Machine Health Report

Condition based vibration and reliability

Prepared by: -
Eng\Hesham Awad
Senior rotating equipment and condition monitoring engineer
VR-06-22-07-D
VCAT III, MLAII, ARPE
 Top & Bottom Ply 1st pump
Area Tag # Equipment Tag # Criticality Report # Date

Approach Bottom Ply D1 Bottom Ply van pump AB-0001 Critical 4 6/2022
Motor rated power 355 Kw-1000 rpm

VFD Problem

Problem Description
▪ The both motors face a repeated problem represented in each interval of time shows raised temperatures around 90 C and as well high vibration
levels and always noise heard by ears like “Whistle sound”
▪ The spectrum shows dominant peak at 9x in one motor and 6X in another time associated with high outer race fault amplitude levels reach to 9
mm/sec in 10816 velocity spectrums.
▪ HD-Enveloping technique shows outer race fault clearly.
▪ Every time this fault appears I advise the electrical department to check VFD and after changing firing card of VFD the problem disappear.
▪ This fault is under analysis and in following pages the analysis steps.
 Analysis guide
Iso 10816 Severity chart
According to ISO 10816 the machines Condition classified to the following levels
New Machine Condition
The Vibration levels are within acceptable parameters, no repairs are need on this stage, Complete to monitor your equipment on a regular basis to watch any new
A
faults that may develop.

Unlimited long-term operation allowable

Equipment at this level is increase a little bit above the reference baseline it’s not an alert Level But it is needing a more observation any increase on temperature or
B
noise need to begin making a maintenance plan.

Short-Term operation allowable

The Vibration levels are reached an alert level, the operation on this level decrease the life span of Equipment, making corrective maintenance on this level can
C
increase equipment life.

Vibration cause damage

D The Vibration levels have reached a fault level. A maintenance action is required immediately and until the repairs are complete. The noise, temperature level of
equipment must monitor at each beginning of the shift to prevent any catastrophic failure with more cost and damage.

Bottom ply 1st pump NDE DE

Location H V A H V A
Motor 2.93 mm/sec 6.02 mm/sec 1.17 mm/sec 1.74 mm/sec 0.82 mm/sec 0.56 mm/sec
Pump 0.82 mm/sec 0.7 mm/sec 0.97 mm/sec 1.16 mm/sec 1.10 mm/sec 0.89 mm/sec

Top ply 1st pump000 NDE DE

Location H V A H V A
Motor 3.4 mm/sec 2.53 mm/sec 2.10 mm/sec 1.57 mm/sec 1.82 mm/sec 1.99 mm/sec
Pump 1.94 mm/sec 1.43 mm/sec 1.45 mm/sec 1.03 mm/sec 1.59 mm/sec 2.69 mm/sec
 radial direction trend

Firing card problem started

After changing firing card

Firing card problem started

After changing firing card

 Problem from Electrical point of view
Variable frequency drive data
LS-Power 375 kw, with switching frequency “2000 Hz”
Switching frequency: -
the rate at which the DC bus voltage is switched on and off during the pulse width modulation (PWM) process, this process done by insulated gate
bipolar transistor (IGBT).
Switching frequency range
is from 4000 Hz to 16000 Hz – “note that the VFD in our mill is 2000 Hz”
Effect of switching frequency on current distortion
▪ The harmonic content in the current waveform generated by the (PWM) process is reduced as the switching frequency increases.

Switching frequency = 4kHz Switching frequency = 8kHz Switching frequency = 16kHz

THD= 17.27% THD= 8.47% THD= 8.47%

THD- total harmonic distortion in current “Current distortion”

“As switching frequency increase the current distortion decrease”
Effect of switching frequency on (IGBT)
▪ As the switching frequency increase, the motor heating due to higher harmonic content in the current waveform decrease, at the same time the
heat generated internally in the VFD due to the IGBT switching on/off process are increased.
▪ IGBT produce a relatively fixed amount of heat loss, so as switching frequency increases so does the overall heat loss of the VFD.
Effect of switching frequency on audible noise
▪ The higher switching frequency decrease the audible noise that can be heard from the motor.
▪ The audible noise from the motor is a result of the stator lamination vibrating at the carrier frequency rate.
▪ As the carrier frequency is increased the pitch of the noise from the stator lamination is increased moving the levels farther out of the normal
hearing range of humans.

Problem from Vibration Point of view

Both Motor data
ABB – 355 Kw-990 RPM
6pole
355 L frame size
# Of rotor bar 85
 Effect of shifting switching “carrier” frequency to be less than 2000 Hz

TWF shows high impacts

Frequency shifted to be 1957.42 Hz

Instead of 2000 Hz due to problem in firing card

Frequency 1957.42 Hz sideband 85

equal to no of rotor bars

2nd harmonic of switching

First Peak in series at frequency frequency 2000 Hz with
85.16 Hz, 6 order with amplitude 5.88 side band 85 equal to no
mm/sec in velocity spectrum - that meet the of rotor bars
outer race frequency second harmonic
region and excite it to reach to 3.66 mm/sec Main switching frequency
in velocity 2000 Hz
 Effect of shifting switching “carrier” frequency to be higher than 2000 Hz

TWF shows lower impacts

Frequency shifted to be 2598.44 Hz higher than
switching frequency as a result to change firing
card

First beak in series at frequency

85.16 Hz, 6 order with amplitude 0.7 mm/sec
in velocity spectrum - that meet the outer Main switching frequency
race frequency second harmonic region and 2000 Hz
excite it to reach to 0.8 mm/sec in velocity
 Conclusion
1- Switching frequency responsible for improve the current distortion and as well improve the signal that feed the motor.
2- As the switching frequency increase, as the current distortion decrease and as well the performance of motor be more steady
“No audible noise, no high temperature”
3- Switching frequency value effect on IGBT. As switching frequency increase the rate of process (on/off) of IGBT increase to draw perfect
current sine wave and as well temperature of IGBT increase and then probability of failure occurrence increases.
4- Ideal switching frequency starts from 4000 Hz to 16000 Hz.

Existing fault condition “Root cause analysis”

A- The manufacturer locked the VFD switching frequency at 2000 Hz to protect the IGBT from probability of failure “Risk”
Consequences
1- The current distortion is too high and this cause
- High audible noise heard by ears “Whistle sound”
- High temperature on both NDE, DE bearing reach to 90 degrees.
B- The manufacturer uses a IGBT controller card to improve the process of draw pure current sinewave to fed the motor “Risk”
Consequences
1- When the controller card is in a good condition it’s try to improve the existing distortion current due to low switching frequency and
it’s shown in spectrum represented in increasing the switching frequency to 2598 Hz although it not enough to improve current
distortion but it makes the anomalous peak at 6X in low amplitude without additional consequences.

2- When the controller card is in a bad condition it lost their benefits and in addition makes the anomalous peak at 6x in high amplitude
and this cause excitation to outer race frequency “BPFO” and excite the rotor bar frequency as well.
 Recommendation
Reliable action in this problem is increase switching frequency to be at least “4000 Hz” to avoid the current distortion and as well the bad
performance of motors represented in high audible noise coming from exciting the rotor bars and as well high temperature that coming from
exciting bearing outer race
This action will directly affect on cost represented in: -
1- Cost of two VFD “up to 800,000 EGP” that can be damaged due to IGBT failures and the consequences.
2- Cost of two motors “up to 1,280,000 EGP” that can be damaged due to high vibration and heat increases.
3- Cost of pm shutdown due to repeated fault “time consumed to fix the problem * production cost/hour”
Other solution from vendor is welcome to improve performance of two motors

Best regards