CWP-B_2011-09-03

ABB MACHsense-P Condition Monitoring Detailed Report

Report No. RAIN CII / CWP-B /46330A404-11-02 Dep/Loc:

India Prepared by: Deepak Nayak

Approved by: Ameet Choughule

Released by: Deepak Nayak

Revision: Date of report: 2011-10-14

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ABB MACHsense-P

MACHINE CONDITION MONITORING DETAILED REPORT

Prepared for:

Measurement date: 03-09-2011 Customer Point of Contact:

G Srinivasa Rao RAIN CII (Carbon)

Phone No.: - Fax:

Mail: G.S Rao <[email protected]>

Motor info:

Plant name: Power Plant Serial number: 46330A404-11-02

Tag No.: CWP-B

Prepared by:

Regional Technical Center

India ABB Limited, Survey Nos. 109/110, Village: Vavanje, Behind Kingfisher Factory, MIDC Taloja,

Dist. Raigad – 410208. Maharashtra. India. Phone No.: +91 22 27412272

Fax: +91 22 27402292 Mail: [email protected]







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Introduction .................................................................................................................... 3�

Analysis Report ............................................................................................................. 5�

Site condition ................................................................................................................. 6�

Summary of findings ..................................................................................................... 7�

Detail condition – Electric quantities ........................................................................... 8�

Harmonic content current ............................................................................................. 9�

Harmonic content voltage ........................................................................................... 10�

Detail condition – Rotor condition ............................................................................. 11�

Detail condition – Bearing details .............................................................................. 13�

Detail condition – Installation ..................................................................................... 15�

Recommendations ...................................................................................................... 17�

Appendix A ................................................................................................................... 19�

Appendix B ................................................................................................................... 20�

Table of contents:







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Introduction General information: Electrical and vibration measurements were carried out on 1 machines at on 14-10-2011 with

custom based portable instrument.

Overall vibration measurements were made at Motor bearing locations as well as other strategic

location on the motor body.

Current and voltage measurements were made using suitable probes.

MCSA

The data collected has been processed, analyzed and compiled in an automated manner by

ABB Machine Monitor which takes the electrical and Vibration parameters as input for assessing

motor health condition.

Qualified professional analysts have reviewed the data and have suggested suitable

recommended corrective actions.







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Standards Applied: 1. ISO � ISO 10816-3 2. NEMA � NEMA MG-1 3. IEC � IEC 61000-2-2 � IEC 61000-2-4







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Analysis Report Nameplate Details

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Site condition Installation ��#� &��-��2�

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Summary of findings Machine name CWP-B Electric quantities

Motor electric quantities appear acceptable

Rotor cage

Dynamic eccentricity level is significantly higher than what is normally observed on the basis of vibration analysis!

Asymmetry or defect severity level in rotor cage winding is above what is normally observed

Static eccentricity level is higher than normally observed values! Static eccentricity level is higher than what is normally observed on the basis of vibration

analysis! Bearings

Bearings quantities appear acceptable

Installation

Installation quantities appear acceptable

Overall required action

Action category:

Probability of fault occurrence in time

scale Service schedule Measurement frequency

Critical

Within Weeks to Months

Scheduled service at next available outage within next

six months

The Machine should be secured / monitored very

closely







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Detail condition – Electric quantities Machine name CWP-B Motor electric quantities appear acceptable Operating condition

� Power Input Slip Speed Frequency Average Current (RMS) Torque

Rated Parameters 412 [kW] 1.3 [-] 980 [rpm] 50 [Hz] 41 [A] 3430.[N-m]

Operating Parameters 317 [kW] 1.09 [-] 990.829 [rpm] 50.19 [Hz] 34.5 [A] 2620.[N-m]

% of Rated 76.8 [%] 83.7 [%] 100 [%] 100.39 [%] 84.2 [%] 76.3 [%]

Power quality

�Deviation from

voltage Deviation from

frequency Deviation from

(V/f) Derating factor

VDF �

�� 4.13 [%] 0.389 [%] 3.72 [%] 100 [%]

� Ia Ib Ic Ua Ub Uc

RMS Value 34.296 [A] 34.789 [A] 34.481 [A] 6883.7 [V] 6858.3 [V] 6875 [V]

% of Rated 83.6 [%] 84.9 [%] 84.1 [%] 104 [%] 104 [%] 104 [%]

Crest Factor 1.443 [-] 1.45 [-] 1.457 [-] 1.421 [-] 1.431 [-] 1.434 [-]

Form Factor 1.112 [-] 1.112 [-] 1.112 [-] 1.11 [-] 1.113 [-] 1.113 [-]

THD 1.67 [%] 1.57 [%] 1.82 [%] 3.06 [%] 2.17 [%] 2.56 [%]

HVF/HCF 0.192 [%] 0.163 [%] 0.188 [%] 0.227 [%] 0.199 [%] 0.209 [%]

Unbalance

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�Voltage 0.201 [%] 0.205 [%] 11.3 [V] 5610 [V] 9.31e-013 [V]

Current 0.508 [%] 0.773 [%] 0.248 [A] 48.8 [A] 0.191 [A]

Other

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Impedance 114 [Ohm] 116 [Ohm] 115 [Ohm]

Impedance Angle 39.5 [deg] 39.2 [deg] 39.1 [deg]

Power Factor 0.771 [-] 0.775 [-] 0.776 [-]

Power 106 [kW]� 105 [kW]� 106 [kW]�







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Harmonic content current This section contains the analysis of harmonic content for current measurements.

Current phase A

0

1

2

3

4

5

6

7

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Harmonic order

perc

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Current phase B

0

1

2

3

4

5

6

7

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Harmonic order

perc

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Current phase C

0

1

2

3

4

5

6

7

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Harmonic order

perc

enta

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om fu

ndam

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Time domain of current of phase A, B, C

-60

-40

-20

0

20

40

60

0 0.02 0.04 0.06 0.08 0.1 0.12

Time [s]

Cur

rent

[A]

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Limit Over limit Comment

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Harmonic content voltage This section contains the analysis of harmonic content for voltage measurements.

Voltage phase A

0

1

2

3

4

5

6

7

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Harmonic order

perc

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Voltage phase B

0

1

2

3

4

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6

7

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Harmonic order

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Voltage phase C

0

1

2

3

4

5

6

7

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Harmonic order

perc

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Time domain of Voltage of phase A, B, C

-15000

-10000

-5000

0

5000

10000

15000

0 0.02 0.04 0.06 0.08 0.1 0.12

Time [s]

Cur

rent

[A]

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Detail condition – Rotor condition Machine name CWP-B Dynamic eccentricty level is significantly higher than what is normally observed on the basis of vibration analysis! Static eccentricity level is significantly higher than normally observed values! Static eccentricity level is significantly higher than what is normally observed on the basis of vibration analysis! Asymmetry or defect severity level in rotor cage winding is above what is normally observed Rotor quantities

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-140

-120

-100

-80

-60

-40

-20

0

47 48 49 50 51 52 53

frequency [Hz]

Cu

rren

t [d

B]

(1-2s)*f, (1+2s)*f side bands







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Detail condition – Rotor condition Machine name CWP-B High frequency spectrum for current phase A, B, C

-160

-140

-120

-100

-80

-60

-40

-20

0

0 100 200 300 400 500 600 700 800 900

frequency [Hz]

Cu

rren

t [d

B]

Vibration spectrum of body measurements

0

0.5

1

1.5

2

2.5

90 92 94 96 98 100 102 104

frequency [Hz]

Vib

ratio

n [m

m/s

]

_________ P*fr, 2f

[(1-s)R/p + 1]*f, [(1-s)R/p – 1]*f principal slot harmonics







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Detail condition – Bearing details Machine name CWP-B Bearings quantities appear acceptable Bearings details

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Spectrum of envelop for vibration bearing drive side

0

0.005

0.01

0.015

0.02

0.025

0.03

0.035

0.04

0.045

0 100 200 300 400 500 600 700 800 900 1000

frequency [Hz]

Vib

ratio

n [

g's]

BSF, BPFO, BPFI frequency of bearing







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Detail condition – Bearing details Machine name CWP-B Spectrum of envelop for vibration bearing non-drive side

0

0.01

0.02

0.03

0.04

0.05

0.06

0 100 200 300 400 500 600 700 800 900 1000

frequency [Hz]

Vib

ratio

n [

g's]

BSF, BPFO, BPFI frequency of bearing







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Detail condition – Installation Machine name CWP-B Installation quantities appear acceptable Overall vibration

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�� 1.75 [g] 1.71 [g] 2.98 [g] 3.56 [g] 3.45 [g] �� 1.35 [mm/s] 1.16 [mm/s] 0.648 [mm/s] 2.2 [mm/s] 1.92 [mm/s]�

Harmonic contents � .��*��! �� /��*��! �� 0��*��! ��

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2.85 [mm/s] 0.0285 [mm/s]� 0.0315 [mm/s]��

Installation PCA analysis

-2.5

-2

-1.5

-1

-0.5

0

0.5

1

1.5

-1.5 -1 -0.5 0 0.5 1 1.5 2 2.5 3 3.5

X

Y

UnbalanceMisalignmentLooseness







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Detail condition – Installation Machine name CWP-B Spectrum of vibration (DE-Horizontal)

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

0 20 40 60 80 100 120 140 160 180 200

frequency [Hz]

Vib

rati

on

[mm

/s]

Detail condition – Installation Machine name CWP-B Spectrum of vibration (DE-Vertical)

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

0 20 40 60 80 100 120 140 160 180 200

frequency [Hz]

Vib

rati

on

[m

m/s

]







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Detail condition – Installation Machine name CWP-B Spectrum of vibration (DE-Axial)

0

0.1

0.2

0.3

0.4

0.5

0.6

0 20 40 60 80 100 120 140 160 180 200

frequency [Hz]

Vib

rati

on

[mm

/s]

Detail condition – Installation Machine name CWP-B Spectrum of vibration (NDE-Horizontal)

0

0.5

1

1.5

2

2.5

3

3.5

0 20 40 60 80 100 120 140 160 180 200

frequency [Hz]

Vib

rati

on

[m

m/s

]







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Summarized Observations: 1. Motor electrical quantities appear acceptable. 2. Bearing quantities appear acceptable. 3. Installation quantities appear acceptable. 4. Asymmetry or defect severity level in rotor cage winding is above what is normally observed

Recommendations: 1. It is recommended to inspect rotor for asymmetry at the earliest available opportunity. If it’s a die cast rotor then it is recommended to check for casting porosity or blow holes. 2. As a matter of good practice, it is recommended to monitor the machine after 6 months or when overall vibration level is above permissible limits. 3. This report can be considered as a baseline report for future reference.







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Appendix A Glossary ��

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Appendix B Machine fault index - severity

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CWP-B_2011-09-03

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