WO2019207457A1

WO2019207457A1 - Method for monitoring and controlling motors and a system thereof

Info

Publication number: WO2019207457A1
Application number: PCT/IB2019/053297
Authority: WO
Inventors: Pravin SHEKHAR; Cajetan Pinto
Original assignee: Abb Schweiz Ag
Priority date: 2018-04-26
Filing date: 2019-04-22
Publication date: 2019-10-31

Abstract

The present disclosure discloses a method and a system for monitoring and controlling a fleet of motors. The system is configured to receive one or more values of a first set of parameters and determines a first value for each motor based on the one or more values of the first set of parameters of corresponding motor. Further, the system is configured to receive one or more values of a second set of parameters and determines a second value for each motor based on the one or more values of the second set of parameters associated with corresponding motor. Thereafter, the system is configured to identify at least one motor as critical, using the first value and the second value, for controlling one of the at least one motor and the condition monitoring device corresponding to the at least one motor.

Description

METHOD FOR MONITORING AND CONTROLLING MOTORS AND A SYSTEM

THEREOF

Technical Field

[0001] The present invention relates to condition monitoring of electric machines. More particularly, the present invention relates to monitoring condition of a fleet of motors and controlling the fleet of motors.

Background

[0002] In an industrial plant, motors (individual or fleet of motors) are used to operate various process equipment (pumps, valves, coolers, and the like). Timely maintenance of motors is required to assess condition of motors. Conventionally, maintenance activity is performed on motors only upon receiving alarms regarding faults in the motors. However, certain conditions of motors (e.g., bent rotor shaft, improper installation of motors and the like) are likely to affect operations of process equipment. As conventional systems identify faults only after the fault has occurred, maintenance activity cannot be initiated immediately to regulate usage of motors. Thus, operations of the process equipment are more likely to be interrupted leading to inefficient working of industrial plant. Hence, there is a need to address the above problem.

Summary

[0003] The present disclosure relates to a method and a system for monitoring and controlling a plurality of motors (also referred as motors/ fleet of motor). The plurality of motors can be operatively connected to a plurality of process equipment in an industrial plant/ process plant. The plurality of motors is monitored and controlled to operate the industrial plant efficiently.

[0004] In an embodiment, a control system is used to monitor and control the plurality of motors. The control system is configured to control and operate the plurality of motors and the plurality of process equipment. A condition monitoring device is mounted on body of each motor. Each condition monitoring device is configured to measure one or more values of one or more parameters related to the corresponding motor. For example, the condition monitoring device on a motor can measure temperature of the motor, magnetic field around the motor and vibrations in the motor.

[0005] In an embodiment, a server is provided in the control system. The server is configured to receive one or more values of a first set of parameters from condition monitoring device mounted on each motor. The first set of parameters indicate a condition of a motor. In an embodiment, the first set of parameters includes the one or more parameters measured by the condition monitoring device. The server determines a first value (value of a condition of a motor/ condition value) for each motor using the one or more values of the first set of parameters of corresponding motor. The server also receives one or more values of a second set of parameters indicative of operation of the plurality of process equipment. Further, the server determines a second value for each motor using the second set of parameters. Furthermore, the server identifies at least one motor as critical to the plurality of process equipment and controls either the at least one motor or the condition monitoring device mounted on the at least one motor to overcome the critical situation.

[0006] In an embodiment, the server may be connected to a controller. The controller may include a clutching mechanism to clutch the at least one motor to the plurality of process equipment. Also, the controller may be operatively connected to a redundant motor. In an embodiment, when the at least one motor is identified as critical, the server configures the controller to disengage the at least one motor and engage the redundant motor using the clutching mechanism. When the redundant motor is engaged, the redundant motor is connected to the plurality of process equipment.

[0007] In another embodiment, when the at least one motor is identified as critical to the plurality of process equipment and a redundant motor is not available, one or more operational parameters of the condition monitoring device mounted on the at least one motor is adjusted. For example, the condition monitoring device can include a processor and a threshold value for vibrations can be set in the processor. The threshold value can be adjusted (decreased/ increased) and can be further monitored.

[0008] In an embodiment, a gateway is configured to determine one or more operating parameters for at least one condition monitoring device from the plurality of condition monitoring devices, based on coordination with the server and at least one of controller associated with process equipment connected to the corresponding motor. In another embodiment, the gateway device includes one or more sensors for measuring ambient physical parameters. The gateway then sends the data based on the measurement of the ambient physical parameters to the server, which is used by the server for monitoring and controlling of motor.

[0009] In yet another embodiment, the control system also includes a mobile device for configuring the condition monitoring devices along with the gateway and for displaying one or more alert messages associated with the detected condition of the at least one motor based on a message from the server. The mobile device includes a plurality of sensors for measuring a plurality of parameters of a corresponding motor, and a processor for determining one or more operating parameters for a corresponding condition monitoring device affixed to the corresponding motor, based on the measured values of the plurality of parameters of the corresponding motor.

[00010] In an embodiment, one or more condition monitoring devices are connected to each other over a short-range communication network for coordination.

Brief Description of the drawings

[00011] The subject matter of the invention will be explained in more detail in the following text with reference to preferred exemplary embodiments which are illustrated in the drawings, in which:

[00012] Figure 1 illustrates a system for monitoring and controlling a fleet of motor, in accordance with an embodiment of the present disclosure;

[00013] Figure 2 illustrates a flow chart for monitoring and controlling a fleet of motor, in accordance with an embodiment of the present disclosure;

[00014] Figure 3 shows a graph illustrating criticality of motors to operations of process equipment, in accordance with an embodiment of the present disclosure; and [00015] Figure 4 illustrates a system for providing maintenance for motors in accordance with an embodiment of the present disclosure.

Detailed description

[00016] In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments, which may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments, and it is to be understood that other embodiments may be utilized, and that logical, mechanical, electrical and other changes may be made without departing from the scope of the embodiments. The following detailed description is, therefore, not to be taken in a limiting sense.

[00017] Figure 1 illustrates a system 100 for monitoring condition of a plurality of motors/ fleet of motors (110, 120, 130 and 140). The system 100 includes a plurality of condition monitoring devices (115, 125 135, and 145), installed on the plurality of corresponding motors (110, 120, 130 and 140), for measuring one or more parameters associated with the corresponding motors (110, 120, 130 and 140) in a non-invasive manner. The system also includes a gateway device 170, a server 160 and a mobile device 150.

[00018] In an embodiment, each condition monitoring device acquires the measurement signals periodically and processes it to acquire the operating conditions of the motor in accordance with an operating configuration. Each condition monitoring device also has memory on board on which the operating configuration is stored. Each condition monitoring device comprises a housing body capable of being affixed to a body of the motor, a plurality of sensors and a communication module for transmitting the measurements, housed in the housing body. In an embodiment, the condition monitoring device is mounted on the surface of a motor close to a drive side to monitor the bearing, the rotor and the operating conditions of the motor.

[00019] The sensors including at least one magnetic field measuring unit, at least one vibration sensor, an acoustic sensor and a temperature sensor. The magnetic field measuring unit measures a first value of magnetic field strength along a first axis substantially parallel to the axis of the rotor of the electric machine and a second value of magnetic field strength along a second axis. The second axis is at an angle to the first axis. The vibration sensor measures at least one of a first value of vibration along the first axis and a second value of vibration along the second axis. The temperature sensor measures a temperature of an area proximal to the electrical machine and an acoustic sensor, for measuring sound around the electrical machine. Accordingly, the one or more parameters including leakage magnetic flux in a first axis and leakage magnetic flux in a second axis, vibration along one or more axes, sound about the motor and temperature about the motor. In an embodiment, each condition monitoring device includes one or more processors configured to receive measurements of one or more parameters related to condition of corresponding motor. The measurements are received from the plurality of sensors. The one or more processors determine a condition of the corresponding motor based on the received measurements. The parameters include but is not limited to average vibration level in the motor per year, average operating hours of the motors, average operating load, number of times the motors are started in a year, time since maintenance is performed on the motors, variation of load (process equipment) connected to the motors, average power consumed by each motor, etc.

[00020] Operating configuration of a condition monitoring device comprises a plurality of operational parameters (and their values) relating to with measurement and diagnostic operations performed by the condition monitoring device and can include parameters such as detection or threshold parameters or alarm values, measurement related parameters such as sampling rates, parameters related to baselining of sensor values, machine construction parameters (stator slots, rotor bars, gear teeth, pump blades), duty cycle rate of the condition monitoring device, etc.

[00021] The processor of the condition monitoring device utilizes the operating configuration i.e. the values of operational parameters for operating the sensors and for performing diagnostics. For example, based on the value of the sensor sampling rate operational parameter, the processors operate the sensors at the defined intervals as per the value of the sensor sampling rate operational parameter for measuring the electrical and mechanical parameters of the corresponding motor. Similarly, the processors utilize the values of operational parameters related to diagnostics in determining the condition of the corresponding motor. For example, when the unbalance in the magnetic field is above value associated threshold parameter for unbalance, then a fault is detected and determined by the processors and is communicated to the server 160 via the gateway device 170.

[00022] The condition monitoring devices (115, 125 135 and 145) are communicatively coupled to a gateway device 170. The communication module of each condition monitoring device can be configured to communicate with the gateway device 170 over a first communication network. In an embodiment the first communication network is based on a wireless protocol such as Bluetooth, WIFI, Zigbee, LoRAWan etc. In an embodiment, the condition monitoring devices communicate their measurement data and data related to the condition of the corresponding motor to the gateway device 170. The gateway device 170 then transmits the measurement data and data related to the condition of the corresponding motor to a server 160. The server 160 utilizes the received data for performing asset analysis of the motors including condition and aging estimation of the motors.

[00023] In an embodiment, the condition monitoring devices (115, 125 135 and 145) can connect to each other over a short-range communication network. For example, in case a condition monitoring device 145 is unable to connect to the gateway 170, then the condition monitoring device 145 can connect to the neighboring condition monitoring device 135 for transmitting data to gateway 170 via the neighboring condition monitoring device 135.

[00024] In an embodiment, the server 160 includes plurality of equipment models corresponding to the plurality of motors (110, 120, 130 and 140). Each equipment model of a particular motor is updated based on the measurements of the parameters of the corresponding motor from the corresponding condition monitoring device mounted on the corresponding motor. The updated equipment model associated with the motor is utilized by the server in performing asset analytics of the motor by the server. In an embodiment, the server 160 is for analyzing the measurements from the condition monitoring devices and store the same in an archive. The server 160 includes a plurality of algorithms for processing the measurements. The server 160 additionally includes a communication interface for informing users associated with the motor about the motor condition using SMS or email, or the like. The server 160 receives one or more values of the first set of parameters for each motor from the plurality of motors. The first set of parameters of each motor is related to a condition of corresponding motor. The first set of parameters include the one or more parameters.

[00025] In an embodiment, the server 160 also receives one or more values of second set of parameters for each motor from the plurality of motors. The second set of parameters of each motor indicates optimality of using corresponding motor for operating one or more process equipment from the plurality of process equipment, connected to the corresponding motor. The server 160 then determines a first value for each motor using the one or more values of the first set of parameters. The first value indicates of a condition of corresponding motor. The server 160 also calculates a second value using one or more values of the second set of parameters. Thereafter, the sever 160 identifies at least one motor from the plurality of motor that is/ are critical or likely to be critical to operations of the one or more process equipment connected to the at least one motor. Further, immediate alerts are generated, and maintenance activity is performed on the at least one motor.

[00026] In an embodiment, the gateway device 170 is also equipped one or more sensors for measuring ambient environmental parameters such as temperature, noise level, background magnetic fields, etc. The measured values of the ambient environment parameters are communicated by the gateway to the condition monitoring devices (115, 125, 135 and 145) and the server 160 for use along with the measurements from the condition monitoring devices for determining the condition of the motors.

[00027] The system 100 further comprises a mobile device 150 associated with a field personnel, for configuring at least one condition monitoring device from the condition monitoring devices (115, 125, 135, 145), and for displaying one or more alert messages associated with the detected condition of the at least one motor. In an embodiment, the condition monitoring devices are triggered to start taking measurements upon receiving a signal from the mobile phone 150 and/or the gateway device 170. Measurements of the parameters of the corresponding motor is stored on a local memory of the sensing block of the condition monitoring device after which the measurements are transferred to the server via the mobile phone 150 or the gateway device 170. [00028] In an embodiment, the mobile phone 150 and the gateway 170 can preprocess the measurements from the condition monitoring devices including performing a data quality check (proper measurement condition verification). The data is stored temporarily in the memory of the mobile phone 150 or the gateway 150 and is then transferred to the server 160.

[00029] It is to be noted by a person skilled in the art while the gateway 170 and the server 160 are shown and described as individual devices, the functionality of the gateway 170 and the server 160 may be performed via one or more devices in coordination and can be realized by dedicated hardware or software components.

[00030] Figure 2 shows a flowchart illustrating steps in monitoring and controlling the plurality of motors/ fleet of motors.

[00031] At step 201, the server 160 receives a first set of parameters related to the plurality of motors from one or more sources including the one or more condition monitoring devices mounted on each motor. The one or more sources can be a database comprising at least one of process data related to the plurality of process equipment and historical data related to the plurality of motors. In an embodiment, the database is associated with the server l60.The first set of parameters includes: age of the motors, average vibration level of the motors per year, average operating hours of the motors, average operating load of the motors, time since maintenance activity on the motors, number of times the motors are initiated/ started, number of failures in the past, variation of load connected to the motors, method employed to initiate the motors, and environmental conditions around the motors.

[00032] In an embodiment, one or more parameters (average vibration level of the motors per year, average operating hours of the motors, average operating load of the motors, time since maintenance activity on the motors, number of times the motors are initiated/ started, variation of load connected to the motors) from the first set of the parameters are received from the condition monitoring devices (115, 125, 1345, 145) in real-time. The remaining parameters (age of the motors, number of failures in the past, method employed to initiate the motors, and environmental conditions around the motors) can be obtained from a database (not shown in figure). In an embodiment, the server 160 populates the database every time it receives the one or more parameters from the condition monitoring devices (115, 125, 1345, 145). Also, the server can populate the database with the environmental parameters measured by the gateway device 170.

[00033] The first set of parameters of each motor indicate a condition of the corresponding motor. For example, if the age of a motor is 10 years, then the motor can be monitored constantly as motors above a certain age (for example motors above 8 years in a specific industrial plant) are more likely to be critical to operations of the one or more process equipment connected to such motors. The age threshold can be determined based on type of industry the motors are used. In an embodiment, each parameter can have a corresponding threshold value to determine condition. For example, all motors aged more than 5 years can be considered for constant monitoring. All such motors can be provided with ratings/ score (e.g., a score of 3 can be given to motors which are aged more than 5 years, a score of 1 can be given to motors which are aged more than 10 years). Similarly, motors having values of vibration above a threshold value can be provided with ratings. Likewise, each parameter from the first set of parameters is provided with a score/ rating. The score/ ratings are provided to each parameter of corresponding motor, upon receiving the first set of parameters of each motor from the one or more sources.

[00034] In an embodiment, each parameter from the first set of parameters is provided with a weight. The weight indicates a priority to be considered among the first set of parameters. In an instance, number of failures in the past can be provided more weight compared to age of the motor as motors that are failed in the past are more likely to affect the operations of the one or more process equipment, than motors aged more than a threshold. For example, consider two motors, a first motor and a second motor. The first motor is 3 years old and has failed 4 times in a year and the second motor is 6 years old and has failed 2 times in a year. Although the age of the second motor is more compared to the first motor, the performance of second motor in view of number of failures in a year is better. Hence, the number of failures can be provided with more weight compared to the age of the motor.

[00035] At step 202, the server 160 calculates a first value/ a value of condition (also referred as condition index) for each motor using value of the score assigned to each parameter from the first set of parameters and value of the weight associated with the corresponding parameters for the corresponding motor. The value of score of a parameter and value of the weight assigned are multiplied to calculate a condition value for that parameter. For example, if a score of 3 out of 5 (where 5 denotes that motor age is less than threshold and 1 denotes motor age is greater than threshold) is assigned to a motor for the parameter“age of the motor”. Let us consider that a weight of 2 out of 5 (where 5 denotes most priority to the parameter and 1 denotes least priority to the parameter) is assigned to the parameter“age of the motor”. The condition value for the parameter “age of the motor” is calculated as 3*2 = 6. Likewise, the condition value is calculated for each of the first set of parameters for a motor. Further, a condition index is calculated by adding the condition value of each parameter for a motor condition index indicates overall condition of a motor.

[00036] At step 203, the server 160 is configured to receive a second set of parameters associated with each motor among the fleet of motor. The second set of parameters indicate effect of each motor on operation of the plurality of process equipment connected to corresponding motor. The second set of parameters include but is not limited to accepted downtime hours of each motor, impact of production downtime on the operation of the plurality of process equipment, criticality of each motor based on condition, and environmental impact of each motor based on failure of motors. Accepted downtime hours indicates the number of hours a motor and / or process equipment is not operated. In an embodiment, the second set of parameters is received from the one or more sources. For example, the second set of parameters are received from the database associated with the server 160.

[00037] In an embodiment, each parameter from the second set of parameters is associated with a score and a weight. In an embodiment, the weight is assigned to each parameter from the second set of parameters based on safety and cost of operating the plurality of process equipment. For example, a failure of a motor operating a water pump in the industrial plant may stop pumping of water which may affect operations of other equipment in the industrial plant. For example, due to a fault in a motor a pump in the industrial plant, connected to the motor may be shut down, thus delaying operations of the industrial plant. In an embodiment, the weight is initially assigned based on an industry plant model. In an embodiment, the weights are dynamically changed based on statistics obtained through real-time data. The weights can be dynamically varied and programmed in the server 170. Also, the cost associated with such failure may be high. The parameters associated with such failure may be criticality of the motor, and environmental impact of the motor. Thus, these parameters can be given a higher weight compared to other parameters of the second set of parameters.

Also, each parameter from the second set of parameters is provided with a score.

[00038] At step 204, the server 170 calculates a second value for each motor. The second value for a parameter is calculated by multiplying the value of weight of the parameter and the value of score of the parameter. Thereafter, a second value second value is calculated for each motor by adding the second value of each parameter for corresponding motor.

[00039] In an embodiment, criticality of using a motor is determined using the second value and the condition index. Figure 3 shows a graph illustrating variation of condition index and second value of a motor. The diagonal line in the graph indicates a threshold for indicating criticality of using a motor. The threshold can be set by a user or the server 170. The graph in Figure 3 shows a motor 310 which is likely to severely affect operations of the one or more process equipment connected to the motor 310. Motor 320 is likely to moderately affect one or more process equipment connected to the motor 320. Motor 330 and motor 340 are not likely to affect one or more process equipment connected to respective motors. The likelihood of a motor affecting the operations of the one or more process equipment connected to the motor is referred as criticality of the motor. The graph is thus used to identify at least one motor among the plurality of motors/ fleet of motor which is critical to the operation of the plurality of process equipment connected to the at least one motor.

[00040] Referring back to Figure 2, at step 205, at least one motor is identified as critical to operations of one or more process equipment connected to the at least one motor. According to the criticality of the at least one motor certain maintenance actions are performed. In an embodiment, maintenance actions can include using redundant motors in place of motors which are identified as severely critical and change operational parameters of the condition monitoring device mounted on certain motors identified as moderately critical and further monitor such motors. For example, consider a motor 320 is identified as moderately critical. The motor 320 can be flagged and can be timely monitored. Also, a maintenance can be scheduled based on the monitoring. Further, operational parameters of the condition monitoring device mounted on the motor 320 can be adjusted. For instance, considering that a rotor bar of the motor 320 has broken which due to which the motor 320 is identified as moderately critical. For example, consider that the motor 320 is operated at half speed of current operating speed by the drive and must be constantly monitored. The server 160 accordingly determines that value of the sampling rate of the vibration sensor of the condition monitoring device mounted on the motor 320, is to be increased by ten percentage of the preset value. Accordingly, the gateway 170, in coordination with the server 160, changes the operating configuration of the condition monitoring device to ensure increased sampling of vibration. Similarly, if the motor drive provides input to the server 160 that the motor 320 will be deenergized for few hours, the server 160 accordingly determines that the condition monitoring device may not monitor frequently, and duty cycle rate of the condition monitoring device is to be increased. Accordingly, the server 160 along with the gateway 170 changes the operating parameter value of the duty cycling rate to preserve energy of the condition monitoring device.

[00041] In an embodiment, motors are identified as severely critical to operations of one or more process equipment connected to the motors, when the condition index and the second value of such motors are above the threshold 341. Motors are identified as moderately critical when condition index and second value lie between the threshold 341 and 342. Further, motors having condition index and second value below the threshold 343 are identified as safe/ risk-free.

[00042] At step Figure 4 shows a system for providing maintenance for motors which are identified as severely critical, in accordance with an embodiment of the present disclosure. As shown in the figure, consider a motor 110 connected to a load 425 via a controller 420. The controller 420 clutches the motor 110 and the load 425. Thus, the motor 110 is contacted with the load 425. As the motor 110 is identified as severely critical, further use of the motor 110 can damage the motor 110. Thus, operations of the load 425 may be halted. In view of this, the motor 110 must be decommissioned and a new/ redundant motor can be connected to the load 425 for continuous operation of the load 425. As shown in Figure 4, a clutching mechanism can be used to disengage the motor 110 and the redundant motor 410 is engaged. The controller 420 can operate the clutch to connect the redundant motor 410 to the load 425. Initially, the controller clutches the motor 110 to the load 425. The server 160 configures the controller 420 to operate a clutch to disengage the motor 110 from the load 425 and engage the motor 410 to the load 425. The server 160 can provide instructions to the controller 420 via the gateway device l70.The controller 420, upon receiving the instructions, operates the clutch to disengage the motor 110 and engages the motor 410. Further, the motor 410 is monitored and criticality of the motor 410 is analyzed.

[00043] In an embodiment, the criticality levels are displayed to operating personnel in the industrial plant. In another embodiment, the criticality levels are displayed by the mobile device 150. In an embodiment, the mobile phone 150 is programmed for automatic or manual commissioning the condition monitoring device. In an embodiment, the mobile device 150 further includes a tag reader for reading a smart name plate associated with the motor and a Global Positioning System (GPS) tracker in an embodiment, a plurality of Near Field Communication (NFC) or similar data tags are attached to the motor body. The mobile device is configured to read these tags and use the information on the tags to configure the condition monitoring device via the gateway device 170.

[00044] In an embodiment, the condition monitoring device includes one or more portable sensors capable of being moved around the motor, and fixed sensors attached to the shell of the motor. In another embodiment, each sensor from the plurality of sensors of at least one condition monitoring device is capable of being mounted on distinct (or different) locations on the corresponding motor and are configured to operate simultaneously to provide measurements.

[00045] The mobile device 150 includes a diagnostic application for processing the measurements in co-ordination with the sensor and for presenting the information associated with the motor on a user interface of the application. In an embodiment, the application includes role and user -based access control.

[00046] In an embodiment, the alerts can be optimized by varying the threshold of the condition monitoring device. Also, timely maintenance can be performed, thus reducing failure of motors affecting the process equipment. In an embodiment, the condition monitoring data can be regularly analyzed to identify faulty parts in the motors and schedule maintenance. Thus, the present disclosure helps in taking preventive measures for failing of motors.

[00047] Accordingly, the present disclosure describes a system for monitoring condition of a plurality of motors having configurable condition monitoring devices configured via the gateway device to accommodate process equipment or motor related inputs. Additionally, the ability to measure data from a plurality of points around the motors and in the environment of the motors is leveraged for configuring the parameters of the condition monitoring devices for ensuring faster and optimized detection by modifying measurement and detection parameters in the condition monitoring device.

[00048] This written description uses examples to describe the subject matter herein, including the best mode, and to enable any person skilled in the art to make and use the subject matter. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Referral Numerals

Control system (100)

Motors (110, 120, 130, 140)

Condition Monitoring Device (CMD) (115, 125, 135, 145)

Mobile device (150)

Server (160)

Gateway (170)

Severely critical motor (310)

Moderately critical motor (320)

Ambient motors (330, 340)

Severe critical threshold (341)

Moderately critical threshold (342) Ambient threshold (343) Redundant motor (410)

CMD of redundant motor (415) Controller (420)

Load (425)

Claims

1. A method of monitoring and controlling a plurality of motors operatively connected to a plurality of process equipment in an industrial plant, wherein the method is performed by a control system, the method comprising:

receiving one or more values of a first set of parameters associated with each motor, wherein the first set of parameters of each motor is indicative of a condition of corresponding motor, wherein one or more values of one or more parameters from the first set of parameters of corresponding motor are received from a condition monitoring device mounted on the corresponding motor;

determining a first value for each motor based on the one or more values of the first set of parameters of corresponding motor, wherein the first value is indicative of a condition of the corresponding motor;

receiving one or more values of a second set of parameters associated with each motor, wherein the second set of parameters is indicative of operation of the plurality of process equipment;

determining a second value for each motor based on the one or more values of the second set of parameters associated with corresponding motor, wherein the second value is indicative of optimality of corresponding motor to operate the plurality of process equipment; and

identifying at least one motor as critical to the plurality of process equipment, using the first value and the second value, for controlling one of the at least one motor and the condition monitoring device corresponding to the at least one motor.

2. The method as claimed in claim 1 , wherein the one or more values of the one or more parameters are received from the condition monitoring device in real-time and one or more values of remaining parameters from the first set of parameters are received from one or more sources comprising at least one of process data related to the plurality of process equipment and historical data related to the plurality of motors.

3. The method as claimed in claim 1, wherein the first value is determined by multiplying a weight associated with each of the first set of parameters and a score associated with one or more values of each of the first set of parameters.

4. The method as claimed in claim 1, wherein the second value is determined by multiplying a weight associated with each of the second set of parameters and a score associated with one or more values of each of the second set of parameters.

5. The method as claimed in claim 1, wherein the at least one motor is controlled by disengaging a load connected to the at least one motor and engaging the load to a redundant motor by operating a clutch, wherein the condition monitoring device is controlled by adjusting one or more operational parameters of the condition monitoring device, wherein the one or more operational parameters are associated with measurement and diagnostics performed by the at least one condition monitoring device.

6. A control system for monitoring and controlling a plurality of motors operationally connected to a plurality of process equipment in an industrial plant, the control system comprising:

a plurality of condition monitoring device, wherein each condition monitoring device is mounted on a body of a motor from the plurality of motors, wherein each condition monitoring device is configured to measure one or more values of one or more parameters associated with corresponding motor;

a gateway device communicatively coupled to the plurality of condition monitoring devices, wherein the gateway device facilitates communication between the plurality of condition monitoring devices and a server configured in the control system,

the server configured to:

receive one or more values of a first set of parameters associated with each motor, wherein the first set of parameters comprises the one or more parameters;

determine a first value for each motor based on the one or more values of the first set of parameters of corresponding motor, wherein the first value is indicative of a condition of the corresponding motor,

receive one or more values of a second set of parameters associated with each motor, wherein the second set of parameters associated with operation of the plurality of process equipment;

determine a second value for each motor based on the one or more values of the second set of parameters associated with corresponding motor, wherein the second value is indicative of optimality of corresponding motor to operate the plurality of process equipment;

and

identify at least one motor as critical to the plurality of process equipment, using the first value and the second value, for controlling one of the at least one motor and the condition monitoring device corresponding to the at least one motor.