CASE STUDY/ 

A Baker ‘Explorer’ Online Motor Testing Case Study

Power Generator Saves Expensive Downtime

Following a Baker On-Line Motor Test

The ‘Explorer’ On-Line Motor Monitoring Unit manufactured by Baker Instrument

Company, (An SKF Group Company), based in Colorado, USA is in use worldwide by motor
rewinders, service providers and motor end-users within their condition monitoring
programmes.

The Explorer monitors a motor’s three phase voltages and currents and diagnoses
problems with regards to power quality and motor performance including rotor bar
issues. Also, as it constantly reads the instantaneous torque being demanded of the
motor, it can detect problems within the load.

It is extremely important when monitoring a motor’s condition that the entire system is
tested. The power supply, the motor itself and the load make up this system. Without
understanding all three elements it is often difficult to make an accurate assessment of
the situation.

In June 2009, Whitelegg Machines were contacted by a customer regarding a problem

motor at a major UK power station. Whitelegg had previously demonstrated the Explorer
unit to station engineers in a meeting room environment in order to highlight its
flexibility.

The motor in question was an 11kv, 2400kw motor, driving a cooling water pump which
is used on a condensing unit.

During power generation, a boiler converts water into steam which then passes through
a steam turbine, turning the blades and shaft. The turbine drives an electrical generator.
The water used in the boilers leaves the turbine as steam and is cooled back to water by
large condensers, and then recirculated. These condensers are cooled by water pumped
from the sea or a river. As such, the motors in question form a vital role in the operation
of the plant.

The station’s engineers suspected rotor bar issues, and this seemed to be backed up
when we noticed the ammeter needle swinging significantly. Cracked or broken rotor
bars typically cause higher current to flow in adjacent bars to the damaged area, and
cause a pulsation of the torque, and therefore current.

After making our connections in the low-voltage cabinet (via voltage and current
transformers) we ran one initial test, acquiring voltage and current readings for 30
seconds. The Explorer then calculated and displayed a host of information regarding the
motor, including a rotor bar graph.

The rotor bar graph (see figure 1) displayed, showed no obvious signs of a rotor bar
issue, although the noise floor was high, which is usually caused by fluctuating load.

For an accurate rotor bar assessment, steady state load of at least 30% is required.
 Fig. 1
Rotor Bar Graph (Test 1)

The torque ripple graph (Fig. 2) shows 26 seconds of instantaneous torque, and
confirmed the fact that the load was varying.
Fans and pumps typically run with steady load, and the torque ripple graph would
normally show a smooth band across the screen, rather than the erratic band displayed.
Since the rotor bar graph showed no obvious signs of a problem, our thoughts turned to
a mechanical problem with the load, such as pump cavitation.

Fig. 2
Torque Ripple Graph (Test 1)

However, as running a single test is not sufficient to make an assessment of motor

condition, we ran a series of ten additional tests, via the Explorer’s automatic ‘loop
acquisition’ function.

During these tests, we observed that the results suddenly changed. Tests one to six
matched our initial test, but on the seventh test, the percentage load and current level
suddenly increased. The load increased from 80% to 92%, the current increased from
115 Amps to 132 Amps.

When the ten tests were complete, we reviewed both the rotor bar and torque ripple
graphs, and found that noise floor of the rotor bar graph was now normal (See Fig. 3)
and the torque ripple graph showed a normal steady band of torque (see Fig. 4).
 Fig. 3
Rotor Bar Graph (Test 7)

The rotor bar sideband frequency is marked with a green line, and any rotor bar issues
would create a current peak at this frequency. The more severe the problem the higher
the amplitude of the current peak; as you can see from figure 3, there is no peak on the
frequency marker.

Fig. 4
Torque Ripple Graph (Test 7)

The torque ripple of test 7 is typical of a pump, and shows a marked difference from the
earlier tests.
Explorer’s Main Screen – Summary of test 7

The colour-coded screens on the main screen above, each contain a series of sub-
screens (see Fig. 5) containing test data on a range of tests performed. Each of these
tests has tolerances applied. For example, within ‘Power Quality’, voltage unbalance is
displayed as a percentage. Normal range is 0 – 2% and will result in a green flag. 2%
- 3.5% will flag yellow as a caution, and 3.5% and above will flag a red warning.
Blue screens signify that no tolerances are applied to the data.

Fig. 5

During discussions with the station engineers after testing was complete, we were
informed that after our initial assessment of possible pump cavitation, an engineer was
sent to check the system.
He found the water pressure gauge reading to be unusually low, and the pipework
‘clanking’. On checking maintenance logs, he noted that some seals had been replaced
several weeks earlier, and he therefore bled the system. When the pressure levels
returned to normal, the Explorer data changed accordingly.

In total, we ran 12 tests, each taking around 45 seconds. These tests resulted in a
saving for the customer in the region of £ 6,000 to £ 8,000, which was the cost to
remove the pump and motor for inspection and overhaul.

The potential loss of power generation capability is not included in the calculation.

Successful condition monitoring on rotating plant requires several technologies including

thermography, vibration analysis and motor current signature analysis.

Whilst motor current signature analysis has been established for many years, the
technology and software is now becoming smarter, and the inclusion of torque analysis is
an important development.

Michael Herring
Sales Director
Whitelegg Machines Ltd
www.whitelegg.com

Whitelegg Machines Ltd are UK and Ireland agents for Baker Instrument Company, an SKF group company.
They have represented Baker in excess of 20 years, offering technical sales, product training and after-sales
service.

Baker, purchased by SKF in 2007, have more than 40 years of motor testing experience, and test equipment
manufacture. Their customer base includes power generation, including nuclear, water companies, food and
drink, pulp and paper, pharmaceutical, automotive and oil and gas, to name but a few.

Jan 12/10