Posted: October 15th, 2022

Failure Mode Effects Analysis (FMEA): Electric Motor for Pumps

Failure Mode Effects Analysis (FMEA): Electric Motor for Pumps
Exercise 1
Failure Mode Effects Analysis is carried out to establish the potential failures in a design system, meeting or manufacturing strategy of the electrical motor utilized in pumps. By way of the Assessment, it’s potential to establish potential errors or defects of a product. The errors are recognized and corrected to forestall them from affecting the purchasers. Nevertheless, the primary aim of the Assessment is to review the implications or the consequences of failures which may render the electrical motor to not function successfully. Due to this fact the aim of FMEA is to take actions which are essential in eliminating or lowering failures by prioritizing the opposed failures. FMEA is employed to regulate and forestall failures through the design course of. There are a number of instances when FMEA is utilized. As an illustration the method could be performed when designing or redesigning a product and utility of a product in a brand new approach.
Throughout the strategy of design and operation, totally different information is critical for the implementation of all of the processes. The info embrace motor present, Voltage ranges, Service issue and security, overloading, and troubleshooting. The quantity of present is critical to find out the extent of torque output. The quantity of present is proportional to the extent of output. The quantity of present determines the rise within the temperature of the tools. Knowledge on voltage is a determinant issue due to the impact of high and low voltages. The low voltages produce excessive quantity of present which causes the rise in temperature whereas the excessive voltage causes much less quantity of present which reduces the overheating course of and subsequently inflicting cooling course of. Knowledge from the voltage take a look at is essential in figuring out the unbalancing or balancing of the system. The info are utilized in assessing the efficiency of the electrical motor. The willpower of the frequency at which the motor operates is necessary in analyzing the operations of the system. A lot of the electrical motors are related to the utility energy line and subsequently the design course of ought to correspond to the frequency of utilization. The service issue determines the circumstances at which the electrical motor will function; the issue needs to be utilized in controlling different elements corresponding to temperature. The opposite kinds of information embrace security, overloading, and troubleshooting. As an illustration, for security functions there may be want for guards corresponding to couplings gears, sheaves amongst others. Within the instances of overloading, there should be information that determines the restrict of overloading.

Determine 1. Practical Block Diagram for Electric Motor Pump
The pump is digitally managed utilizing a easy logic circuit. Within the block diagram, 4 positions are utilized in figuring out the route of present within the coil or on and off present within the mover coil.

Determine 2: The Reliability Diagram for Electric Motor Pump
The reliability block diagram is used within the identification of the potential areas of poor reliability or the place enhancements could be made. The strategy can be utilized at each operational and design phases. The diagram exhibits the logical connections between the electrical motor pump. A method is employed within the calculations of the reliability which later guides the design and operation course of.

Determine Three: Diagrammatic Illustration of Rotor Bar

Desk 1: Work sheet
System Electric Motor
Gear Rotor
Drawing Rotor Association FAILURE MODE EFFECTS ANALYSIS WORKSHEET Date Right this moment’s Date
Sheet 1 of __
Complied By Reliability Enchancment Workforce
Authorised Engineer in Cost
ID No Merchandise Description Features of Merchandise Perform Failure Mode Failure Mode Causes Failure Impact
Damages/Prices/Losses/Security Signs of Failure Mode Failure Mode Detection Technique Rectification on Failure Motion to Stop Failure Causes
The Merchandise Its Neighbors Complete System CM Method
1 Rotor bars To differ the velocity of toque traits within the induction electrical motor of the pump Damaged Rotor bar Mechanical Points Overworking of the merchandise The Rotor bars work together with radial flux
Toque produce acts in the identical route because the rotating area The eventual rotor failure
Failure within the transmission of present Noise
Arcing Vibration Assessment
Present measurements Substitute a brand new rotor bar Monitor the rotor bars time to time to forestall it from injury or keep away from the overworking of the tools
2 Rotor Core To hold the rotating magnetic area that induces because of Three-phase provide Thermal stress
Thermal overloading
Unbalanced section voltage Poor location or uninsulated rotor core Incorrect becoming/ Lack of insulation The electrical system
Interplay between rotor core and ventilating duct The eventual failure of rotor
Uneventful winding wire Noise
Arching
Overheating of the motor Analysis of the temperature
Analysis of the present move Set up a substitute rotor core Insulating of the gadget
Motor designed with the NEMA requirements
Three Rotor Shaft Passes rotational motion from the rotor and the facility on downstream parts Rotor shaft misalignment
Corrosion and put on and tear Friction between components which trigger corrosion Incorrect set up or not firmly put in The overheating of the opposite components of the rotor Eventual Rotor failure

Noise
Arching
Overheating The fatigue or working abnormally
Set up a brand new rotor shaft Greasing/ oiling of the components to forestall corrosion

Desk 2: Failure Mode for a Rotor defect
Failure Mode Failure Impact Failure trigger Failure Case Trigger Prevalence Present controls Detection
Rotor defect Injury of the rotor Brocken rotor bars
Eccentric rotor Imbalance
Thermal stress
Meeting points Getting old

1 Checking air between the gaps of the rotor and stator 10

Merchandise Sub-Assy DAFT Value Score Chance Criticality by Threat Matrix Required Working Apply Required Upkeep Criticality after Mitigation
Whole Loss Value
$ Partial Loss Value
$ Time to Rebuild
Days Failure Charge – MTBF From CMMS Gear Historical past Consequence ; Chance = Threat Score Have to be substantial discount in stage or likelihood of stress on merchandise
Electric Pump Motor 550,000 120 TOTAL RISK
= 480000 1. Too costly to hold emergency spare ?Three; Three > M
Rotor Bars 20,000 25 1 in 40,000hr Three ; Three = M 1. Substitute the Rotor bas
2. Conduct a verify on the bars ceaselessly 1. Examine and take a look at the working mechanism
2. Substitute the rotor bars Three ; 2 = M
Rotor Core 45,000 30 1 in 10,000hr Three; four = H 1. Substitute the rotor core
2. Monitor present move Three. Use greatest apply for rotor core administration strategies

four. Rotor core exams four: Three = M
Rotor Shaft 250,000 10 1 in 60,000hr four ; Three = H 1. Operator skilled to not overload truck and over-rev motor
2. Set up wi-fi engine monitoring and reporting 5. Inspection of the shaft Three: 2= M
Finish Ring 140,000 32 1 in 50,000hr Three; four =H 1. Substitute the rotor ring
2. Diagnose the working situation 6. Guaranteeing finish rings are in place four: four= M
Ventilating Duct 25,000 14 1 in 10,000hr four; four=M 1. Substitute the ventilating duct
2. Examine the working situation on frequent foundation 7. Monitoring the work situation 2: 2= M

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