ANTARA STEEL MILLS | LABUAN EQUIPMENT: 1223 Motor & Gearbox

VIBRATION ANALYSIS REPORT Data Collection Date: 26/7 – 20/12/2018

Vibration Analysis
Component Faults Spectrum Time Wave Enveloping Cross Phase
Imbalance Yes - - Slight
Eccentric stator : soft foot None - - -
Eccentric Rotor None - - -
Loose Rotor bar Yes - - -
Motor Cracked Rotor bar Yes - - -
AC Non VFD Beating Yes Yes - -
Rotor Bow None None - None
Bearing – NDE None None None -
Bearing –DE None None None -
Rotating Looseness None None - None
Coupling
Misalignment None - - None
Motor-Gearbox
Bearing DE None None None -
Gearbox Bearing NDE None None None -
Input Shaft Gear :
Gear Fault None None None -
Pinion
Gear Resonance None
Bearing DE None None None -
Gearbox Bearing NDE None None None -
Intermediate or
Gear Fault - - - -
Output
Gear Resonance None
Coupling - - - -
Misalignment
Driver-Driven
Imbalance - - - -
Rotating Looseness - - - -
Bearing – DE - - - -
Bearing – NDE - - - -
Driven
Pump Cocked Bearing - - - -
Compressor Bent Shaft - - - -
Fan - - - -
Resonance
Cavitation - - - -
Flow Turbulence - - - -
Vane Pass - - - -
Structural Looseness - - None
Structure
Baseplate Structural Weakness - - Slightly Flex
Piping Resonance None
**Note: Bearing condition steps: Good -> Early Stage 1 (5 kHz-40 kHz) -> Early Stage 2 (1khz-5kHz) -> require
replacement: Intermediate or premature Stage 3 (0-1kHz) -> Late Stage 4 (0-1kHz noise)

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ANTARA STEEL MILLS | LABUAN EQUIPMENT: 1223 Motor & Gearbox
VIBRATION ANALYSIS REPORT Data Collection Date: 26/7 – 20/12/2018

Finding(s)

1. Overall vibration trending jumped from 3 to 11mm/s and consistent till present.
2. FFT at high resolution shows strong 1x in horizontal direction as well as 1x harmonics (1x-4x)
with pole pass frequency sidebands. A pattern of rotor bar faulty, or other faults shorted end
rings, rotor laminations.
3. Time waveform with beating phenomenon which gives audible modulating growling noise at
site.
4. Time waveform is asymmetrical indicates impacts is directional.
5. FFT: 2xLF amplitude varies up and down. Rotor bar frequency with 2LF sideband shows fault
on the rotor bar (loose joint)
6. Motor speed fluctuates: without load 1491/1482/1477 with load 1450/1444/1428 rpm
7. Motor Body temperature 35-44’C
8. Gearbox starts to pick up strong vibration from the motor.

Action(s) taken

1. Repair worn out hinge bolt for gearbox and motor's mounting base – Material Sec.
2. Repair leak through from backstop flange and top up oil for gearbox. – Material Sec.
3. Retighten all the bolts

Suggestion(s)

1. Carry out Motor Current Signature Analysis, MCSA, to further determine faults and severity
damage of rotor bar.
2. Rotary don’t have special SKF Current clamp that can be connected to our vibration device
to carry out the Motor Current analysis.
3. Below are some reference and faults example:

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ANTARA STEEL MILLS | LABUAN EQUIPMENT: 1223 Motor & Gearbox
VIBRATION ANALYSIS REPORT Data Collection Date: 26/7 – 20/12/2018

4. Monitor other signs of severe damage: the motor will run hot, the motor will lose Power, the
motor amps will constantly drift up and down, and the speed of the motor will continually
fluctuate. The damage or vibration energy will transmit to other machine and it will
progressively damage the gearbox gears.
5. Other technologies and field experience to determine the root cause are advisable.

Notes:

1X-5X with PPF sidebands

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ANTARA STEEL MILLS | LABUAN EQUIPMENT: 1223 Motor & Gearbox
VIBRATION ANALYSIS REPORT Data Collection Date: 26/7 – 20/12/2018

PPF sidebands

Rotor bars faulty

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ANTARA STEEL MILLS | LABUAN EQUIPMENT: 1223 Motor & Gearbox
VIBRATION ANALYSIS REPORT Data Collection Date: 26/7 – 20/12/2018

Beating sound

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ANTARA STEEL MILLS | LABUAN EQUIPMENT: 1223 Motor & Gearbox
VIBRATION ANALYSIS REPORT Data Collection Date: 26/7 – 20/12/2018

Latest data
Machine name POINT name Date/Time Last value Units
Motor 1 Vel H 20/12/2018 10.5 mm/s
Motor 1 En3 H 20/12/2018 0.9 gE
Motor 1 Vel V 20/12/2018 5 mm/s
Motor 2 Vel H 20/12/2018 8.6 mm/s
Motor 2 En3 H 20/12/2018 0.9 gE
Motor 2 Vel A 20/12/2018 2.9 mm/s
Gearbox 3 Vel H 20/12/2018 4.6 mm/s
Gearbox 3 En3 H 20/12/2018 1.5 gE
Gearbox 3TH 20/12/2018 0.6 g
Gearbox 3 Vel V 20/12/2018 6.8 mm/s
Gearbox 3 Vel A 20/12/2018 2.9 mm/s
Gearbox 3 En3 A 20/12/2018 1.8 gE
Gearbox 4 Vel H 20/12/2018 4.1 mm/s
Gearbox 4 En3 H 20/12/2018 0.3 gE
Gearbox 4TH 20/12/2018 0.6 g
Gearbox 4 Vel V 20/12/2018 7.7 mm/s
Gearbox 4 Vel A 20/12/2018 2.8 mm/s
Gearbox 4 En3 A 20/12/2018 1.4 gE
Gearbox 5 En3 H 20/12/2018 0.8 gE
Gearbox 5TH 20/12/2018 0.4 g
Non Route Motor Low 5/10/2018 14 mm/s
frequency 1H
Non Route Motor High 5/10/2018 0.3 g
frequency 1H

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ANTARA STEEL MILLS | LABUAN EQUIPMENT: 1223 Motor & Gearbox
VIBRATION ANALYSIS REPORT Data Collection Date: 26/7 – 20/12/2018

Notes
VIBRATION SPECTRUM ANALYSIS - This test can detect cracked or loose bars while
under load. Under load, the vibration will modulate at a rate equal to the number
of poles times slip frequency. With a broken rotor bar, the amplitude of the beat
increases with load. A cracked rotor bar can also cause localized heating of the
rotor which causes un-even expansion and rotor bowing. This results in an
unbalance and a strong 1 times running speed vibration as well as the side bands
related to slip frequency. Loose rotor bars may give similar symptoms and also
will show vibration at rotor bar passing frequencies. This test will not show up at
no load running because a broken rotor bar cannot carry current. When it is in an
area of high flux, the magnetic forces on the rotor are unbalanced. Since the
current flow through the rotor bar is proportional to slip, at no load when rotor
current is low, the bar has virtually no magnetic forces acting on it.

Todd A. Hatfield, VP Engineering & Repair

Today many instruments incorporate the use of computer algorithms to

automatically identify the frequency peaks of interest and the amplitudes of these
peaks to aid in analysis. What appears to be a very challenging task becomes
quite simple with the aid of industrial designed software. Of the various methods
put forth in this article, no single test will definitively prove the presence of a rotor
bar defect. Understanding why these peaks are where they are, and what is
actually causing the increases in amplitude, allows us to better analyse the
condition of our machines. The use of these methods will also provide additional
clarity to the vibration data. Luckily, very few rotor bar defects lead to
catastrophic motor failure. All of the data analysis methods described in this
article have trend able indicators. Trend the relative amplitudes for motors,
compare these results to other motors of the same design, and make an educated
decision that is practical concerning motor criticality. The presence of broken bars
will cause an increase in overall motor losses and a decrease in motor efficiency.
The additional heat generated from the added current will also further increase
the rate of insulation degradation in the stator. Taking routine data on your
motors, analysing that data as described above and trending this data over time
will allow you the confidence to “make the right the call”.

Drew Norman is currently working with Baker Instrument Company, an SKF

Group company

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