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This data set was acquired on a 200 hp motor in a paper plant as

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.”

displays. Data acquisition was set at a “4 hour trend.” ∑ Load is cycling, and overload
displays. Data acquisition was set at a “4 hour trend.” ∑ Load is cycling, and overload

Load is cycling, and overload is severe.

Overload period will significantly shorten motor life.

This situation needs further investigation.

motor life. ∑ This situation needs further investigation. Greased bearing . ∑ This information indicates a
Greased bearing .
Greased bearing
.

This information indicates a bad bearing.

The last trend point was acquired after 7 shots of grease.

HFD confirmed using 2120 Machinery Analyzer.

Upper, non-synchronous increases with load. Alarms in this parameter usually indicate a bearing problem. Bearing

Upper, non-synchronous increases with load. Alarms in this parameter usually indicate a bearing problem.

Alarms in this parameter usually indicate a bearing problem. Bearing frequency? Suspect large high frequency peak
Bearing frequency?
Bearing frequency?

Suspect large high frequency peak is caused by bearing defect. Confirmation of bearing defect frequency is needed.

defect. Confirmation of bearing defect frequency is needed. ∑ Previous motor failed the inboard bearing in

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.

Data was acquired over a 2 month period. Load , vibration , and t e

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.”

period. Status acquisition was set at “monthly trend.” Corrected process problem Load was spiking due to
Corrected process problem
Corrected process problem

Load was spiking due to a process problem, which was corrected on

11/4/97.

due to a process problem, which was corrected on 11/4/97. Motor fan cleaned ∑ Motor fan
Motor fan cleaned
Motor fan cleaned

Motor fan clogged with pulp.

Motor heating (frame-ambient) increased by 11 o C.

Motor was cleaned 11/19/97.

Vibration problem corrected
Vibration problem corrected

Vibration problem was fixed

11/7/97.

Corrected alignment, greased coupling, repacked pump.

Spikes after correction are believed to be cavitation by the analyst.

correction are believed to be cavitation by the analyst. ∑ Overall vibration 0.23 in/sec. ∑ Spectrum
correction are believed to be cavitation by the analyst. ∑ Overall vibration 0.23 in/sec. ∑ Spectrum

Overall vibration 0.23 in/sec.

Spectrum shows coupling or looseness problem.

Vibration decrease by factor of 10 after repair.

∑ Vibration decrease by factor of 10 after repair. ∑ Often machines have multiple problems as

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.

∑ Data taken from a 900 hp, 3585rpm booster feed pump. ∑ Non-redundant pump. ∑

Data taken from a 900 hp, 3585rpm booster feed pump.

Non-redundant pump.

Plant will lose 350mw if this pump goes down.

pump. ∑ Plant will lose 350mw if this pump goes down. ∑ Machine averages 91% load,

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.

13% time above 100% load. ∑ Motor has 1.2 service factor. 1x mechanical vibration is steadily

1x mechanical vibration is steadily climbing and has doubled in the last 4 months. This indicates a balance or bearing problem.

1x mechanical 120Hz electrical
1x mechanical
120Hz electrical

The two dominate peaks are 1x mechanical and 2x electrical line.

two dominate peaks are 1x mechanical and 2x electrical line. The presence of 2x line is

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.

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.

Outboard bearing replaced
Outboard bearing replaced

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.

Maximum 1x vibration still peaks very high.

still high. ∑ Maximum 1x vibration still peaks very high. Electrical 120 Hz peak is still

Electrical 120 Hz peak is still a concern. Average 120 Hz trend is continuing to slowly increase.

A problem still exists in this motor.

∑ Data taken on a 2400 hp boiler feed pump. ∑ Sleeve bearing machine. ∑

Data taken on a 2400 hp boiler feed pump.

Sleeve bearing machine.

Data acquired in July.

Service factor is 1.0.

∑ Data acquired in July. ∑ Service factor is 1.0. ∑ Load cycles over a 24

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.

80% at night. ∑ This motor is being severely overloaded. ∑ HFD is much higher than

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.

Frame temperature cycles up to 71 o C. Motor heating averages 25 o C (45

Frame temperature cycles up to

71 o C.

Frame temperature cycles up to 71 o C. Motor heating averages 25 o C (45 o

Motor heating averages 25 o C

(45 o F). This is excessively hot for an open frame motor. Normal temperatures range is 10 o C to

15 o C.

6.5 o C rise is due to overload.

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.

∑ 500 Hp motor-compressor ∑ Machine vibration is known to be very load sensitive. ∑

500 Hp motor-compressor

Machine vibration is known to be very load sensitive.

∑ Machine vibration is known to be very load sensitive. ∑ Vibration increase with high load.
∑ Machine vibration is known to be very load sensitive. ∑ Vibration increase with high load.

Vibration increase with high load.

Vibration has a strong daily cycle.

Daily ambient temperature swings from 9 0 C at night to over 40 0 C

Daily ambient temperature swings from 9 0 C at night to over 40 0 C during the day.

from 9 0 C at night to over 40 0 C during the day. ∑ 2xline

2xline shows a strong reverse relationship with ambient temperature.

Low ambient occurs with high

2xline.

2xline usually caused by rotor eccentricity or soft foot.

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).