Engineered Test Labs

Reportable. Repeatable. Industrial Testing Solutions Thu, 06 Jan 2022 20:51:22 +0000 en-US hourly 1 https://wordpress.org/?v=6.1.3 https://staging-miwanisa.kinsta.cloud/wp-content/uploads/2019/04/cropped-etl-logo-letters-32x32.png Engineered Test Labs 32 32 SRMFA Case Study – Westinghouse SCI Rotor – H2S Damage https://staging-miwanisa.kinsta.cloud/rotor-lab/srmfa-case-study-westinghouse-sci-rotor-h2s-damage/ Wed, 15 Dec 2021 21:28:07 +0000 https://staging-miwanisa.kinsta.cloud/?p=4493 An SRMFA test verified the effectiveness of the rotor repair and the restoration of the rotor cage integrity.

The post SRMFA Case Study – Westinghouse SCI Rotor – H2S Damage appeared first on Engineered Test Labs.

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Ref. #:: 485376
Date:: December, 2020

Make:: Westinghouse
Nameplate:: 700 HP \ 4000 VAC \ 891 RPM

Job Description

This rotor was brought into Brandon & Clark’s facility showing signs of corrosion from H₂S. Sour gas exposure for fabricated SCI machines, even with rigorous PM and protective coatings, has proven to wreak havoc over an extended period of time. The brazed endring connections of this rotor had areas of visible corrosion. However, SRMFA testing revealed the truth beneath the surface. This rotor needed to be sandblasted and rewelded to repair the open bars. An additional SRMFA test verified the effectiveness of the repair and the restoration of the rotor cage integrity.

Before Reweld

After Reweld

Available Downloads

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Download
SRMFA Case Study - SCI Rotor - H2S Damage
733 KB

The post SRMFA Case Study – Westinghouse SCI Rotor – H2S Damage appeared first on Engineered Test Labs.

]]> SRMFA Case Study – Siemens-Allis 700hp Recondition https://staging-miwanisa.kinsta.cloud/rotor-lab/srmfa-case-study-siemens-allis-700hp-recondition/ Mon, 13 Dec 2021 18:21:19 +0000 https://staging-miwanisa.kinsta.cloud/?p=4463 Complete rotor rebuild due to damaged rotor cage elements and core laminations.

The post SRMFA Case Study – Siemens-Allis 700hp Recondition appeared first on Engineered Test Labs.

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Ref. #:: 481243
Date:: July, 2020

Make:: Siemens-Allis
Nameplate:: 700 HP \ 2300 VAC \ 1785 RPM

Job Description

Our customer asked for their motor to be reconditioned before redeployment, as a precautionary measurement and as part of their SOP.

Testing and Assessment

The rotor was SRMFA tested as part of standard diagnostic procedure and was found to have a single cracked bar, at the welded endring interface. The resultant SRMFA color map definitively reveals the defective bar in the #9 slot. This rotor defect could have easily been overlooked, only to show up as part of vibration analysis during proof-of-run testing, wasting valuable time. The Brandon & Clark team did a superb job of following procedure and catching this defect early in the reconditioning process.

Rotor Bar Damage

SRMFA Test Results

Available Downloads

Download
SRMFA Case Study - Siemens-Allis 700hp Recondition
1.3 MB

The post SRMFA Case Study – Siemens-Allis 700hp Recondition appeared first on Engineered Test Labs.

]]> SRMFA Case Study – Toshiba 1000hp Reweld https://staging-miwanisa.kinsta.cloud/rotor-lab/srmfa-case-study-toshiba-1000hp-reweld/ Thu, 09 Dec 2021 17:08:33 +0000 https://staging-miwanisa.kinsta.cloud/?p=4445 Complete rotor rebuild due to damaged rotor cage elements and core laminations.

The post SRMFA Case Study – Toshiba 1000hp Reweld appeared first on Engineered Test Labs.

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Ref. #:: 456200
Date:: June, 2018

Make:: Toshiba
Nameplate:: 1000 HP \ 4160 VAC \ 885 RPM

Job Description

Rotor was exhibiting excessive vibration and taken out of service due to corrosion related to H₂S gas exposure.

Testing and Assessment

There were several areas of highly visible corrosion at the bar-to-end-ring interface. SRMFA testing revealed several broken and damaged rotor bars. Due to the severity of the damage, this rotor was sandblasted and rewelded at Brandon & Clark’s facility in Lubbock, TX.

Corrosion from H₂S Gas Exposure

SRMFA Test Results

Available Downloads

Download
SRMFA Case Study - Toshiba 1000hp Reweld
1.7 MB

The post SRMFA Case Study – Toshiba 1000hp Reweld appeared first on Engineered Test Labs.

]]> SRMFA Case Study – Westinghouse 600hp Rebuild https://staging-miwanisa.kinsta.cloud/rotor-lab/srmfa-case-study-westinghouse-600hp-rebuild/ Wed, 01 Dec 2021 21:53:02 +0000 https://staging-miwanisa.kinsta.cloud/?p=4349 Complete rotor rebuild due to damaged rotor cage elements and core laminations.

The post SRMFA Case Study – Westinghouse 600hp Rebuild appeared first on Engineered Test Labs.

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Ref. #:: 454798
Date:: May, 2018

Make:: Westinghouse
Nameplate:: 600 HP \ 4160 VAC \ 3555 RPM

Job Description

Complete rotor rebuild with new core steel and rotor bars. Rotor was refurbished. Brandon & Clark performed SRMFA via Rotor Lab both before and after repair.

Testing and Assessment

Our standard visual inspection procedure revealed enough damage to warrant a complete rebuild. Although this rotor could be sufficiently diagnosed by trained in-house personnel, the visual inspection is only effective for a subset rotor cage designs where the end ring interface is sufficiently exposed for inspection. A visual inspection is a good tool for diagnosing a rotor failure, but is insufficient for accurate reporting of complete rotor condition and has proven unreliable in detection of minor defects.

Before Rotor Rebuild

After Rotor Rebuild

Available Downloads

Download
SRMFA Case Study - Westinghouse 600hp Rebuild
1.2 MB

The post SRMFA Case Study – Westinghouse 600hp Rebuild appeared first on Engineered Test Labs.

]]> Pump Lab Metering https://staging-miwanisa.kinsta.cloud/pump-lab/pump-lab-performance-test-metering/ Wed, 07 Apr 2021 21:54:26 +0000 https://staging-miwanisa.kinsta.cloud/?p=3548 An overview of commonly measured values for a pump performance test.

The post Pump Lab Metering appeared first on Engineered Test Labs.

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Pump Test Lab Metering and Measurement

Let’s discuss commonly measured values for a pump performance test, the associated metering equipment, and the application of those measured values on a pump performance report.

Input Power

Input power is most commonly derived from an electric motor (although other sources such as internal combustion engines may also be utilized, we will not be discussing these today). ETL labs may utilize a variety of calibrated electrical measurement devices for capturing input power from submersible motors, but may use a calibrated torque meter for other motor types.

Speed

Motor speed is ideally measured with a torque meter, however motor speed can be approximated from power/frequency measurements and motor nameplate data.

Head

Head is derived from measurements taken during test operation and static measurements of the pump lab configuration. Calibrated pressure transducers are utilized for capturing pressure head. ETL pump labs will take into consideration (where applicable) velocity head, pressure head, friction head and elevation head, when calculating TDH “Total Dynamic Head”.

Flow

Flow rate is measured with inductive flow meters in the discharge piping. Careful consideration is given for spacing both before and after the meter to allow sufficient stabilization distance.

OPTIONAL MEASUREMENTS

Vibration (multiple sensors may be integrated)
Fluid temperature, density, viscosity
Ambient temperature

The post Pump Lab Metering appeared first on Engineered Test Labs.

]]> Rotor Bar Testing – Temperature Indicating Paints https://staging-miwanisa.kinsta.cloud/rotor-lab/rotor-bar-testing-temperature-indicating-paints/ Mon, 29 Mar 2021 19:32:33 +0000 https://staging-miwanisa.kinsta.cloud/?p=2819 Temperature indicating paints allow a technician to visually inspect a rotor for locally isolated temperature variation.

The post Rotor Bar Testing – Temperature Indicating Paints appeared first on Engineered Test Labs.

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Test Overview

A thorough visual inspection process may include the use of temperature indicating paints. Testing steps include:

Rotor is removed from stator
Temperature indicating paint(s) are applied to the rotor surface
Motor is reassembled and run under load
Motor is once again disassembled and further inspected for change in color to localized areas

Related Testing:

Advanced Rotor Testing

Learn more about advanced rotor testing, from Engineered Test Labs.

Learn More

The post Rotor Bar Testing – Temperature Indicating Paints appeared first on Engineered Test Labs.

]]> Rotor Bar Testing – Single Phase Rotation https://staging-miwanisa.kinsta.cloud/rotor-lab/rotor-bar-testing-single-phase-rotation/ Thu, 25 Mar 2021 18:01:38 +0000 https://staging-miwanisa.kinsta.cloud/?p=2661 Test Procedure While the motor is in an assembled/disconnected state, apply low voltage single phase power to any two of the motor leads and slowly rotate the shaft. While rotating the shaft, observe an ammeter connected to one of the motor’s phases, keeping a close eye on fluctuation of the measured current. Variations in the […]

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Test Procedure

While the motor is in an assembled/disconnected state, apply low voltage single phase power to any two of the motor leads and slowly rotate the shaft. While rotating the shaft, observe an ammeter connected to one of the motor’s phases, keeping a close eye on fluctuation of the measured current. Variations in the measured amps by as little as ±3%, could indicate an open rotor. Increased electrical noise, during this test, may also be indicative of an open rotor.

Test Deficiencies

While the single phase rotation test is quite effective on detecting an open circuit, there are a couple things that an evaluator must be aware of before taking the results to the bank. The single phase rotation test does not detect minor defects in the rotor cage/casting, the motor must be in an assembled state (and preferably heated from recent operation), and the results of this test are 100% dependent on a qualified technician’s observations during the test.

Advanced Rotor Testing

Learn more about advanced rotor testing, from Engineered Test Labs.

Learn More

The post Rotor Bar Testing – Single Phase Rotation appeared first on Engineered Test Labs.

]]> Rotor Bar Testing – Digital Low Resistance Ohmmeter (DLRO) https://staging-miwanisa.kinsta.cloud/rotor-lab/rotor-bar-testing-dlro-digital-low-resistance-ohmmeter/ Thu, 25 Mar 2021 18:01:10 +0000 https://staging-miwanisa.kinsta.cloud/?p=2659 Test Overview During a DLRO test, resistance measurements are taken across single rotor bars and then evaluated (relative to other bars from the same rotor) for values above an acceptable range. Test Deficiencies Although DLRO testing is an effective method of evaluating rotors for cracked/broken or otherwise damaged/defective rotor bars, the test methodology has its […]

The post Rotor Bar Testing – Digital Low Resistance Ohmmeter (DLRO) appeared first on Engineered Test Labs.

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Test Overview

During a DLRO test, resistance measurements are taken across single rotor bars and then evaluated (relative to other bars from the same rotor) for values above an acceptable range.

Test Deficiencies

Although DLRO testing is an effective method of evaluating rotors for cracked/broken or otherwise damaged/defective rotor bars, the test methodology has its shortcomings. In the case of a die cast rotor, the rotor must be modified to access the individual rotor bars, creating extra work for repair technicians. In addition, the DLRO test doesn’t necessarily provide a definitive pass/fail; it can raise more questions than answers.

Advanced Rotor Testing

Learn more about advanced rotor testing, from Engineered Test Labs.

Learn More

The post Rotor Bar Testing – Digital Low Resistance Ohmmeter (DLRO) appeared first on Engineered Test Labs.

]]> Rotor Bar Testing – Rotor Rated Flux https://staging-miwanisa.kinsta.cloud/rotor-lab/rotor-bar-testing-rotor-rated-flux/ Thu, 25 Mar 2021 18:00:17 +0000 https://staging-miwanisa.kinsta.cloud/?p=2655 Test Overview A rotor rated flux test or high-current excitation test, often performed with a core tester acting as the power source, can be administered with some degree of success for detection of major rotor bar defects. During a high-current test, an infrared thermal imaging camera is utilized to locate hot spots which indicate broken/damaged […]

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Test Overview

A rotor rated flux test or high-current excitation test, often performed with a core tester acting as the power source, can be administered with some degree of success for detection of major rotor bar defects. During a high-current test, an infrared thermal imaging camera is utilized to locate hot spots which indicate broken/damaged rotor bars.

Test Deficiencies

The rotor rated flux test is performed with extremely high current which presents a degree of safety concern for the technician. In addition, this test method subjects the rotor to those same high currents, which could be damaging to the rotor laminations. Finally, the high-current test is difficult to document, report, and doesn’t provide automated evaluation of the test results.

Advanced Rotor Testing

Learn more about advanced rotor testing, from Engineered Test Labs.

Learn More

The post Rotor Bar Testing – Rotor Rated Flux appeared first on Engineered Test Labs.

]]> Rotor Bar Testing – Growler (voltage monitoring) https://staging-miwanisa.kinsta.cloud/rotor-lab/rotor-bar-testing-growler-voltage-monitoring/ Thu, 25 Mar 2021 17:59:54 +0000 https://staging-miwanisa.kinsta.cloud/?p=2653 The post Rotor Bar Testing – Growler (voltage monitoring) appeared first on Engineered Test Labs.

]]> The post Rotor Bar Testing – Growler (voltage monitoring) appeared first on Engineered Test Labs.

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Job Description

Before Reweld

After Reweld

Available Downloads

Download SRMFA Case Study - SCI Rotor - H2S Damage 733 KB

Job Description

Testing and Assessment

Rotor Bar Damage

SRMFA Test Results

Available Downloads

Download SRMFA Case Study - Siemens-Allis 700hp Recondition 1.3 MB

Job Description

Testing and Assessment

Corrosion from H2S Gas Exposure

SRMFA Test Results

Available Downloads

Download SRMFA Case Study - Toshiba 1000hp Reweld 1.7 MB

Job Description

Testing and Assessment

Before Rotor Rebuild

After Rotor Rebuild

Available Downloads

Download SRMFA Case Study - Westinghouse 600hp Rebuild 1.2 MB

Pump Test Lab Metering and Measurement

Input Power

Speed

Head

Flow

OPTIONAL MEASUREMENTS

Test Overview

Advanced Rotor Testing

Test Procedure

Test Deficiencies

Advanced Rotor Testing

Test Overview

Test Deficiencies

Advanced Rotor Testing

Test Overview

Test Deficiencies

Advanced Rotor Testing

Download
SRMFA Case Study - SCI Rotor - H2S Damage
733 KB

Download
SRMFA Case Study - Siemens-Allis 700hp Recondition
1.3 MB

Corrosion from H₂S Gas Exposure

Download
SRMFA Case Study - Toshiba 1000hp Reweld
1.7 MB

Download
SRMFA Case Study - Westinghouse 600hp Rebuild
1.2 MB