Improvement of Induction Motors Reliability in Fertilizers Plants Using IOT and Enterprise Resource Planning

Induction motors are integral to the operations of large-scale factories, powering essential equipment such as pumps, belts, fans, mills, and vibrators. However, they are susceptible to various faults including electrical issues like insulation failure and overcurrent, as well as mechanical problems such as bearing failure, vibration, and misalignment. Environmental factors like temperature rise also contribute to their reliability challenges. To address these issues and enhance the reliability of induction motors, IoT offers a compelling solution by shifting from traditional time-based maintenance to condition-based maintenance through remote monitoring. In today's industrial landscape, IoT is widely recognized for its ability to facilitate predictive maintenance and fault analysis, thereby improving operational efficiency. Given that energy costs represent a significant portion of operational expenses, optimizing motor performance through proactive monitoring and adjustments can lead to considerable cost savings. This research advocates for the adoption of IoT, specifically utilizing ABB smart sensors tailored to monitor induction motor conditions like temperature, bearing health, and vibration. The gathered data can then be stored and analyzed to guide maintenance decisions effectively. By integrating with Enterprise Resource Planning (ERP) systems such as SAP, maintenance orders can be efficiently managed, covering preventive, corrective, and rehabilitation maintenance tasks. This comprehensive approach not only ensures timely interventions but also streamlines resource allocation, thereby enhancing the overall reliability and performance of induction motors in industrial settings. It emphasizes that improving the reliability of induction motors necessitates not only performance monitoring but also a dependable maintenance system, which SAP facilitates.