Reduce Motor Maintenance Costs Through On-Line Monitoring - MTA-MA-002

Administrative Items
Date	12/15/2020
Functional Area Where Benefits Will Be Realized	Maintenance
Reference Implementation Guidance	Developing a Technical Basis for Using On-Line Equipment Condition Monitoring to Reduce Time-Based Preventive and Predictive Maintenance (EPRI 3002012784) Preventive Maintenance Database (PMBD) Vulnerability Tool (EPRI 3002005428) PMBD Quick Reference Guide (EPRI 3002007394) Wireless Sensor Survey and General Specification (EPRI 3002011818) COLM Quick Guide – Horizontal Motors (EPRI 3002012766) COLM Quick Guide – Vertical Motors (EPRI 3002012765, 3002012781)
Industry SME	Mike Taylor – EPRI Christopher Kerr – EPRI Contact: NuclearPlantMod@epri.com
Previous Implementation	Please contact EPRI for implementation examples and contacts.
Implementation Enablers	Wireless Communications; Accessible Locations
SWEEP Score	Cost – Level 3 – Implementation cost is less than USD 1M Savings – Level 1 – Savings are less than USD 1M per year Payback – Level 2 – Payback period is greater than one year but less than 5 years Technology Readiness – Level 3 – The technology is ready for wide operational deployment. Advanced OLM has already been implemented at fossil facilities and piloted at nuclear facilities. Licensing Readiness – Level 3 – No changes are required Implementation Proficiency – Level 3 – The technology can be implemented by all sites regardless of digital experience. Implementing an advanced OLM program should not require a design change.
Applicability	All Reactor Types All Regions
Keywords	Condition-based maintenance; Equipment reliability; On-line monitoring; Motors; Sensors
Business Case Analysis Cross-Reference	N/A

Description

Nuclear utilities use a variety of motors for essential site operations. As with all mechanical components and sub‑components, these components require routine inspection and maintenance. Historically these inspections and maintenance have been performed periodically on a time and material basis. Technology advances in sensors, wireless communications, and data analysis now enable continuous monitoring and trending of various component parameters. Broadly referred to as Continuous On‑line Monitoring (COLM), this MQG applies more specifically to the monitoring of motor components and the associated maintenance tasks that can be eliminated or conducted less frequently.

Benefits

Benefits Estimate

Level 1 – Savings are less than USD 1M per year

Benefits Description

• Labor savings for some eliminated Preventive Maintenance (PM) tasks and for interval extension for other PM tasks
• Early detection of equipment degradation resulting in reduced equipment forced outages and corrective maintenance (CM) costs and a transition from periodic maintenance to condition‑based maintenance
• Improved PM/CM KPI performance
• Improved visibility to asset or system condition through more frequent data collection
• Reduction of potential rework for inaccurate maintenance (avoided costs)

Costs and Schedule

Cost

Level 3 – Implementation cost is less than USD 1M

Schedule

Less than 6 months

Scope Context

Component / System – The scope of the cost and benefit estimates assumes 4‑5 motors per unit. Results for multi‑unit sites or across a fleet should be scaled, accounting for any potential efficiencies in larger deployments

Risks

IT risks: If the IT interfaces with the new sensors are not considered, then there could be schedule delays in getting the sensors installed. Addressing IT concerns at the requirements phase of the project (e.g., how the sensor data will be gathered and used) will mitigate this risk.