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Motor Inspection

Power quality

Bearing

Stator

Shaft

Rotor

Foundation

Stator

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  • Flux coil analysis

  • Inductive imbalance

  • Resistive imbalance

  • Insulation

  • Contamination

  • Impedance imbalance

  • Voltage imbalance

  • Current imbalance

  • In-Rush current

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Flux coil analysis captures flux signals which provide an electrical quality signature. This electrical signature is sensitive to conditions which alter the electrical characteristics of the motor, such as broken rotor bars, eccentricity, imbalance between phases, and stator faults.

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Measuring the inductance per phase any extreme imbalance in the readings would indicate turn-to-turn stator fault and quality of the insulation.

Power quality

  • Voltage imbalance %

  • Current imbalance %

  • Impedance imbalance %

  • Total Harmonic Distortion %

  • Power Factors

  • Over/Under Voltage

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Power quality focuses on the condition of the voltage and current in a motor’s branch circuit. Poor power quality can greatly affect the operation and health of an electric motor. During operation, several stresses are brought to bear upon key components of the motor. Variances or distortions in the voltage powering motor result in increasing both thermal and electrical stresses to the stator windings and in some cases components of the rotor.

Bearing

  • Vibration

  • Peak Vue

  • Ultrasound

  • Oil/Grease analysis

  • Shaft voltage test

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Bearing failure is one of the foremost causes of breakdowns in rotating machinery and such failure can be catastrophic, resulting in costly downtime. 

 

Vibration analysis is the key to bearing prognostics is to detect the defect at its incipient stage and alert the operator before it develops into a catastrophic failure.

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Peak Vue is a 'Stress Wave Analysis’ rather than conventional vibration data. These stress waves travel further than conventional vibration signals so a true indication of fault severity is obtained.

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Ultrasonic inspection is a necessary element that identifies bearing wear in its early stages can be a valuable tool toward avoiding major downtime. As internal components in moving machinery begin to wear, increased friction creates subtle changes in the ultrasonic sound being generated. 

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Shaft voltage monitoring is the purpose to indicate the presence of high levels of voltage or current on the motor or generator shaft in order to detect poor grounding shaft performance prior to bearing failures.

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Oil Analysis can identify performance or condition of machines and equipment from determining degree of wear (normal or abnormal), degree of oil degradation and degree of oil contamination. Oil analysis testing and result must encompass three sections as follow

 

  • Wear Condition: Wear debris analysis related to health condition of the machine (Normal wear or Abnormal)

  • Oil Condition: Viscosity, Oxidation, Nitration, Total Acid Number (TAN)

  • Contamination: Water, Dust, Fuel, Coolant, Wrong oil, Particle contamination

Rotor

  • Flux coil analysis

  • Eccentricity

  • Vibration

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Flux coil analysis captures flux signals which provide an electrical quality signature. This electrical signature is sensitive to conditions which alter the electrical characteristics of the motor, such as broken rotor bars and eccentricity

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Eccentricity

Evaluates the current and voltage spectrums using a Fast Fourier Transform (FFT), which converts the time waveforms to a frequency spectrum.  The FFT highlights amplitudes and frequencies identify faults such as eccentricity.

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Vibration analysis is another purpose to indicate rotor faults such as rotor bow, crack, and rubbing.

Lubrication

  • Vibration

  • Peak Vue

  • Ultrasound

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Vibration analysis is a very powerful technology. It can be used to detect a wide range of fault conditions in rotating machinery including defects from lubrication in the bearings such as lack of lubrication and oil whirl.

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Peak Vue analysis is actually a measure of “stress wave” activity in a metallic component. Such stress waves are associated with impact, friction, fatigue cracking, and lubrication

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​Ultrasonic inspection and monitoring of bearings is by far the most reliable method for detecting incipient bearing failure and conditions such as lack of lubrication. 

Shaft

  • Shaft grounding

  • Unbalance

  • Misalignment 

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Shaft grounding

The flow of current coming from the rotor to the stator can damage every bearing if countermeasures are not implemented. Electric discharge can be measured by checking the shaft voltage and current amplitudes to protect before bearing failure.

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Unbalance

The balancing of rotating body is important to avoid vibration. Balancing in Heavy Industrial machinery such as generators and motors can cause catastrophic failure. Vibration analysis is the important tool for fault diagnosis in rotating machinery the unbalance is the most common reason in machine vibrations.

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Misalignment produces excessive vibration, noise, coupling- and bearing-temperature increases, and premature failure of bearings, couplings, or shafts. Vibration analysis is defined as a process for measuring the vibration levels and frequencies of machinery and then using that information to analyze how healthy the machines and their components are.

Foundation/Structure

  • Vibration

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Foundation/Structure 

The effect of the dynamic fluid force on the pump structure system is considered vibrate at its natural frequency but the amplitude is determined by the initial conditions. If the motion of the system tends to increase the energy of the pump structure system, the vibration amplitude will increase and the pump structure system is considered to be unstable. 

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