Fault Zone Analysis

ROTOR

Doug Swinskey
PdMA Corporation
Motor Reliability Technical Conference
May 9-11, 2006 Clearwater Beach, FL
 Objectives
Discuss Rotor Fault Mechanisms
Analysis Methods
Case Studies
 Rotor Fault Mechanisms
Mechanical

Dynamic

Residual

Electromagnetic

Environmental

Thermal
Mechanical Stress
Thermal Damage
Excessive Load Cycling
Broken Bars
Broken Bars
 Several Motors to Examine
In the following slides we will examine
data from several different motors.
The data collected includes EMAX and
MCE data for rotor problems.
First Motor

Spectrum
Cursor
Indicated
Speed
Select
Speed
 Mechanical or Electrical?
Rotor Speed?

Rotor Has Broken

Bars
 Swirl Effect
Select
First Peak

Selected
Speed Is
Negative of
Actual Speed
 Same Motor, Lower Peaks
Rotor Speed
After Repair of
Rotor
 Use All Resources
Take pictures of the motor with a digital
camera
Perform motor testing with MCEMAX
Perform infrared imaging
Perform vibration testing
Second Motor
 Advanced Spectral Analysis
Rotor Speed
 High Resolution 60 Hz

Rotor
Speed
 Swirl Effect
Swirl
Peaks
Standard Test
Rotor Influence Check
 Advanced Spectral Analysis
2 Years Later
Rotor Speed
 High Resolution 60 Hz
2 Years Later

Rotor
Speed
 Swirl Effect
2 Years Later
Swirl
Peaks
Standard Test After Repairs
Rotor Influence Check
After Repairs
 Advanced Spectral Analysis
After Repairs
Rotor Speed
 High Resolution Test 60 Hz
After Repairs
Rotor
Speed
 Swirl Effect
After Repairs
Swirl
Peaks
 Third Motor
Sidebands

Speed
 High Resolution Time Domain
Oscillating
Current
 Swirl Effect
Swirl
Peaks
 MCE Testing
If EMAX testing cannot be accomplished?
What testing options do you have in this situation?
Infrared imaging
Not useful if motor is cooled down
Vibration
None to measure when the motor is not running
Perform MCE testing
 Low Influence Rotor
Non-changing
Inductance
 Broken Bars
Repeatable
Pattern
Eccentricity
Healthy Rotor
 Summary
Identify Fault Mechanism Before the
Actual Fault Occurs
Correlate Test Data
Minimize Additional Damage