Rotor Analysis

MCEMAX Current Analysis

Cement Facility

Rick Waters
Rockwell Automation
PdMA Motor Reliability Technical Conference
May 9-11, 2006 Clearwater Beach, FL
New Cement Plant
Baseline MCE Test All New Critical Motors

Low and Medium

Dynamic Testing
Voltage AC Motors
Plant/Motor Commissioning
New plant commissioning and start-up in the fall
of 2003
Initial vibration data collected and analyzed by
plant personal with slight indication of a potential
problem
We were not made aware of a problem during
start-up
Initial dynamic data captured in January 2004
revealed minimal indication of rotor anomaly
MCEMAX Dynamic Analysis
One year later vibration data still indicated
potential problem
We were asked to re-test the motor using
MCEMAX dynamic analysis in January 2005
Dynamic data indicated rotor anomaly
Customer was notified and the process to
identify anomaly began
Manufacturing specifications indicated the rotor
was cast aluminum
Initial Dynamic Test Data January 2004
Low Resolution Average db 46.9
Initial Dynamic Test Data January 2004
Low Resolution at 300 Hz
Initial Dynamic Test Data January 2004
High Resolution Average db 65.4
Demod Data Amplitude at .469 Hz was .018
Dynamic Test Data January 2005
Low Resolution Average db 41.9
Dynamic Test Data January 2005
Low Resolution at 300 Hz
Dynamic Test Data January 2005
High Resolution Average db 44.7
Demod Data Amplitude at .718 Hz was .016
Motor Removal and Additional Testing

Decision was made to remove the motor

during scheduled shutdown
Motor sent to Reliance Electric Service
Center for extensive testing
Testing included single phase rotor test,
locked rotor test, growler test as well as
visual inspection
All tests were inconclusive
OEM Engineering Assessment

Based on shop testing and analysis

engineering representatives stated that
there was nothing wrong with the rotor
I was not convinced based on my analysis
and strongly disagreed with manufacturing
Thus began the political nightmare
Customer Response

Based on my experience I was certain that

the rotor had developed a major problem
The customer believed that if I was
convinced that there was a rotor anomaly
we should cut the rotor end-rings
Reluctantly all parties agreed
4160-volt 750 HP 1190 RPM Tatung
Brand OOPS
New Rotor Built

A new rotor was built, installed, load tested

at the service center, and returned to
service
New Rotor Dynamic Analysis
Low Resolution
New Rotor Dynamic Analysis
Low Resolution 300 Hz
New Rotor Dynamic Analysis
High Resolution
New Rotor Dynamic Analysis
Demod Data Amplitude at .469 Hz was .16
Summary
During the process the customer told me
that if the rotor was determined to be
defective the cost savings from potential
lost production would pay for a lifetime of
service at their facility.
I think that OEM engineering now believes
that MCEMAX dynamic testing is a viable
tool for rotor analysis, although they have
not told me so.