Archives for 2017

Decatur Industrial Electric was one of three companies who had the opportunity to bid on a new large motor for a power generation facility. The customer was looking to replace an old open drip proof motor.

We did not want to simply quote a replacement; but wanted to look at the application and see if there was a better motor solution.

In the pursuit of a replacement motor, our team reviewed the following:

1. Review more efficient and newer technology available
2. Changing the application to a TEFC (Totally Enclosed, Fan cooled) -due to the motor operating environment
3. Performance data, including torque requirements for blower

After the review, we proposed for purchase a TEFC that would fit the present base and meet blower torque requirements. This motor was a standard stock item and was on-site quickly, but it also alleviated the requirement of needing a spare being stocked.

The customer awarded Decatur Industrial the job, which included the purchase and install of the new motor along with a new coupling. Even after the purchase and installation, the savings to the Municipal was $21,551 lower compared to other bids. Plus, the customer did not have to invest in a spare.

The next time you need to replace a motor, give Decatur Industrial Electric a call. We partner with you to see if there is a better motor solution for your application that over time will save you Total Cost of Ownership.

A plastics company contacted Decatur Industrial Electric for our expertise in repairing a failing gearbox which also needed modified in order to fit an application. The OEM had estimated 8 weeks for the repair turn-around time and the customer needed it sooner.

The gearbox was suffering from bearing failure, seal damage, gear wear, and other costly issues.

Decatur Industrial was awarded the repair and completely rebuilt and modified the gearbox, with the goal of extending its life. Some of what we did included:

1.       Relocation of the mounting holes

2.       Rerunning of the oil feed lines

3.       Removal of oil troughs in order to go from fling oil system to a force feed oil system

4.       Installation of new piping for oil scrubber

5.       Rebuild of oil cooler and oil cooler pump

Our full-service machine shop also modified it from a vertical position to a horizontal position, as seen in the final “after” picture below. This customer was saved approximately 6 weeks of additional repair time. Plus, since they didn’t have to get on an airplane to go down to the OEM, the customer was able to visit their equipment and follow the progress more closely, which was important to them.

Steel Mill Facing Nine Motor Rebuilds a Year Due to Premature & Severe Commutator Wear

A customer from the metal industry was pulling multiple motors from service within eight months or less due to severe commutator wear. At that time, D.I.E. was not the chosen repair partner, but was asked to help. Our experts, in order to reduce the commutator wear and attain better and longer motor life between rebuilds, engaged in root cause failure analysis techniques.

After our initial inspection, we found two main issues at play:

1.       Blowers were running backwards, allowing for the possibility that heat could be a contributing factor.

2.       Motors were not running at anywhere near nameplate load ratings.

After identifying these problems, we worked with the brush manufacturer to come up with a brush that would be better suited to the lower amp draw (load). At the next planned maintenance check, our technicians ensured the new brushes were installed and seated properly. We also made sure the blowers on all units were running in the right direction to assure good air flow through the motor.

By reducing the commutator wear, we expect to double the time between reconditioning of the motor, saving them downtime and dollars.