Archives for 2021

RCFA: A Key Element to Improved Reliability

A Decatur Industrial customer had back-to-back motor failures on a 300HP boiler fan. This was a critical application and the failures greatly impacted plant production.

Issues often occurred during startup from maintenance outages while the fan was being energized or a short time later when the unit had reached speed.

We needed to do two things: On-site evaluation + motor disassembly and RCFA in shop.

The motor was found to have failed due to moisture condensing on the windings. When the units were offline for maintenance, they failed to have the proper accessories to prevent moisture. D.I.E. installed silicone space heaters on the winding.

On-site inspection found a steam leak in an adjacent area that vented into the room where the motor was sitting idle during the outages. The customer needed to the change the venting to send the energy outside the building for the steam to be released.

Lastly, we reviewed the motor for opportunities to improve performance. The OEM winding design was not optimal as it produced high voltage stresses within the stator. D.I.E. redesigned the winding for better performance and increased reliability. The new winding has:

50% less voltage, at 77 volts per coil
300% more phase-to-phase and coil-to-coil insulation
Air gap harmonics mitigation
Optimum Chord factor where each turn produces higher torque
10% increase in the circular-mil-per-ampere area of wire allowing the motor to operate cooler under the same load due to reduced copper losses

In this case study, RCFA was necessary in-shop as well as at the customer site to identify and isolate issues. The savings in motor repair or replacement cost alone is significant.

Rewound/Repaired Motor $15,000
Replacement Motor $25,500

Industrial Plant Custodian

Pay: $20-22/hour. Easy application!

This is a PART-TIME position – minimum 20-24 hours a week between Monday-Friday.

Job Summary

In addition to normal custodian responsibilities (cleaning bathrooms, dusting offices, floors, etc) – light mechanical assistance for projects with the Maintenance Manager will be expected.

We are seeking a reliable Custodian to join our team. The ideal candidate will be responsible for maintaining cleanliness and orderliness in our facility (plant, warehouse, offices) ensuring a safe and welcoming environment for all occupants. This role is essential in supporting the overall functionality of our spaces through effective cleaning and maintenance practices.

Duties

Clean and maintain designated areas, including offices, restrooms, hallways, and common areas.
Perform floor care tasks such as sweeping, mopping, buffing, and waxing to ensure high standards of cleanliness.
Conduct commercial cleaning duties in various settings, adapting to the specific needs of each environment.
Monitor and maintain supplies needed for cleaning activities, reporting any shortages or equipment issues.
Support facilities maintenance by performing minor repairs or reporting larger maintenance needs to management.

Requirements

Previous experience in custodial or commercial cleaning roles is preferred
Strong attention to detail with the ability to clean efficiently and effectively.
Knowledge of floor care techniques including buffing and maintenance of various flooring types.
Ability to work independently as well as part of a team in a fast-paced environment.
Excellent time management skills to prioritize tasks effectively.
Physical stamina to perform manual labor, including lifting, bending, and standing for extended periods.
A proactive attitude towards maintaining cleanliness and safety standards in all areas.

Join our team as a Custodian where your contributions will help create a clean and inviting atmosphere for everyone!

Shantel Rogers Awarded Claud Thompson Scholarship

Shantel Rogers, a former student at Eisenhower High School and Richland Community College, has received a $1,000 scholarship to help cover educational related expenses for the upcoming school year. She will be studying business at Millikin University.

“Winning this scholarship means confirmation, for me.” Rogers went on to add, “Life has a way of switching our paths in unexpected ways. In these transitional periods we can doubt the work we’re putting in and feel it’s in vain. Winning this scholarship has shown me that no matter what may be in front of me, if I stay true to myself and keep pushing forward, things will work for my good.”

Her long term career goals have changed since the onset of COVID 19. Initially her goal was to climb the corporate ladder in a good company. However, COVID and the changes it brought to the workspace sparked her entrepreneurial spirit. Her goal after college is to build her own company that great people want to climb the corporate ladder at.

The Claud Thompson Decatur Industrial Electric Scholarship
This scholarship assists students seeking a career in business through the Tabor School of Business (PACE included) at Millikin University or students pursuing engineering technology degrees at Richland Community College. Additional criteria online includes financial need and students who are self-driven and leadership-oriented with a record of community service. High school seniors and college students may apply for the scholarship on the Community Foundation of Macon County website at www.endowdecatur.org.

To find out more about our founder, click here.

Redesign a Motor to Increase HP VS Purchasing New

$80,000 saving PLUS no emergency production downtime!

A food packaging plant was experiencing ongoing motor failures due to starting amperage kicking out the main compressor motor. Each time the kickout happened, production on the line would be damaged and lost. Not only was the motor kicking out, but significant motor damage was occurring causing frequent rebuilds and rewinds.

It was determined that the amperage being produced by the starter was going beyond the service factor of the 450HP motor and the compressor OEM believed a 500HP motor was needed.

Instead of selling the packaging plant three new motors, the experts at D.I.E determined that the original motors could easily be rewound by our technicians to convert the 450 HP motor to 500 HP and provide the increased horsepower needed to safely operate the applications. It would also mean the customer would not have to perform expensive equipment modifications.

The redesigned motors, with the D.I.EndurLast Global Vacuum Pressure Impregnation system, are operating very well and D.I.E. saved the customer $80,000+ downtime!

Click on images to enlarge.

No Current Imbalance Doesn’t Mean No Problem

Just because the three phase current data being returned by the installed relay is balanced, doesn’t clear the power circuit of possible anomalies. Remember from previous tips that the opposition to AC current is influenced by impedance, which is the combination of reactance and resistance. Not just resistance. A high resistance connection may be a small part of the overall impedance, but can still create a significant amount of localized heating. This localized heating can lead to big problems if not corrected. Waiting until the problem is severe enough that the resistance element dominates the total impedance and changes the AC current may be too late and risk a single-phase fault. Using the MCE® technology for precision resistance measurements will give an early indication of power circuit anomalies so they can be repaired before causing a high current imbalance.

Source PdMA