TECHNICAL COMPETENCE ENGINEERING ( TCE DEPARTMENT )

CM2131 SIEMENSS WORKSHOP VISIT REPORT

Contents 1/ 2/ 3/ 4/ 5/ 6/ 7/ Technical Data Failure Report Vibration Historical Data Vibration Data Collected at Siemens W/shop and Finding Photo Conclusion Recommendation

CM2131_Siemens Wshop visit 170805.doc

Page 1 of 9

Date of Visit Topic Venue Participants

17 .August.2005 19 .August.2005 CM2131 - Collect Vibration data before refurbish. Siemenss Workshop, Bkt.Raja, Shah Alam ,Sgor. BPC Mohd Hasrani,Mazlan Zain & Rashid Kay. Siemens Mr.Villalan Ramasamy & Mr.Harban Singh

th

th

1/ TECHNICAL DATA Tag No Manufacturer Type S/N Volts Power Frequency Current RPM No. Of pole No. Of Slots CM 2131 SIEMENS Eex AC MOTOR 1MJ8500 9- AE60 Z 5128532 400 / 690 v 200 KW 50 Hz 500/290 AMPS 296 rpm 20 120

2/ FAILURE REPORT by En.Mazlan Zain

Brief
The motor failed before due to loose connection, which caused damages to the terminal studs & porcelain bushing. Siemens did repair in March 2003. In January 2005 motor was put to service back and noticed motor had 2x line frequency peak which kept on increasing up to 2.7 mm/s. The motor was removed from service by PWS in June 2005 for rectification.

Finding:
Arc tracking on stator winding due to insulation defect. Mechanical faults in the electrical insulation system include stress cracking, vibration and mechanical incursion. The forces within a coil during various operations will cause mechanical movement (2 line frequency as in the vibration spectrum) and fracturing of insulation materials. Electrical and mechanical vibration cause undue stress on the insulation system resulting in stress fractures and looseness of the insulation system. Mechanical incursion includes the movement of materials into the insulation system either between conductors and or insulation system to ground.

Possible Causes of Failure

Running with high winding temperature which contributed thermal aging of an insulation system, occurs as electrical insulation systems degrade. During last refurbishment, the stator winding was not been re-varnish after steam wash & oven bake.(refer to siemens report )

CM2131_Siemens Wshop visit 170805.doc

Page 2 of 9

SIEMENS SERVICE REPORT

CM2131_Siemens Wshop visit 170805.doc

Page 3 of 9

3/ VIBRATION HISTORICAL DATA The vibration spectrum data since last February 2005 indicates the presence of 2X Line frequency (2XLF) and the peak was dominant. The peak was clearly can be identified at all 3 directions of Vertically, horizontally and axially. Since Feb05 until last data on May05, noticed that the amplitudes of the 2XLF were increasing from 1.811 mm/s to 2.72 mm/s RMS Velocity. The highest peak recorded is 2.821 mm/s on Apr05. Based from this data, its confirmed that this problem is related to ELECTRICAL DEFECT. The motor winding temperature trending was carried out by OOI on Apr05 till May05. th The thermography was shoot on Apr08 .to observed any specific localized temperature and the highest is 78 deg C located surrounding middle of motor body at power terminal. The motor was removed for service on last June05 Shutdown and was sent to Siemens Workshop at Bkt,Raja, Shah Alam,Selangor. PREVIOUS VIBRATION SPECTRUM & RELATED DATA COLLECTED : Spectrum as collected on Feb05:
RMS Velocity in mm/Sec 2.4 2.0 1.6 1.2 0.8 0.4 1X RPM 0 0 0.6 Acceleration in G-s 0.3 ALERT 0 -0.3 -0.6 0 20 40 Time in mSecs 8000 16000 Frequency in CPM FAULT 24000 32000 2X LF 01 - C2131_C3 Gas Compressor C2131 -M1V Motor Outboard Vertical Route Spectrum 02-Feb-05 15:09:38 (SST-Corrected) OVERALL= 2.09 V-DG RMS = 2.09 LOAD = 100.0 RPM = 298. (4.96 Hz)

Route Waveform 02-Feb-05 15:09:38 RMS = .1358 PK(+/-) = .2919/.3417 CRESTF= 2.61

ALERT FAULT 60 80 100 Freq: Ordr: Spec: Dfrq: 6003.9 20.16 1.811 5697.8

*Spectrum as collected on Apr05 and May05:

C2131 Max Amp 2.68 Plot Scale 3.0 R MS Ve lo c ity in m m /Se c C221 - C3-GAS COMPRESSOR -MOH MOTOR OUTBOARD HORIZONTAL

5 99 8 .5

6 0 0 8 .6

2.821mm/sec RMS

X 2.627mm/sec RMS

18-Apr-05 14:06:59

6000 Frequency in CPM

12000

18000

03-Mei-05 11:34:19 Freq: Ordr: Sp 2:

6008.6 20.30 2.821

CM2131_Siemens Wshop visit 170805.doc

Page 4 of 9

*Motor Winding Temperature Trending:

CM2131 motor winding temperature by date

123.00 121.00 119.00 117.00 115.00 113.00 111.00 109.00 107.00 105.00 10,11,12 13,14,15 16,17,18 19,20,21 22,23,24 25,26,27 winding terminal number 6-Apr-05 12-Apr-05 14-Apr-05 19-Apr-05 22-Apr-05 27-Apr-05 29-Apr-05 3-May-05 10-May-05 12-May-05

*Thermography Record :

4/ VIBRATION DATA AT SIEMENSS WORKSHOP & FINDING 1/ The main proposed of the visit are: 1.1/ To identify either the 2XLF is the main factor of electrical defect of the motor. 1.2/ To have a joint witness with Siemens 1.3/ The motor will be dismantling based on the vibration data results. 2/ During the inspection of motor solo run, decided to collected more detail vibration analysis by increasing the maximum of frequency up to 140,000 rpm with 3200 lines. 3/ We were very surprised that spectrum indicates the existing of 1 X Slot Pass Frequency with 1X Turning speed sidebands. This phenomena was considered that stationary part i.e stator, winding, slots or insulation might have a problem.( see attached spectrum ) 4/ Short meeting was held with Mr.Harban to highlighted the finding and agreed by both Parties to dismantle immediately the motor for further internally inspection. 5/ Dismantled and found that was a defected of the winding at 12 oclock position.( see photo)

CM2131_Siemens Wshop visit 170805.doc

deg C

Page 5 of 9

*Vibration Spectrum indicates the Slot Pass Frequency: 1/ At Motor NDE side:
0.07 C2131 C221 - C3-G AS COMPRESSOR -MOH MO TO R OUTBOARD HORIZONTAL Analyze Spectrum 17-O gos-05 16:38:34 RMS = .0611 LOAD = 100.0 RPM = 300. (5.00 Hz)

0.06
1X Sl ot Pass F req uency

R S V loc in m /S c M e ity m e

0.05

0.04

0.03

0.02

0.01

1X T S Sid eb an d s

1X T S Si d eb an d s

0 30000 32000 34000 36000 Frequency in CPM 38000 40000 42000 Freq: Ordr: Spec: Dfrq: 36326. 121.09 .00289 300.65

0.030

C2131

C221 - C3-G AS COMPRESSOR -MOH MO TOR OUTBOARD HORIZONTAL Analyze Spectrum 17-Ogos-05 16:38:34 RMS = .0402 LOAD = 100.0 RPM = 300. (5.00 Hz)

0.025

RM V loc in mm e S e ity /S c

0.020

2X Sl ot Pass F req uency + 1X TS Sideban ds

0.015

0.010

0.005

0 66000 68000 70000 72000 Frequency in CPM 74000 76000 78000 Freq: Ordr: Spec: Dfrq: 71766. 239.22 .00945 290.57

CM2131_Siemens Wshop visit 170805.doc

Page 6 of 9

2/ At Motor DE side:
0.07 C2131 C221 - C3-G A COMPRESSOR S -MIV MOTOR INB ARD VERTIC O AL Analyze Spectrum 17-O gos-05 16:48:07 RMS = .0942 LOAD = 100.0 RPM = 296. (4.94 Hz)
2X L f an d Harmo n ics

0.06

R SV lo ityin m /S c M e c m e

0.05

0.04

0.03
1X Slot Pass

0.02

0.01

0 0 30 60 90 Frequency in kCPM 120 150 Freq: Ordr: Spec: 6.004 20.26 .05258

0.032

C2131

C221 - C3-G A COMPRESSOR S -MIV MOTOR INB ARD VERTIC O AL Analyze Spectrum 17-O gos-05 16:48:07 RMS = .0311 LOAD = 100.0 RPM = 300. (5.00 Hz)

0.024 R SV lo ityin m /S c M e c m e

1X Slot Pass

0.016

0.008

1X T S Sid eb an d s

1X T S Si d eb an d s

0 30000 32000 34000 36000 Frequency in C PM 38000 40000 42000 Freq: Ordr: Spec: Dfrq: 35724. 119.08 .00594 299.12

0.08

C2131

C221 - C3-G A COMPRESSOR S -MIA MOTOR INBO A RD AXIAL Analyze Spectrum 17-O gos-05 16:49:52 RMS = .0672 LOAD = 100.0 RPM = 300. (5.00 Hz)

0.07

0.06 R SV lo ityin m /S c M e c m e
1X Sl ot Pass F req uency

0.05

0.04

0.03

0.02

0.01

1X T S Si d eb an d s 1X T S Sid eb an d s

0 30000 32000 34000 36000 Frequency in C PM 38000 40000 42000 Freq: Ordr: Spec: Dfrq: 36332. 121.11 .00706 303.70

CM2131_Siemens Wshop visit 170805.doc

Page 7 of 9

5/ PHOTO * Picture of Motor at Siemens Workshop:

Motor Solo run on Test Bay

Stator

Rotor

Winding

Zoom winding defect

Stator Front view

Burning Mark at Rotor

CM2131_Siemens Wshop visit 170805.doc

Page 8 of 9

5/ CONCLUSION

# THE MOTOR NEED TO BE RE-WIND.

6/ RECOMMENDATION

IMPROVE THE COOLING SYSTEM OF MOTOR TO REDUCE WINDING TEMPERATURE.TO CONSULT OEM. MONITOR VIBRATION AND POLARIZATION INDEX (P.I.) VALUE. The frequency of monitor to be decide later.

Prepared by : Mohd Hasrani ,TCE Rotating Eng. Date : 30h.August.2005

Reviewed by: Ir.Ismail Abdullah, TCE Snr.Mgr.

CM2131_Siemens Wshop visit 170805.doc

Page 9 of 9