing and permanently installed technology are changing the efficiency of maintenance departments overnight. Fewer analysts are required, and those who remain are spending more time analyzing the problem applications and less time collecting data. When appropriately used in a supervised machine learning environment, AI can be a full-time analyst providing valuable insights into trends and timely warnings about condition-based patterns.
The value of continuous monitoring with the PdMAEYE was revealed recently at a pumping station. The PdMAEYE discovered a rotor degradation issue in a critical motor at a remote location. Because of this information from the PdMAEYE, the company was able to monitor the rotor fault around the clock and decide when to repair it. Instead of being blindsided by rotor failure and having to arrange emergency repairs at a difficult-to-reach location, the company took charge of the situation and made the repairs when it was most convenient for them. The PdMAEYE also improved resource efficiency by eliminating the need for workers to frequently drive to the remote location to test the motor. Instead, they can now use that time to work on other essential tasks.
The future of efficient industrial manufacturing facilities
While most industrial manufacturers now recognize the importance of motor efficiency, many still do not understand the technology’s significance or that resource efficiency is an additional key to maximizing productivity and profitability. It is imperative for officials to realize that motor efficiency without motor reliability is expensive, motor efficiency without reduced power consumption is wasteful, and motor efficiency and reliability without personnel safety is dangerous.
Recent technological advances, such as MCE, EMAX, MCEMAX, MTAP2, MTAP3, and PdMAEYE, have changed the landscape of motor monitoring and predictive maintenance. These tools increase safety and reduce connection time for online motor testing, allowing users to capture data safely and quickly to determine motor health. Through continuous monitoring of electric motors, organizations can allocate their limited resources and attention to other priorities while maintaining a high degree of efficiency, enabling organizations to achieve higher levels of profitability and market success.
By focusing on three major areas, companies can best position themselves for continued success going forward. Those three areas are:
- Quality control. By ensuring motor quality at the beginning of the process, companies increase their chances of achieving long-term reliability.
- Trend awareness. Proper data collection frequency allows companies to identify trends early and take appropriate action to avoid negative issues.
- Troubleshooting prowess. It is also imperative for companies to have experts trained in troubleshooting and repair to rectify faults and avoid or minimize unplanned shutdowns.
By taking this approach and using advanced technology to optimize testing, reduce waste, and make better use of time, energy, and materials, manufacturers can lower operational costs while maintaining or improving product quality. They can also experience faster production cycles and more consistent output while responding faster to market demands. In short, they can unlock higher performance that powers them to new heights of success.
About the Author:
Noah Bethel, CMRP, is vice president of product development for PdMA Corporation, Tampa, FL, the leader in the field of predictive maintenance, condition monitoring applications, and development of electric motor test equipment for motor circuit analysis. Tel: (800) 476-6463. www.pdma.com
