Predictive Maintenance

Online / Off-line Predictive Maintenance for 3-phase Induction Motor

 

 

 

 

 

 

 

 

 

 

 

 

 

A New Approach in Predictive Maintenance

e-MCM is an advanced online tool for condition monitoring, predictive maintenance, and power metering of critical AC rotating equipment. Using a patented machine learning algorithm, it can detect faults up to 6 months in advance.

The system offers 24/7 monitoring and real-time voltage and current analysis, identifying electrical, mechanical, and process issues in both fixed and variable speed motors and generators. e-MCM provides these benefits without the complexity and high cost of traditional monitoring systems.

e-MCM monitors equipment driven by electric motors by using the motor’s electrical supply as a sophisticated transducer, eliminating the need for specialized equipment. With its permanent installation, e-MCM offers continuous fault monitoring without relying on costly manual data collection.

Provides clear information for fault detection, diagnostics, time to failure and corrective actions.

It automatically assesses the severity of any variations from normal operation and presents the results of its sophisticated analysis to the user in a simple display

Solution Overview

1
The customer discovered blade damage on large exhaust fan. (Figure 1)
The existing vibration sensors cannot provide relevant information on root cause of the blade damage.
2
We installed an advanced online tool for condition monitoring, predictive maintenance, and power metering of critical AC rotating equipment.
3
The system offers 24/7 monitoring and real-time voltage and current analysis, identifying electrical, mechanical, and process issues in both fixed and variable speed motors and generators.
4
According to the motor condition monitoring and data analysis from the device, the PSD signal "Rotor / Misalignment" are abnormal (the red line) before maintenance. (Figure 2)
5
Facility maintenance carried out on 16/3/2023. The root cause of the blade damage was identified – one of screws on the exhaust fan got loose, problem fixed afterwards. (Figure 2)
6
Comparing energy usage before and after the repair, there is a 10.8% reduction, equivalent to a savings of 28.8 kWh per day. As a result, the customer saved HK$1,399 per month.

Figure 1: Blade damage on large exhaust fan

Figure 2: e-MCM: Detecting Rotor/Misalignment Issues and Recovery

Customer Benefits

  • Prevent problem reoccurring
  • Reduce unnecessary energy lost and to improve energy efficiency
  • Decrease on maintenance cost, increase productivity
  • Equipment life extension
  • Improved process safety
  • Spare parts are expensive and require long delivery lead time, advance planning of orders are necessary
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