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    Electrical Signature Analysis Performed On Vertical Turbine Pump Motors in Municipal Application

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    ENRIQUE

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    Electrical Signature Analysis Performed On Vertical Turbine Pump Motors in Municipal Application

    Uploaded by

    ENRIQUE
    14 views6 pages

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    ESAHEN-FINAL-Draft-10-13-15 (2)

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    14 views6 pages

    Electrical Signature Analysis Performed On Vertical Turbine Pump Motors in Municipal Application

    Uploaded by

    ENRIQUE

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 6

    Electrical Signature Analysis Performed on

    Vertical Turbine Pump Motors in Municipal Application

    Authored by William Kruger, Technical & Training Manager, ALL-TEST Pro, LLC, and Alex Panattoni,
    Control Systems Technician II, City of Henderson Department of Utility Services Electrical Section

    Background
    Vertical Turbine Pump Info

    Originally put into operation in 1999, Pump Station P-19A OEM: Goulds
    supplies drinking water to the City of Henderson, which is the Model: VTC-1
    second largest city in Nevada. Serving a population well over
    GPM: 7400 GPM
    270,000 people, P-19A is one of the most critical potable pump
    stations operated by the city. The pump station originally utilized # of Stages: 5 Stage

    three pumps when its operation began, but in 2006, two more Size: 20x20 GHC-5
    vertical pumps were installed in the pump station
    Suction Size: 20-inches
    (Pumps 1 & 5).
    RPM: 1200 RPM

    Cause for Concern

    In 2006, the pump size was increased, but the motor horsepower remained the same. The
    motors have a service factor of 1.15 and often exceed 105% of nameplate full-load amperage
    (FLA). Although this is within the capabilities of the motors, they operate at near maximum
    output.

    In November 2014, vibration analysis was


    performed as part of the plant’s Predictive
    Maintenance Program. While those test
    results suggested the possibility of early
    bearing degradation in Motor 5, the rotor bar
    passing frequency was within range (see
    Figure 1). The vibration summary concluded
    Figure 1. November 17, 2014 - 2AS - Motor Inboard
    that systems were operating within acceptable Axial - Acceptable Vibration - Note: High Frequency
    Vibration ~81,102 cpm is Rotor Bar Passing
    limits and that no maintenance actions Frequency. No Maintenance Action Recommended
    needed to be taken at that time. at this time. Continue to Monitor.

    Two months later, in January 2015, Motor 5 exhibited signs of overheating; reaching
    temperatures that exceeded 160-degrees Celsius. While the other pumps did not show any
    symptoms similar to that of Motor 5, the maintenance team took action and initiated an in-house
    investigation of all five pump motors using their predictive maintenance equipment.

    Comprehensive Testing to Prevent Motor Failure

    The in-house maintenance team utilized their hand-held ALL-TEST


    PRO 31™ and ALL-TEST IV PRO™. These high-tech instruments,
    which are used for de-energized testing, are designed to detect
    potential winding faults and provide indications of rotor problems.
    First, they used both the ALL-TEST PRO 31™ and ALL-TEST IV
    PRO™ to perform winding tests and confirm that the windings ALL-TEST PRO 31™ for initial tests

    were in good condition. Then they used this equipment to conduct


    ‘insulation to ground’ tests to prove the insulation was not grounded.
    Next, they performed a rotor inductance test, which measures the
    inductance of all three phases of a motor at different individual
    rotor positions. During the test, the rotor is positioned at exact
    intervals, as seen in the picture to the right. Rotor Tested at 5-degree Intervals

    “We performed an extensive rotor test - taking readings every 5


    degrees of shaft rotation using the ALL-TEST IV PRO™ - only then
    did indications show an issue with both Pump 1 and Pump 5,”
    explains Alex Panattoni, the Control Systems Technician leading the
    Electrical Section of the City of Henderson’s Department ALL-TEST IV PRO™ for initial tests

    of Utility Services. “While the tests indicated the


    possibility
    of a rotor problem, the results didn’t show the problem
    definitively. We knew the current was modulating and
    we put a time trace on it, but we needed to do more
    extensive testing,” explains Panattoni. At the
    maintenance team’s request, a third-party specialist
    went to the pump station to perform vibration analysis.
    When the vibration analysis did not indicate any
    electrical faults (pole pass frequency sidebanding) in Figure 2. January 23, 2015 - Vibration analysis
    the associated vibration FFT signatures (see Figure 2), for Motor 5 indicates the presence of low
    amplitude non-synchronous energy in the
    the decision was made to bring in technical PeakVue timedomain data collected on the upper
    motor bearing. Only recommendations made
    support from ALL-TEST Pro to perform additional were to monitor bearings for further degradation.
    Vibration analysis gave no indication of potential
    testing.
    problems with the rotor.
    William Kruger, Technical and Training Manager at ALL-TEST Pro,
    went to the pump station in January to perform an Electrical Signature
    Analysis. Electrical Signature Analysis is a diagnostic technology that
    uses the motors supply voltage and operating current to identify
    existing and developing faults in the entire motor system. To perform
    the Electrical Signature Analysis, he brought with him the ALL-TEST
    PRO On-Line II™. The ATPOL II™ is an energized motor testing tool
    which, when in ESA mode, evaluates the condition of incoming power,
    the control circuit, the motor itself, and the driven load. Kruger
    requested that MVA data be taken simultaneously while the Electrical
    Signature Analysis was being performed. ALL-TEST PRO On-Line II™

    Electrical Signature Analysis Reveals Broken Rotor Bars

    During the energized motor tests, data was taken at


    ESA Data from ATPOL II™
    different times; first shortly after start-up, then again
    after the pump had been running. Of significance was Pump 1 Pump 5

    the large change in rotor speed with a very small Pump Speed: 1183 RPM 1175 RPM
    change in motor load. The rotor was running
    Demand Power: 738.98 HP 726.96 HP
    considerably below name plate; after running about
    Load: 100.7% 99.1%
    thirty minutes, the rotor speed was 1171 RPM. This
    was also confirmed by an independent tach system Output Load: 507.95 KW 495 KW
    provided by the third-party who performed the vibration
    Severity Rating: 6 out of 7 7 out of 7
    analysis. While the results of the vibration analysis did
    not show any indications of rotor problems, the speed The RPM values shown in the chart above are
    consistent with rotor bar anomalies. Motors
    and the ESA data taken with the ATPOL II™ indicated 1 & 5 indicate an increased "slip frequency".
    that several rotor bars were broken (see Figure 3).

    Figure 3. January 2015 – Electrical


    Signature Analysis using the
    ATPOL II™ - (Before repair) pole
    pass frequency side bands indicate
    very severe rotor bar damage;
    current draw was 820 amps and
    modulating around16 amps.
    Rotor bars are solid continuous bars that run through the rotor’s steel laminations, which are
    spaced to allow air flow to cool the rotor. Once the maintenance team received the report from
    the Electrical Signature Analysis, which showed severe indications of rotor bar issues (Pump 1
    had a severity rating of 6 out of 7 and Pump 5 had a severity rating of 7 out of 7), they pulled
    Motor 5 and found that 30% of the rotor bars were in fact broken.

    Rotor bar breaks all occurred in the middle three rows of laminations.
    Rebuilding the Rotor with Different Metallurgy

    After discussing the issues with the motor manufacturer and a third party motor repair company,
    the maintenance team chose to have both Motor 1 and Motor 5 rebuilt with copper rotor bars.
    Pumps 2, 3, and 4 had copper rotor bars and did not have the same issues as Pumps 1 and 5.
    The original rotor bars in Pump 1 and Pump 5 had been made of aluminum. This was believed
    to be the root cause of the problem. Because the motors at P-19A normally run 100% to 110%
    of load, there is a high current flowing through the rotor. This produces heat that causes
    expansion and contraction. Over a period of time, the aluminum rotor bar breaks under tension,
    then the arcing occurs at the spot of the break. The currents are then forced through the
    remaining bars, putting more loads on them and causing more broken bars, weakening the
    strength of the entire rotor. This issue would have eventually shorted out the stator winding by
    the increased operating temperature or arcing metal from the rotor, and would have caused the
    need for a rewind or possible scrapping of the entire motor, in addition to the repair or
    replacement of the rotor. Having the motors rebuilt with copper rotor bars enabled the
    maintenance team to avoid catastrophic failure of their vertical turbine pump motors.

    Motor 5 was rebuilt and installed in May


    of 2015. Another round of MVA and ESA
    testing was performed immediately after
    installation to ensure proper operation.
    The electrical signatures taken in May
    reported excellent rotor condition (see
    Figure 4). It also showed that rotor speed
    increased, while overall current dropped.
    Figure 4. May 5, 2015 – Electrical Signature Analysis
    The newly rebuilt Motor 1 was installed using the ATPOL II™ - (After repair) pole pass
    in September 2015 and a third round frequency side bands were gone and current draw
    was 754 amps with 2 amps modulation.
    of testing was performed.
    Lessons Learned
    Having a Predictive Maintenance and proper
    diagnostic tools program is important. It is essential
    to equip your maintenance team with state-of-the-art
    equipment to increase the effectiveness of your
    Preventive Maintenance program. Tools like the
    ATPOL II™ exist so you can perform higher level
    Chart from third-party vibration analysis performed
    testing, such as Electrical Signature Analysis, in May 2015: Rotor bar issues produce low-
    amplitude sideband sets spaced at "pole passing
    which is proving to be a very effective technology
    frequency". The red circle highlights the location of
    for detecting faults before they lead to calculated pole pass frequency sidebands (vertical
    lines). The absence of these sidebands indicate
    catastrophic failure.
    motor rotor is in good health, as expected with a
    newly rebuilt rotor.

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