Electrical Motor Maintenance (PM)

you could try getting the casting of the motor made from a different material, I guess that the motors you have are cast aluminum. You could also try a different paint that offers better protection. You might also have the reaction between different metals causing the severe corrosion, that is, the feet of the motor are aluminum bolted to steel, this could up a chemical reaction and the feet of the of the motor become something similar to a sacrificial anode due to the corrosive atmosphere, so try separating the metals. As for the internal failures of the motor, try an Ex rated motor. For bearing problems, get an Laser alignment tool that will help you to determine "soft foot" etc to perfectly aline your motor and/or change your couplings to a "flexi type" to give you a little play on alinement. Not having the motor alined or reducing the "soft foot" will wear the bearings and shaft and the vibration from this will also have an adverse affect on the motor.

Solve the plant's containment problem. Not just to preserve the motors. Spills and losses have health issues, product quality issues, waste management issues, re-work issues, etc., all of which negatively affect the operation's profitability.

Hi. I think that the containment problem will not be addressed, it's Malaysia. They are not known for their H&E, (I've worked there), and while I'm sure that they would clean up spills etc, my guess is it's an old plant which is over worked, with old machines and even older staff, who cannot be re-educated (and that would include the senior management too). Great answer if it was the UK and something would be done about. Now I've said that, if it was the UK it wouldn't be an issue. A drug maker in the UK, in South Wales, had a similar problem. They replaced motors with new "Ex rated" ones, but ducted circulating air to each motor, (I know it sounds like a contradiction but it worked) raised the motors off the floor out of any spillage and ensured any spillage from pumps etc, was channeled/drained (within the specs of environment protection) away from moving machinery and reduced damage to motors and plant. We can only give brief comments based on our experiences, to give a total answer we would have to be there.

Most of what you said is mechanical failure that you must maintain though I believe in the concept unless it is obvious "Let it fail" in the move 2001 Space Odyssey with the high gain antenna.

First I would recommend applying a Epoxy Coating over the already existing paint on the motor. Depending upon the size of your motor, I have had to fabricate stainless steel shafts or have the fits tungstin carbide to deter the corrosion. Also we have had stainless fan covers fabricated. As for the bearing failures, if the alignment is the problem there is only one solution, Align the motor to your equipment. However the chemical in the atmosphere could be attacking the lubricant in your bearings. You may try installing Automatic Lubricators on each bearing chambers (such as SKF brand).

I´ve seen motors in acidic corrosive enviroments that have their feet mounting base sprayed with a rubber like compound. These motors & panels are mounted on a metal grid where a puddle would not be alowed to form.... I like the idea of getting IP65 motors & then wash them dowm on a regular time interval...