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The power & utilities department lacked an effective maintenance tracking system for maintaining various HT and LT motors in the refinery complex, which resulted in either over or under-greasing of motors due to a lack of visibility in their run hours. To address this issue, a Condition-based Maintenance system was implemented in the first phase of the project for 1800 motors. A Preventive Maintenance Planner module was incorporated in the second phase to keep track of maintenance frequencies, last maintenance dates and present a prioritized list of motors for upcoming maintenance activity through an interactive dashboard, saving time and money for the maintenance team.
This allows to prioritize and schedule maintenance for Equipment based on actual conditions, saving time and money.
Supervisor can easily assign tasks to maintenance personnel on account of daily email reports indicating list of equipment needing maintenance.
Periodic motor maintenance was enhanced considering varied factors. Weekly and daily reports facilitated efficient planning and comparison of motor health between maint. cycles.
No over-greasing or under-greasing of equipment now, as there is clarity on the exact motor run hours and last recorded maintenance activity.
CONSYST’s IIoTNext Platform centralized Motor Management for 1800 motors by collecting required parameters from existing DCS via OPC-UA, storing data in a high-performance historian, and using interactive dashboards for data visualization and analysis. The platform records maintenance needs of each motor in real-time, saving time and money. Customizable dashboards using smart widgets to depict, metadata for monitoring run hours of each motor, maintenance frequencies, last maintenance dates, motor health comparison and plant-wise motor maintenance management information were developed to meet customer’s requirement, keeping teams updated and cross checked.
