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How to Increase the Lifetime of a Motor from Two Weeks to Over a Year: Contaminated Environments

May 8, 2020/0 Comments/in Electric Motor Protection, Electric Motors /by Lynn Dreisilker

For over 65 years, Dreisilker has been driven to improve our customers’ reliability and increase uptime through problem solving. A common problem we have found for customers is contamination of the motors, leading to premature failure. A unique customer success story relating to failure from contamination involved motors that were failing every 2 weeks. Through talking with the customer and examining their operations, we were able to help them improve the motors’ reliability.

Customer Success Story:

Our customer talked with us about a series of motors that were failing every 2 weeks or less. The motors power large rollers that have water being sprayed over large steel slabs for cooling purposes. The water was negatively affecting these motors and causing failure every two weeks. While the replacement motors were relatively economical, the cost of downtime and the added cost of the labor to uninstall and reinstall was adding up. Our customer asked us if we would be able to come up with a solution to help these motors last 4 to 6 months versus 2 weeks.

Ultra Seal Application

Ultra Seal Application

Our engineering team worked with our customers’ maintenance crew to figure out the best solution for this issue. After reviewing the motor and its application, we determined that it would be best to utilize our Ultra Seal winding technique to fully insulate the motor’s winding and protect it from contamination. The Ultra Seal Winding technique involves us fully impregnating and sealing the coils with a high molecular weight thermoset polymer resin. Below shows a winding before and after the Ultra Seal Winding process.

Left: Ultra Sealed windings. Right: Normal windings.

Crosscut of Ultra Sealed windings.

The customer agreed to try out an Ultra Sealed motor to see how long it would last. The process involved us purchasing a brand new motor, stripping the motor of its windings, winding a new core, and then using our Ultra Seal process. If you are wondering why we would need to strip a brand new motor of its windings, it is because the Ultra Sealed windings do not require standard motor varnish (see our blog on different types of varnishing methods) and it actually acts as the insulator for the windings.

New motor to be Ultra Sealed.

New motor after being Ultra Sealed.

We delivered the new, Ultra Sealed motor to our customer and they put it into production. Two weeks passed by with the motor still running and it exceeded their desired 4-6 month target. The customer recognized the reliability of the new motor and ordered more for the operations and they have been running for over a year.

Some common industrial applications for Ultra Sealed motors include:

• Machine tool CNCs – Servo and Spindle Motors
• Steel Mills: Continuously wet and hot environments that demand reliable 24/7 uptime
• Poultry Processing Facilities
• Irrigation Operations.
• Pulp & Paper Mills
• Mining Operations
• Plastics Injection Molders.
• Petroleum Drilling Operations
• Food Processing
• Foundry Operations

While heat dissipation was not a clear problem with the customer success story above, it is still important for other applications. In addition to protecting the motors from contamination, the Ultra Seal Winding allows for efficient cooling of the motors. The resin used within the process is approximately 40 times more efficient at heat transfer than air. This is useful especially for motors found in extreme temperatures.

If you have motors operating in harsh environments and they are failing prematurely, you may want to consider the Ultra Seal method. Reach out to us today if you have questions regarding the process or would like a quote.

How to: Laser Shaft Alignment

August 16, 2018/0 Comments/in Electric Motors, Predictive Maintenance, Reliability Services /by Lynn Dreisilker

Alignment in your machines is vital to the reliability of your operations. When two machines are misaligned, severe failure can occur causing unplanned downtime and loss of revenue. Some negative consequences are seal failure, bearing failure, energy loss from inefficiencies, increased vibration, and excessive heat.

For normal operation, both of the machines’ shafts need to be collinear, meaning that they are in the same line. There are two types of misalignment: offset and angular (Figure 1). Keep in mind that your machines can have both offset and angular misalignment simultaneously.

 

Figure 1

 

To check alignment of your machines, we utilize laser technology to accurately test the alignment. Here are the steps we use to align motors and generators to their mates:

Prealignment

  • Safety Check: We follow Lock Out Tag Out (LOTO) procedures to ensure no energy is present or available in the systems we are working on. Safety guards are then removed for access to adjustment points.
  • Mounting Check: All mounting surfaces and conditions are checked prior to installing the motor. Both the feet and the mounting base should be clear of any rust, paint or dirt.
  • Soft Foot Check: We use the Pruftechnik ROTALIGN Ultra iS to check the motor for soft foot (distortion of the equipment frame). ). If your motor or generator has soft foot, a false alignment of the bearings internally can occur cocking one or both bearings in the housing. This means that one foot could be tightened down and distort the bearing housing too much putting tension on the bearings. IEEE 1068‐2015 specifies a coplanar tolerance of 0.005 inches (0.127 mm) of the motor feet on a fully assembled motor. Click here to learn how a motor frame can warp via burnout oven stripping.

Alignment Steps

  • Fasten Brackets: Brackets are fastened to the driven shaft and the driving shafts.
  • Mount Laser: The laser is mounted to the stationary end and the receiver to the end that will be in motion.
  • Conduct Alignment Check: Using our Pruftechnik equipment, we select what types of equipment we are analyzing (ie. Motor + pump, motor + air compressor, and etc), input the dimensions of the equipment, and the points where the laser and receiver are located. We then manually and simultaneously turn both shafts 360 degrees by hand to conduct a test. The equipment takes a reading at every degree and calculates the level of movement as it goes around. The parameters are within thousandths of an inch. After the full 360 degree rotation, we can analyze the data on our equipment. The equipment will inform us to correct the machine positions.

After the first adjustments, we check the alignment again, repeating the same alignment check until the machines are aligned within proper tolerances.

Sometimes a “hot alignment check” is necessary. Machines can grow or shrink during operation causing misalignment.  We run the equipment for a period of time to see if there is any thermal growth or shrinkage. It is necessary to align the motor or generator to its proper working conditions.

During the alignment process of a non reconditioned or new motor/generator, our technicians can find other problems. For example, if alignment is off from 5 to 6 thousandths of an inch after each check, this is a sign that the bearing housings could be loose. Our technicians will recommend if bearings need to be replaced, machining is needed, or other improvements to extend the service life of your machines. In some instances, we can also make recommendations on the remaining service life, based on the condition of the motor/generator or load.

Overall, alignment is a crucial step to maximizing the amount of profit you can get out of a motor, generators, or loads service lifetime. Improper alignment will cost you and your operation money!

Cooling Towers Need Long Lasting Reliable Motors

June 11, 2018/0 Comments/in Cooling Season, Electric Motors /by Lynn Dreisilker

When the temperatures are climbing, you need a reliable cooling tower motor to keep your cooling towers running. Dreisilker stands behind the Leeson Totally Enclosed Air Open (TEAO) Cooling Tower Motors. Through many summers, the Leeson TEAO Cooling Tower motors have proven their quality and reliability for our customers.

There are many features of the Leeson TEAO Tower Motors that make an exceptional cooling tower motor including:

Designed for shaft up mounting: The Leeson motors are known for being able to fit in most applications.

Shaft grounding rings preinstalled: Having shaft grounding rings is added protection for your motor’s bearings. To learn more about shaft grounding rings, read our blog about Aegis Shaft Grounding Rings

Epoxy Painted: Leeson electric motors have the most durable paint in order to withstand the harsh environment that they are found in.

Complete Cast Iron Construction: This allows for rigidity and reduced vibration in the motor which can increase the service life of the motor.

Severe Duty: The internal components such as the rotor and the stator are severe duty treated so that they can withstand harsh environments.

Inverter Duty: The motors are inverter duty, allowing them to work with Variable Frequency Drives.

Some other premium features include:

  • Made in the USA
  • 3 Year warranty
  • 10:1 constant and variable torque rated
  • Inpro shaft seal protected
  • Class F insulation
  • F-1/F-2 Capable
  • Extra nameplate with CE for external mounting
  • Brass T Drain installed (both ends at 6:00)
  • Re-greasable bearings
  • 1.15 S.F. under sine wave power

When we discuss options with our customers, we always recommend Cooling Tower Duty (CTD) motors over the misapplied Open Drip Proof (ODP). The CTD motors can more completely protect the motor from the harsh environment compared to ODP motors. You want added protection for your cooling towers motors considering that in some cases the installation and removal of a cooling tower motor is extremely difficult and labor intensive.

During the summer months, we stock 3 – 100 HP TEAO Cooling Tower motors. For higher HP needs, there is stock readily available at a nearby distribution warehouse. If you have a cooling tower motor go down, consider the high quality Leeson TEAO Cooling Tower Motor.

 

Cooling Tower Motor

Cooling Tower Motors Selection

Electric Motors and Generators Fail from Contamination

March 7, 2018/0 Comments/in Bearings, Electric Motors, Reliability Services /by Matthew Dreisilker

Motors and generators are often mounted in a location that makes them susceptible to contamination. Over time, these contaminants cause major problems that can lead to bearing or complete motor failure. In this article, we’re going to outline four common scenarios in which contamination impacts motors and generators. We’re also going to provide solutions to keep your bearings and motors clean and free from contamination.

Breakdown of bearing lubrication or damage to the bearing surface.

Contaminants can breakdown your bearing lubrication and damage the bearing surface. This will cause a buildup of heat from friction. If the problem isn’t corrected, the added heat can lead to a catastrophic failure of your bearings and motor or generator.

Blockage of airflow or liquid cooling passages.

Motors naturally create heat which is caused by wasted energy. Motors and generators are designed with cooling fans, external blowers, vents, heat sinks, and liquid cooling systems to allow for heat to dissipate. Contaminants can clog the vents, cooling pipes, and cooling surfaces and prevent the motor from cooling properly. This added heat will eventually break down the mechanical and electrical components of your motor and can lead to motor failure.

Creating an imbalance to rotating components.

When contaminants stick to your motor rotors, fan blades, or other rotating components, they add excess weight. This weight creates an imbalance which can lead to increased vibration. The vibration caused by an out-of-balance rotating component will decrease the life of your bearings and could cause motor or bearing failure.

Deteriorating electrical insulation:

Not only will contaminants not allow your winding not to cool, the electrical insulation will breakdown over time. Contaminants will allow currents to discharge from conductors in the windings. In form wound windings, insulation tapes and varnish/resin carbonizes and breaks down. In random wound windings “pinholes” in the enamel insulation cause an electrical short when stress caused by contaminants break down the insulation. The result of insulation breakdown is lowering insulation resistance which can eventually causes an electrical short. Also on brushed motors and generators, brush dust can build up and cause shorts as well.

What are some solutions to preventing contamination in motors?

Electric Motor Contamination

Make sure your motor/generator is selected properly for the correct application

Example: This open vented motor filled up with corn dust. The motor has to be replaced with a totally enclosed fan cooled motor.

Electric Motor Contamination

Install and maintain filters in your air or liquid cooling system to prevent blockages

Example: This printing press motor filled with paper dust because it was not filtered properly.

Electric Motor contaminated by metal chips

Control nearby sources of contamination

Example: This motor was splashed with coolant and metal chips from machine tools.

Contamination from worn seal

Ensure bearing, cooling systems, brakes, or other motor system components are sealed properly

Example: This motors seal wore out allowing liquid to enter the motor.

Direction of electric motor

Ensure air patterns from cooling systems do not change allowing contaminates to travel in the wrong direction

Example: This motor is designed to run in one direction.

Motor cooling surface clogged with contaminants

Clean cooling vents and heat sink surfaces as needed without letting contaminates to ingress the motor/generator

Example: This motors cooling surfaces have clogged with contaminates.

Clean grease guns for lubricating motor bearings

Make sure bearing lubrication tools are clean and do not let contamination in

Example: These grease guns are kept in a clean storage area for lubricating motor bearings.

If you find your motor has been contaminated make a plan to send it in for minor reconditioning before it fails and becomes a more costly repair or replacement.

Example: A 1,600 kW generator being cleaned to remove contaminants.

Contamination in electric motor

Vacuum or blow out dust in brush applications per manufacturers recommendations

Example: Carbon/Graphite dust was not blown out of the motor on this brushed DC motor causing electrical problems.

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