alpsmsirepairs-blog

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ENERGY EFFICIENCY LUBE

The more there is friction on the rolling element of bearing; motor exerts more power thereby increase your energy consumption. Suitable and correct amount of lubricants feed into the bearing will lessen friction, reduces load (HP), and make the whole drive system more efficient.

Bearing failure is a major cause of equipment downtime in today‘s industrial environment, most often resulting from improper lubrication. Improper lubrication scenarios include the contamination of the lubricant by dust, dirt and moisture, inadequate amounts of lubricant applied to the bearing, and/or over-lubrication of the bearing.

Each bearing failure directly impacts the production cycle. While bearings can be expensive, replacement cost alone is often miniscule compared to lost production and the cost to repair the damage.

Fig 1 shown that 51% of motor failure is caused by bearings. This is our experience in the repair of motors.

According to a recent study as shown in Fig. 2, 15% is caused by insufficient lubrication; 5% liquid contamination; 20% solid contamination (grease container exposed to environment not properly covered or sealed).

Contamination is caused by foreign substances getting into bearing lubricants or cleaning solutions. These include dirt, abrasive grit, dust, steel chips from contaminated work areas and dirty hands or tools.

Why, in the age of technology, is this a problem? It is because many bearings are still lubricated manually. No matter how diligently a maintenance staff adheres to a lubrication schedule, it is a difficult task. Because employees are expected to manage multiple responsibilities in the lean environment of today‘s plants, it is common that proper lubrication is not considered a priority.

Solutions:

Use the appropriate type and     correct amount of lubricant, avoid grease loss, and follow appropriate     re-lubrication intervals.

Filter the lubricant using     automatic lubricators and clean work areas, tools, fixtures and hands to     reduce the risk of contamination.

Reference: http://www.slideshare.net/dmanney/why-electric-motors-fail      http://vmpauto.com/article/v-debryakh-tribologii

Automatic Lubrication for Manufacturing Applications

ATS Electro-Lube manufactures self contained single-point and multi-point automatic lubrication products that provide effective, dependable lubrication for manufacturing equipment of all types. Our self-contained mechanical lubricators can deliver up to two full years of continuous lubrication, and can be installed almost anywhere—including remotely, as much as 30‘ from the lubrication point. Our devices are a safe, efficient alternative to daily manual lubrication.

We also offer a variety of accessories, including mounting brackets, control options and power options. ATS‘ motor-driven units, the ULTIMATE, TITAN, OILER and JACK series can all lubricate multiple points with a single unit via distribution blocks. Our TITAN, OILER and JACK units are refillable, for added convenience.

ATS‘ innovative auto lubers are ideal for bearing lubrication, engine lubrication, and any other machine lubrication needs your manufacturing processes may have. Our automatic mechanical lubricators deliver a reliable, consistent solution for any machinery that requires regular lubrication.

#Alignment, #VibrationAnalysis, #MotorEnergySavings, #MotorRepairs, #MotorRewinding, #Coolingtower, #EnergyefficiencyHVAC, #pumps, #blowers, #gearbox

http://alpsmsi.com/alps/energy-efficiency-lube/

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SYSTEM ANALYSIS

Vibration Analysis

Unscheduled downtime may cost millions of pesos per hour. Fortunately, modern vibration analysis equipment and software predict developing problems so that repair happens before disaster strikes.

ALPS MSI has the expertise and license to conduct vibration analysis with end result of providing Reliability Improvement, Condition Monitoring and Precision Maintenance

Case Study: Pump

The pump is brand new and operational 2008. In August 12, 2009 equipment owner hired our services to conduct Proactive Reliability Maintenance – Vibration Analysis. Below is the screenshot of the vibration results.

We recommended inspection why bearings were failing in spite that it was still considered brand new. In early part of April 2010, equipment owner called our attention that pump casing cracked as show in Figure 1.

Further inspection revealed as follows:

Defective     Pump Inboard Bearing No. 7314 BEJ single

Defective     Pump Outboard Bearing no. NU 314 ECJ/C3.

Damaged     oil seals.

Mechanical     seal condition was still good.

Action taken:

Re-machine     the shaft to the required interference fits that will fit two pieces of     7314 BECBJ arranged backto-back. Aligned motor and pump shaft using Fixturlaser     NXA Alignment System.

Click here to Email and Contact Us after repair Results.

#Alignment, #VibrationAnalysis, #MotorEnergySavings, #MotorRepairs, #MotorRewinding, #Coolingtower, #EnergyefficiencyHVAC, #pumps, #blowers, #gearbox

 http://alpsmsi.com/alps/system-analysis/

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Gearbox Repair Maintenance

Gearboxes are essential devices found everywhere in industrial manufacturing facilities, providing even distribution of power and torque wherever needed to fuel manufacturing productivity and profits. Despite how ubiquitous gearboxes may be, it‘s easy to overlook their repair needs. Forgoing routine maintenance on any gearbox could spell disaster for the entire production system. In order to keep everything running smoothly, be sure to take the time to perform basic upkeep and repairs on gearboxes to get the most out of their lifespan.

In order to prevent the need for any costly repairs or downtime, the first and most important part of any maintenance plan is diagnosing problems before they happen using vibration analysis.

It can assess what and where the damage has occurred simply by analyzing the frequency of the vibration being produced by the gearbox. Each gear mesh and bearing, depending on its size and shape, creates a certain frequency. Spikes in these frequencies can give an engineer insight into what is happening inside the gearbox – data that can be used to diagnose the problem.

Another tool is oil analysis, a key indicator of gearbox health and can prolong gearbox life span.

The gearbox‘s oil should be regularly changed according to the needs of the specific system. Just like in a car‘s engine, oil lubricates the gears and prevents them from grinding against each other.

In the process of changing oil, a sample of the old oil can be collected and sent to a lab, where an analysis of particles inside it can reveal potential underlying issues in the gearbox.

Even without this analysis, taking note of any excessive surface heat, odd vibrations or unusual noises coming from a gearbox can help identify most issues that may need a closer look.

ALPS MSI offers comprehensive solutions to keep your rebuilt gearbox work reliably. It‘s possible to schedule proactive repairs ahead of time, as well as keep an inventory of spare parts stocked and ready for quick fixes.

#Alignment, #VibrationAnalysis, #MotorEnergySavings, #MotorRepairs, #MotorRewinding, #Coolingtower, #EnergyefficiencyHVAC, #pumps, #blowers, #gearbox

 http://alpsmsi.com/alps/services/gearbox-repair-maintenance/

[alpsmsirepairs-blog]

SYSTEM ANALYSIS

Vibration Analysis

Unscheduled downtime may cost millions of pesos per hour. Fortunately, modern vibration analysis equipment and software predict developing problems so that repair happens before disaster strikes.

ALPS MSI has the expertise and license to conduct vibration analysis with end result of providing Reliability Improvement, Condition Monitoring and Precision Maintenance

Case Study: Pump

The pump is brand new and operational 2008. In August 12, 2009 equipment owner hired our services to conduct Proactive Reliability Maintenance – Vibration Analysis. Below is the screenshot of the vibration results.

We recommended inspection why bearings were failing in spite that it was still considered brand new. In early part of April 2010, equipment owner called our attention that pump casing cracked as show in Figure 1.

Further inspection revealed as follows:

Defective     Pump Inboard Bearing No. 7314 BEJ single

Defective     Pump Outboard Bearing no. NU 314 ECJ/C3.

Damaged     oil seals.

Mechanical     seal condition was still good.

Action taken:

Re-machine     the shaft to the required interference fits that will fit two pieces of     7314 BECBJ arranged backto-back. Aligned motor and pump shaft using Fixturlaser     NXA Alignment System.

Click here to Email and Contact Us after repair Results.

#Alignment, #VibrationAnalysis, #MotorEnergySavings, #MotorRepairs, #MotorRewinding, #Coolingtower, #EnergyefficiencyHVAC, #pumps, #blowers, #gearbox

http://alpsmsi.com/alps/system-analysis/

[alpsmsirepairs-blog]

Energy Efficiency Solutions

Clean Energy Solutions: HVAC Systems

Philippines is one of the highest electricity rates in South East Asia. Each industrial facility finds ways to reduce its Energy, Operating & Maintenance Cost (E&OM).

ALPS MSI in partnership with Siemens Philippines, Inc. is committed to help industrial motor users in reducing its power consumption. Proper design that is suitable for its use and optimized for its consumption plays an essential role for the energy efficiency of motors and its drive systems. Modern drive technology offer an enormous saving potential of up to 70 percent. This is the case for new plants as well as for modernization’s (retrofits).

The key for this is in a targeted analysis of drive systems regarding their respective degree of utilization and energy consumption. The tailored selection or modernization of motors and converters based on this, often already pays off in a very short time through the energy cost savings achieved.

The decisive factor for the most efficient use of energy is in reducing the energy consumption to the real demand of the application. The path to this is via a comprehensive bundle of measures. For this purpose:

costs and benefits of possible     savings are compared with each other,

the drive components are designed     according to the requirements and

the ideal path to sustainable     realization of the entire concept are formulated.

ALPS MSI offers industrial facilities our technical and financing for reducing your energy consumption.

Your benefits:

Efficient use of energy through     installation of modern energy-saving motors;

Optimized use of energy through     retrofit to variable-speed drives;

Adjusting the energy expenditure     to the specific requirement of the application;

Improved motor start-up behavior;

Low network load due to fewer     harmonics;

Reduced operational noise; and

Less wear and tear through     adjusted speed.

#Alignment, #VibrationAnalysis, #MotorEnergySavings, #MotorRepairs, #MotorRewinding, #Coolingtower, #EnergyefficiencyHVAC, #pumps, #blowers, #gearbox

 http://alpsmsi.com/alps/services/energy-efficiency-solutions/

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ABOUT US

ALPS Maintaineering Services, Inc. (ALPS MSI) is a family owned corporation, has been in the business of improving the energy and operating efficiency of existing motors and its drive systems in industrial plants in the Philippines since 1996 by:

1.  Employing vibration analysis & power analysis, and correcting if not improving efficiency of drive systems;

2.  Improving motor efficiency after rewound using high-end technologies;

3.  Efficient use of energy through installation of modern energy-saving motors;

4.  Adjusting the energy expenditure to the specific requirement of the application;

5.  Improving motor start-up behavior;

6.  Supply, install, and/or maintain pumps, blowers & other machineries; and

7.  Providing operations and maintenance (O&M) services to guarantee its energy savings performance.

ALPS MSI is committed to be part in the implementation of REPUBLIC ACT NO. 9729 AN ACT MAINSTREAMING CLIMATE CHANGE INTO GOVERNMENT POLICY FORMULATIONS, ESTABLISHING THE FRAMEWORK STRATEGY AND PROGRAM ON CLIMATE CHANGE, CREATING FOR THIS PURPOSE THE CLIMATE CHANGE COMMISSION, AND FOR OTHER PURPOSES.

Company‘s Certification

Professional Electrical Engineer     PRC# 2030, Registered Mechanical Engineer and Registered Electrical     Engineer

Vibration Institute Category II     Vibration Specialist

Mobius Institute Category III     Certified Vibration Analyst ISO 18436-2

Certification of Attendance CAT     III Vibration Institute of USA

Level 2 Condition Monitoring     Engineer, FIS Services, Germany

Laser Alignment Specialist,     Fixturlaser

EPRI Motor/Generator Rewind,     TECO-WH

Understanding Power Quality     Problems & Solutions, APQi Philippines

Member, Electrical Apparatus Service     Associa7 on of USA

Industrial Users Training on     Energy Management System based on ISO 50001 Framework sponsored by Gef,     DOE, and UNIDO.

#Alignment, #VibrationAnalysis, #MotorEnergySavings, #MotorRepairs, #MotorRewinding, #Coolingtower, #EnergyefficiencyHVAC, #pumps, #blowers, #gearbox

http://alpsmsi.com/alps/about-us/