3DJH  RI 

0RWRU67$786 &DVH 1XPEHU 

&DVH+LVWRU\
This data set was acquired on a 200
hp motor in a paper plant as a
quick demonstration of the
MotorSTATUS unit. The motor
had been in place for 2 weeks,
replacing a motor that had failed
after only 6 months.

Data was acquired over an 80-

minute period. Note the fault
alarms in the load, HFD, and
upper non-synchronous displays.
Data acquisition was set at a “4
hour trend.”

• Load is cycling, and overload is

severe.

• Overload period will

significantly shorten motor life.

• This situation needs further

investigation.

• This information indicates a

bad bearing.

• The last trend point was

acquired after 7 shots of
grease.

• HFD confirmed using 2120

Greased bearing Machinery Analyzer.

$XWKRU Bruce Hoge 'DWH December 15, 1997

&RPSDQ\ MJ Electric 3ODQW Plant (anonymity requested)
 3DJH  RI 
0RWRU67$786 &DVH 1XPEHU 

&DVH+LVWRU\
Upper, non-synchronous increases
with load. Alarms in this parameter
usually indicate a bearing problem.

Suspect large high frequency peak

is caused by bearing defect.
Confirmation of bearing defect
frequency is needed.

Bearing frequency?

&RQFOXVLRQV5HFRPPHQGDWLRQV
• Previous motor failed the inboard bearing in 6 months.
• Severe overload exists.
• New motor showing early signs of a bearing problems.
• Process needs to be changed or motor resized.

$XWKRU Bruce Hoge 'DWH December 15, 1997

&RPSDQ\ MJ Electric 3ODQW Paper Plant (anonymity requested)
0RWRU67$786
3DJHRI
&DVH1XPEHU

&DVH+LVWRU\
Data was acquired over a 2 month
period. Load, vibration, and
temperature problems occurred
during the monitoring period.
Status acquisition was set at
“monthly trend.”

Load was spiking due to a process

problem, which was corrected on
11/4/97.

Corrected process problem

• Motor fan clogged with pulp.

• Motor heating (frame-ambient)

increased by 11oC.
Motor fan cleaned
• Motor was cleaned 11/19/97.

$XWKRUBruce Hoge 'DWHDecember 15, 1997

&RPSDQ\MJ Electric 3ODQWPaper Plant (anonymity requested)
0RWRU67$786
3DJHRI
&DVH1XPEHU

&DVH+LVWRU\

• Vibration problem was fixed

11/7/97.

• Corrected alignment, greased

Vibration problem corrected
coupling, repacked pump.

• Spikes after correction are

believed to be cavitation by the
analyst.

• Overall vibration 0.23 in/sec.

• Spectrum shows coupling or

looseness problem.

• Vibration decrease by factor of

10 after repair.

&RQFOXVLRQV 5HFRPPHQGDWLRQV

• Often machines have multiple problems as illustrated in this case history.

• The systematic identification and correction of this machine’s operational, environmental and mechanical
problems will increase its life by many years over by allowing it to run in a degraded condition.

$XWKRUBruce Hoge 'DWHDecember 15, 1997

&RPSDQ\MJ Electric 3ODQWPaper Plant (anonymity requested)
0RWRU67$786
3DJHRI
&DVH1XPEHU$

&DVH+LVWRU\
• Data taken from a 900 hp,
3585rpm booster feed pump.

• Non-redundant pump.

• Plant will lose 350mw if this

pump goes down.

• Machine averages 91% load,

but peaks most days up to
110% to 120%.

• Motor averages 13% time

above 100% load.

• Motor has 1.2 service factor.

1x mechanical vibration is steadily

climbing and has doubled in the last
4 months. This indicates a balance
or bearing problem.

$XWKRUSean McGrady 'DWHDecember 18, 1997

&RPSDQ\CSI 3ODQWPower Plant (anonymity requested)
0RWRU67$786
3DJHRI
&DVH1XPEHU$

&DVH+LVWRU\

The two dominate peaks are 1x

mechanical and 2x electrical line.

1x mechanical

120Hz electrical

The presence of 2x line is unusual

at this amplitude. The fact it is
increasing signals a growing
problem. This parameter usually
indicates rotor eccentricity.

&RQFOXVLRQV 5HFRPPHQGDWLRQV

• As of 12/18/97, motor is operating and problem is being watched.

• A full 2120 Machinery Analyzer work up has been performed. Data indicates lack of axial vibration and phase
orientation indicating that misalignment is unlikely.

• Suspect mechanical imbalance or worn bearings.

$XWKRUSean McGrady 'DWHDecember 18, 1997

&RPSDQ\CSI 3ODQWPower Plant (anonymity requested)
0RWRU67$786
3DJHRI
&DVH1XPEHU%

&DVH+LVWRU\
The plant opened the motor
referred to in case history
9712012A for inspection. The
outboard bearing was found to be
“wiped” and replaced.

• Average 1x vibration was

reduced by the repair, but it is
still high.
Outboard bearing replaced
• Maximum 1x vibration still
peaks very high.

Electrical 120 Hz peak is still a

concern. Average 120 Hz trend is
continuing to slowly increase.

&RQFOXVLRQV 5HFRPPHQGDWLRQV

A problem still exists in this motor.

$XWKRUSean McGrady 'DWHDecember 22, 1997

&RPSDQ\CSI 3ODQWPower Plant (anonymity requested)
0RWRU67$786
3DJHRI
&DVH1XPEHU

&DVH+LVWRU\

• Data taken on a 2400 hp boiler

feed pump.

• Sleeve bearing machine.

• Data acquired in July.

• Service factor is 1.0.

• Load cycles over a 24 hour

period.

• Peaks up to 133% during the

day and drops to about 80% at
night.

• This motor is being severely

overloaded.

• HFD is much higher than

would be expected on a sleeve
bearing motor.

• HFD cycle is opposite load, i.e.

high HFD occurs on lowest
load.

• High HFD could mean broken

rotor bar.

$XWKRUBruce Hoge 'DWHDecember 22, 1997

&RPSDQ\MJ Electric 3ODQWFossil Fuel Steam Plant (anonymity requested)
0RWRU67$786
3DJHRI
&DVH1XPEHU

&DVH+LVWRU\

Frame temperature cycles up to

71oC.

Motor heating averages 25oC

(45oF). This is excessively hot for
an open frame motor. Normal
temperatures range is 10oC to
15oC.

6.5 oC rise is due to overload.

&RQFOXVLRQV 5HFRPPHQGDWLRQV

• The excessive load and high temperature experienced by this motor will significantly shorten its life.

• When this motor is replaced next it should be upgraded to handle the actual load. Load should be verified with
a motor current measurement.

• A motor current signature analysis should be performed to check for broken rotor bars.

$XWKRUBruce Hoge 'DWHDecember 22, 1997

&RPSDQ\MJ Electric 3ODQWFossil Fuel Steam Plant (anonymity requested)
0RWRU67$786
3DJHRI
&DVH1XPEHU

&DVH+LVWRU\
• 500 Hp motor-compressor
• Machine vibration is known to
be very load sensitive.

• Vibration increase with high

load.
• Vibration has a strong daily
cycle.

$XWKRUJohn Schultz 'DWHDecember 22, 1997

&RPSDQ\IVC 3ODQWPharmaceutical Plant (anonymity requested)
0RWRU67$786
3DJHRI
&DVH1XPEHU

&DVH+LVWRU\
Daily ambient temperature swings
from 90C at night to over 400C
during the day.

• 2xline shows a strong reverse

relationship with ambient
temperature.
• Low ambient occurs with high
2xline.
• 2xline usually caused by rotor
eccentricity or soft foot.

&RQFOXVLRQV 5HFRPPHQGDWLRQV

• Plant found a soft foot condition which allowed vibration to increase with load.

• Data after correction is not shown.

• 2xline frequency energy is no longer significant component of data.
• Since the soft foot correction, no failure (4 months) versus previous MTBF (2 months).

$XWKRUJohn Schultz 'DWHDecember 22, 1997

&RPSDQ\IVC 3ODQWPharmaceutical Plant (anonymity requested)