Electric motors are key to production and service delivery in commercial and Industrial work environment and according to the international Energy Agency (IEA), they consume about 45% of global electricity. Electric motors are invaluable in the workspace.
Industries rely heavily on electric motors in Manufacturing Industries, HVAC (Heating, Ventilation and Air condition), Transportation, Mining & Extraction, water & waste management and Agriculture…. etc. for their processes and operations.
Electric motor failures are common, devastating and costly to facilities.
Draining businesses of revenue and reputation, causing downtime, low performance, loss of productivity, missed schedules, unmet target and generally service deliveries.
Preventing or mitigating, require an understanding of the symptoms, likely causes and solutions to be implemented for reliability and continual operation of electric motors in the facility.
Here are 8 guidelines that will serve as a roadmap for optimal efficiency and costs savings.
- Overheating:
Causes:
Overloading, poor ventilation, or excessive ambient temperature are culprits in motor overheating.
Solution:
Ensure motors are adequately sized for the load, provide proper ventilation, maintain clean cooling systems, and monitor ambient temperature. Implement thermal protection devices to prevent overheating.
- Electrical Power Issues.
Causes.
Voltage fluctuations, unbalanced power supply, or power surges can damage motor windings and affect performance.
Solution.
Install surge protection devices, voltage regulators, and ensure a stable and balanced power supply. Regularly monitor voltage levels and address any power quality issues promptly.
- Mechanical Issues.
Causes.
Misalignment, bearing failure, or excessive vibration can cause motor problems.
Solution:
Regularly inspect and maintain motors, align shafts correctly, lubricate bearings as per manufacturer recommendations, and address any signs of excessive vibration. If possible implement vibration monitoring systems to detect issues early.
- Insulation Failures.
Causes.
Aging, contamination, or excessive heat lead to insulation breakdown, resulting in motor failures
Solution.
Regularly inspect and test motor insulation, clean and remove contaminants, and ensure proper ventilation to prevent excessive heat buildup. Implement insulation resistance testing and insulation monitoring systems.
- Inadequate Maintenance.
Causes.
Lack of regular maintenance, such as cleaning, lubrication, and inspection, can contribute to motor problems.
Solution.
Establish a comprehensive maintenance program, including regular cleaning, lubrication, and inspection of motors. Follow manufacturer guidelines for maintenance intervals and procedures.
- Environmental Factors.
Causes.
Harsh environments with dust, moisture, or corrosive substances can impact motor performance and lifespan.
Solution.
Protect motors from environmental factors by using appropriate enclosures, seals, and ventilation systems. Regularly clean and inspect motors for any signs of environmental damage.
- Age and Wear.
Causes.
Aging electric motors or those nearing the end of their expected lifespan are more prone to failures.
Solution.
Implement a proactive motor replacement or refurbishment plan based on manufacturer recommendations and regular condition monitoring. Track motor age and performance to identify motors at risk of failure.
- Improper Installation.
Causes.
Incorrect motor installation, such as improper wiring, inadequate grounding, or incorrect mounting, can lead to motor problems.
Solution.
Ensure motors are installed correctly by following manufacturer guidelines and industry standards. Verify proper wiring, grounding, and mounting to prevent issues.
@fullspectrum, our solutions include bespoke trainings and offering sustainable solutions that enhance bottom line, reduce downtime, extends motor lifespan, seamless operations and savings across industries without borders.
Call and book for a free survey today!
Enquiries
Victor Oyedu, FNSE, FNIEEE, CPQ.
Power Quality and Energy Management Specialist.
Publisher at Afrienergyonline.com
CEO, FullSpectrum Energy Solutions Limited, Nigeria.
