Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006

Calidad: NORCONTROL, garantiza que este trabajo se ha realizado cumpliendo con las condiciones requeridas
Garanta de Calidad
por el Sistema de Calidad de la compaa. Si desean expresar algn comentario les rogamos se dirijan al responsable de la
unidad que lo ha realizado, o si lo prefieren, al Gerente de Applus - NORCONTROL COLOMBIA Ltda. Cra 11 # 73-32
Bogot D.C. Telfono (571) 3765000 - FAX: (571) 3765006 mcastrog@appluscorp.com.

Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

Elaborado por:
Billy Baute Bornacelli

Aprobado por:
Lilian Henao

CERTIFICADO::
INFORME O CERTIFICADO
1. DESCRIPCIN DE LOS TRABAJOS
1.1 Objetos
1.2 Trabajos realizados
1.3 Fechas de Inspeccin
1.4 Lugar de inspeccin
2 DOCUMENTACIN APLICABLE
3 PERSONAL
4 EQUIPOS
5 RESULTADOS

6. ANEXOS
Datos y grficos.
grficos.
ANEXO 1
Motor ABB N 1 Pala KOMATSU K01
ANEXO 2
Motor ABB N2 Pala KOMATSU K01
ANEXO 3
Motor ABB N1 Pala KOMATSU K02
ANEXO 4
Motor ABB N2 Pala KOMATSU K02
ANEXO 5
Motor ABB N1 Pala KOMATSU K03
ANEXO 6
Motor ABB N2 Pala KOMATSU K03

Fecha / Firma:
06/02/2008

Fecha / Firma:
06/02/2008

CLIENTE:
CARBONES DEL CERREJON

ASUNTO:
INFORME PRELIMINAR DE ENSAYOS DE
MANTENIMIENTO PREDICTIVO SEIS
MOTORES ELECTRICOS.

REFERENCIA :
OF 07.110.1234
OT 110.0042.08
Este documento y los anexos en l referenciados tienen paginacin
independiente con indicacin del nmero total de pginas en cada uno
de ellos (tipo pgina X de Y)

FR-ADM-060.07

Este documento no deber reproducirse sin la

aprobacin por escrito de NORCONTROL y del
cliente

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

1
1.1

DESCRIPCIN DE TRABAJOS
Objetos:

Evaluar, mediante el anlisis de las corrientes de carga y los voltajes de alimentacin, la

condicin mecnica y elctrica de los motores de induccin asociados a las palas KOMATSU PC
8000.
1.2
Trabajos realizados
Se realizaron los siguientes ensayos de mantenimiento predictivo en los motores:
A. Evaluacin mediante MCSA de motores elctricos retroexcavadoras KOMATSU
PC8000 k01, k02, k03.
1.3
Fechas de inspeccin
30 y 31 de Enero de 2008.
1.4
Lugar de Inspeccin
Instalaciones del CERREJON S.A., en el departamento de La Guajira

DOCUMENTACIN APLICABLE

Para la realizacin del informe se tuvo en cuenta las siguientes disposiciones legislativas y
documentos de referencia:

Los manuales de los equipos de ensayo.

Reglamento Tcnico de Instalaciones Elctricas Colombia (RETIE).
Cdigo Elctrico Colombiano NTC 2050.

3 PERSONAL
Las actividades correspondientes a la realizacin de los ensayos estuvieron a cargo de los
ingenieros Ivan Gonzalez Roa y Felipe Diaz, la interpretacin de los resultados y la elaboracin
del informe estuvo a cargo del ingeniero Billy Baute Bornacelli, todos los anteriores
trabajadores activos de APPLUS NORCONTROL COLOMBIA.
La revisin y posterior aprobacin del informe, estuvo a cargo de la ingeniera Lilian Henao
trabajador de APPLUS NORCONTROL COLOMBIA.

EQUIPOS

Para la realizacin de los trabajos se emplearon los siguientes equipos:

Sistema para evaluacin de equipos de conversin a travs del anlisis de las

corrientes de carga y las tensiones de alimentacin, marca FRAMATOME ANP INC.,
modelo EMPATH 2000 versin 4.4.

Computador porttil.

Palm TX-Series/ Toma de datos en campo.

Software para procesamiento y anlisis de condicin.

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 2 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

RESULTADOS
Se realizaron los ensayos de mantenimiento predictivo en seis motores pertenecientes a
tres PALAS KOMATSU, con el fin de conocer el estado actual del mismo y su evolucin.
5.1

Motor ABB N 1 Pala KOMATSU K01

DIAGNOSTICO GENERAL
Aspecto evaluado
Condicin
Elctrico
Mecnico
Buena
Tolerable
Cuestionable
Deficiente

Los datos y grficos obtenidos en el anterior ensayo se aprecian en el anexo 1.

Conclusiones:
El comportamiento de esta unidad es normal en todos sus parmetros, tanto elctricos como
mecnicos. Los voltajes para las tres fases corresponden al valor nominal. Los valores
registrados son consistentes con las lecturas efectuadas en campo sobre el rele de proteccin.
Las condiciones del equipo son ptimas para su operacin.
Recomendaciones:
No se considera necesario emprender ninguna accin correctiva a corto plazo. De cualquier
manera se recomienda hacer un seguimiento peridico de las condiciones mecnicas, elctricas y
de operacin de la mquina.

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 3 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

5.2

Motor ABB N2 Pala KOMATSU K01

DIAGNOSTICO GENERAL
Aspecto evaluado
Condicin
Elctrico
Mecnico
Buena
Tolerable
Cuestionable
Deficiente

Los datos y grficos obtenidos en el anterior ensayo se aprecian en el anexo 2.

Conclusiones:
La condicin de esta unidad es normal en sus parmetros elctricos. Los voltajes para las tres
fases son equilibrados y no presentan niveles importantes de distorsin. Las corrientes son
balanceadas dentro de lmites razonables y tampoco muestran un contenido armnico
apreciable. No hay evidencias de defectos en el rotor. En el caso de los rodamientos hay indicios
de dao.
Recomendaciones:
No se considera necesario emprender ninguna accin correctiva a corto plazo. No obstante, se
recomienda efectuar medicin y anlisis de vibraciones para determinar la condicin real de los
rodamientos.

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 4 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

5.3

Motor ABB N1 Pala KOMATSU K02

Condicin

DIAGNOSTICO GENERAL
Aspecto evaluado
Elctrico

Mecnico

Buena
Tolerable
Cuestionable
Deficiente

Los datos y grficos obtenidos en el anterior ensayo se aprecian en el anexo 3.

Conclusiones:
La condicin de esta unidad es normal en sus parmetros elctricos. Los voltajes para las tres
fases son equilibrados y no presentan niveles importantes de distorsin. Las corrientes son
balanceadas dentro de lmites razonables y tampoco muestran un contenido armnico
apreciable. No hay evidencias de defectos en el rotor. En el caso de los rodamientos hay indicios
de dao.
Recomendaciones:
No se considera necesario emprender ninguna accin correctiva a corto plazo. No obstante, se
recomienda efectuar medicin y anlisis de vibraciones para determinar la condicin real de los
rodamientos.

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 5 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

5.4

Motor ABB N2 Pala KOMATSU K02

Condicin

DIAGNOSTICO GENERAL
Aspecto evaluado
Elctrico

Mecnico

Buena
Tolerable
Cuestionable
Deficiente

Los datos y grficos obtenidos en el anterior ensayo se aprecian en el anexo 4.

Conclusiones:
Los voltajes y las corrientes son equilibrados dentro de mrgenes razonables y los niveles de
distorsin se encuentran por debajo de los lmites mximos establecidos por norma El sistema
detect la presencia de componentes asociadas a defectos del rotor, y tanto el ndice de
severidad como el parmetro rotor bar health index son inaceptables.
Recomendaciones:
Se recomienda efectuar anlisis de vibraciones con el fin de obtener informacin adicional
acerca del estado del rotor. En el momento en que se realice un overhaul se debe verificar
fsicamente la condicin que presentan las barras.

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 6 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

5.5

Motor ABB N1 Pala KOMATSU K03

DIAGNOSTICO GENERAL
Aspecto evaluado
Condicin
Elctrico
Mecnico
Buena
Tolerable
Cuestionable
Deficiente

Los datos y grficos obtenidos en el anterior ensayo se aprecian en el anexo 5.

Conclusiones:
En trminos generales el comportamiento de esta unidad es normal en todos sus parmetros,
tanto elctricos como mecnicos, aunque los niveles de distorsin en voltaje son relativamente
altos. En campo se pudo detectar la presencia de ruidos en las cercanas del cuarto de control,
probablemente por fallas en el sistema hidrulico de accionamiento de la pala durante la
operacin del motor 1.
Recomendaciones:
Recomendaciones:
No se considera necesario emprender ninguna accin correctiva a corto plazo. De cualquier
manera, se recomienda hacer un seguimiento peridico de las condiciones mecnicas, elctricas
y de operacin de la mquina.

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 7 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

5.6

Motor ABB N2 Pala KOMATSU K03

DIAGNOSTICO GENERAL
Aspecto evaluado
Condicin
Elctrico
Mecnico
Buena
Tolerable
Cuestionable
Deficiente

Los datos y grficos obtenidos en el anterior ensayo se aprecian en el anexo 6.

Conclusiones:
Tanto los voltajes como las corrientes son equilibrados dentro de mrgenes razonables, pero los
niveles de distorsin en voltaje se encuentran por encima de los lmites mximos establecidos
por norma. El sistema detect la presencia de componentes asociadas a defectos del rotor. No
obstante, si bien el ndice de severidad es inaceptable, el parmetro rotor bar health index se
puede considerar normal. En el caso de los rodamientos hay indicios de dao.
Recomendaciones:
Se recomienda efectuar anlisis de vibraciones con el fin de obtener informacin adicional
acerca del estado del rotor. En el momento en que se realice un overhaul se debe verificar
fsicamente la condicin que presentan las barras.

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 8 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

ANEXOS

ANEXO 1.
Empath 2000 4.4 Analysis Results
PERFORMANCE SUMMARY
Bottom Line
X

This motor is operating normally, no action is required.

This motor exhibits suspicious operation, trending of the motor is warranted.
This motor exhibits abnormal indications, action is warranted, NOW.

Power Factor Commentary

X

Power factor exceeds 0.85.

Power factor is below 0.85, see detailed report.

Current Commentary
X

Current variation is within normal limits.

Current variation is beyond normal limits, see detailed report.

Voltage Commentary
X

Voltage variation is within normal limits.

Voltage variation is beyond normal limits, see detailed report.
RMS voltage differs from nameplate by more than 5%.

Load Commentary
X

Load on the motor is consistent with nameplate values.

Load on the motor exceeds nameplate values, see detailed report.
Load on the motor is less than 25%.

Phase Connection Commentary

X

Connections are normal.

Voltage ground reference is NOT neutral.
Loose connection.

Rotor Commentary
X

Rotor bar health is normal.

Rotor bar health is questionable, see detailed report.
Load is insufficient to determine rotor bar health, at this time.

Stator Commentary
X

Stator health is normal.

Stator mechanical health is questionable.
Turn to turn short.

Rotor/Stator Air-gap Characteristics

X

Dynamic or static eccentricity indications do not exist.

Indications of static eccentricity exist.
Indications of dynamic eccentricity exist.

Harmonic Distortion Commentary

X

There is no evidence of harmonic distortion.

There is evidence of harmonic distortion, see detailed report.

Misalignment Indications
X

There are no indications of mechanical problems like misalignment or unbalance.

There are indications of mechanical problems like misalignment or unbalance. Perform vibration survey to identify
and correct the cause.

Bearing Commentary
X

There is no evidence of bearing problem.

Indications of potential bearing problems, perform vibration survey to verify.

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 9 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

INPUT SUMMARY
INFORMACION DE PLACA [Palm TX-Series]]
Units
Manufacturer
Serial Number
Model Number
Motor type
Power
RPM
AC/DC
Poles
Phases:
Voltage
Full Load Current
Number Stator Slots
Rotor Bars
Torque (ft-lbs):
CT Ratio
PT Ratio
Duty Cycle
Service Factor
Frame Size
Insulation Type
Ambient Temperature
Motor efficiency
Power factor

ABB
4574642
AMA500L4ABAXYH
Induction
1943.60
1767
AC
4
3
7200.0
140.00
1
68
5774.7
35.000
72.000
S1
115
****
F
70.0
1.000
1.000

HP
Rpm

Volt
Amp

Ft.Lb

Detailed Calculations
LEGENDS:
Impedance
= Complex Impedance = vi/ci
CF
= Crest Factor = (waveform peak)/(waveform rms)
CFC
= Carrier Frequency Content = 10^(x/20)/frms, %
THDF
= Transformer Harmonic De-rating Factor = sqrt(2)/CF, %
VDF
= Voltage De-rating Factor = 100 - (voltage unbalance, %)^2, %
Se, fund
= Location of pole pass frequency fundamental, Hz
Se, harm
= Number of pole pass frequency harmonics
Level
= Sum of spectral amplitudes of pole pass frequency fundamentals and harmonics
Slip %
= SRSS sum of slip and harmonic "levels" divided by RMS level of RMS DEMOD spectra
between 0 and 65 Hz.
Upper sb
= dB level of upper slip sideband of power line peak
Lower sb
= dB level of lower slip sideband of power line peak
Rotor bar health = Estimate of the percent of broken or cracked rotor bars
Thd
= Total harmonic distortion
+Ve
= Positive sequence harmonic
-Ve
= Negative sequence harmonic
Zero
= Zero sequence harmonic

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 10 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

Running Speed
= 29.940 Hz / 1796 Rpm
Pole pass frequency = 0.046 Hz
Load
= 64.7 %
Time
RMS
Peak
CF
126.985
218.112
1.626
Current 1
126.011
226.189
1.697
Current 2
126.389
269.170
1.659
Current 3
125.998
287.550
1.641
Average
1.2
1.9
1.1
% dev
THDF = 52.8
Time
Voltage 1
Voltage 2
Voltage 3
Average
% dev
VDF = 52.8

RMS
4751.220
4734.730
4628.620
4940.212
1.4

Peak
6146.015
6534.026
6298.000
6324.012
0.9

CF
1.627
1.460
1.885
1.798
1.6

App. Power
Real Power
Reac. Power
Power factor
Impedance
kVA
kW
kVARS
0.746
94.400
1212.326
1376.614
357.360
Phase 1
0.876
87.611
1010.800
1205.460
375.740
Phase 2
0.932
93.932
1487.000
1249.000
317.990
Phase 3
98.876
3917.000
1221.972
351.090
Avg/Total 0.987
1.5
1.1
% dev
Demand Pwr = 1582.90 HP [Load: 64.7 %, Motor Eff.:74.0 %, Output Pow: 1652.3 KW, Imp.Unb. Eff.Reduc: 2.21
%, Output Trq.:4820.0 Ft.Lb]
Summary of Rotor Bar Health
Se, fund
Se, harm
Level %
1.743
0
Measured
Severity level
Rotor Condition Assessment
Excellent
1
Harmonic Distortion Results:
Voltage input, from 59.949 Hz harmonics
THD Odd %
THD Even %
1.54
0.33
Current 1
1.79
0.42
Current 2
1.71
0.31
Current 3
1.65
0.21
Voltage 1
1.55
0.27
Voltage 2
1.33
0.24
Voltage 3

FR-ADM-060.07 (EL CERREJON Motores elctricos)

+ve%
0.57
0.60
0.62
0.28
0.37
0.49

(Ao 2008)

Power line dB diff.

Rotor bar
Health index
Upper SB
Lower SB
100.0
-100.0
0.0350
Recommended Corrective Action
None

-ve %
1.45
1.69
1.57
1.64
1.50
1.21

Zero %
0.21
0.42
0.41
0.14
0.31
0.35

Pgina 11 de 44

THD All %
1.58
1.84
1.74
1.67
1.58
1.35

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

Figure- 1: Current Harmonic distortion graph

Figure- 2: Voltage Harmonic distortion graph

Hz
60
120
180
240
300
360
420
480
540
600
660
720
780

Cur1
129.55
0.65
0.19
0.09
0.47
0.00
0.28
0.09
0.28
0.56
12.65
0.19
3.07

Harmonic distortion table

Vlt1
Cur2
Vlt2
5724.15
129.55
5729.73
1.02
0.56
1.21
0.19
0.09
0.47
0.09
0.19
0.65
0.47
0.37
0.74
0.00
0.00
0.00
0.74
0.65
0.56
0.09
0.09
0.28
0.47
0.56
0.09
0.47
0.28
0.37
11.81
8.65
12.28
0.19
0.37
0.28
2.88
3.07
2.98

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Cur3
129.74
1.02
0.19
0.09
0.47
0.00
0.74
0.09
0.47
0.47
11.81
0.19
2.88

Vlt3
5725.08
0.65
0.19
0.09
0.47
0.00
0.28
0.09
0.28
0.56
12.65
0.19
3.07

Pgina 12 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

CORRIENTE DE CARGA (A) Vs TIEMPO (s).

ESPECTRO DE CORRIENTE

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 13 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

VOLTAJE RMS DE ALIMENTACIN (V) Vs TIEMPO (s)

ESPECTRO DE VOLTAJE

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 14 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

ANEXO 2
Empath 2000 4.4 Analysis Results
PERFORMANCE SUMMARY
Bottom Line
X

This motor is operating normally, no action is required.

This motor exhibits suspicious operation, trending of the motor is warranted.
This motor exhibits abnormal indications, action is warranted, NOW.

Power Factor Commentary

X

Power factor exceeds 0.85.

Power factor is below 0.85, see detailed report.

Current Commentary
X

Current variation is within normal limits.

Current variation is beyond normal limits, see detailed report.

Voltage Commentary
X

Voltage variation is within normal limits.

Voltage variation is beyond normal limits, see detailed report.
RMS voltage differs from nameplate by more than 5%.

Load Commentary
X

Load on the motor is consistent with nameplate values.

Load on the motor exceeds nameplate values, see detailed report.
Load on the motor is less than 25%.

Phase Connection Commentary

X

Connections are normal.

Voltage ground reference is NOT neutral.
Loose connection.

Rotor Commentary
X

Rotor bar health is normal.

Rotor bar health is questionable, see detailed report.
Load is insufficient to determine rotor bar health, at this time.

Stator Commentary
X

Stator health is normal.

Stator mechanical health is questionable.
Turn to turn short.

Rotor/Stator Air-gap Characteristics

X

Dynamic or static eccentricity indications do not exist.

Indications of static eccentricity exist.
Indications of dynamic eccentricity exist.

Harmonic Distortion Commentary

X

There is no evidence of harmonic distortion.

There is evidence of harmonic distortion, see detailed report.

Misalignment Indications
X

There are no indications of mechanical problems like misalignment or unbalance.

There are indications of mechanical problems like misalignment or unbalance. Perform vibration survey to
identify and correct the cause.

Bearing Commentary
X

There is no evidence of bearing problem.

Indications of potential bearing problems, perform vibration survey to verify.

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 15 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

INPUT SUMMARY
INFORMACION DE PLACA [ Palm TX-Series]]
Units
Manufacturer
Serial Number
Model Number
Motor type
Power
RPM
AC/DC
Poles
Phases:
Voltage
Full Load Current
Number Stator Slots
Rotor Bars
Torque (ft-lbs):
CT Ratio
PT Ratio
Duty Cycle
Service Factor
Frame Size
Insulation Type
Ambient Temperature
Motor efficiency
Power factor

ABB
4574642
AMA500L4ABAXYH
Induction
1943.60
1767
AC
4
3
7200.0
140.00
1
68
5774.7
35.000
72.000
S1
115
****
F
72.0
0.860
0.980

HP
Rpm

Volt
Amp

Ft.Lb

Detailed Calculations
LEGENDS:
Impedance
CF
CFC
THDF
VDF
Se, fund
Se, harm
Level
Slip %

= Complex Impedance = vi/ci

= Crest Factor = (waveform peak)/(waveform rms)
= Carrier Frequency Content = 10^(x/20)/frms, %
= Transformer Harmonic De-rating Factor = sqrt(2)/CF, %
= Voltage De-rating Factor = 100 - (voltage unbalance, %)^2, %
= Location of pole pass frequency fundamental, Hz
= Number of pole pass frequency harmonics
= Sum of spectral amplitudes of pole pass frequency fundamentals and harmonics
= SRSS sum of slip and harmonic "levels" divided by RMS level of RMS DEMOD spectra
between 0 and 65 Hz.
Upper sb
= dB level of upper slip sideband of power line peak
Lower sb
= dB level of lower slip sideband of power line peak
Rotor bar health = Estimate of the percent of broken or cracked rotor bars
Thd
= Total harmonic distortion
+Ve
= Positive sequence harmonic
-Ve
= Negative sequence harmonic
Zero
= Zero sequence harmonic

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 16 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

Running Speed
= 29.619 Hz / 1777 Rpm
Pole pass frequency = 1.398 Hz
Load
= 75.1 %
Time
RMS
Peak
CF
262.410
2.374
Current 1 110.520
221.880
1.883
Current 2 117.810
341.420
2.615
Current 3 130.570
119.630
275.240
2.291
Average
9.1
24.0
17.8
% dev
THDF = 61.7
Time
Voltage 1
Voltage 2
Voltage 3
Average
% dev
VDF = 90.5

RMS
6764.500
6779.600
6789.000
6945.000
1.6

Peak
6806.000
6894.000
6851.000
6984.000
1.6

CF
1.771
1.698
1.565
1.778
1.8

App. Power
Real Power
Reac. Power
Power factor
Impedance
kVA
kW
kVARS
0.930
60.301
440.640
411.070
241.050
Phase 1
0.934
83.863
470.460
451.310
51.476
Phase 2
0.949
113.270
503.610
466.330
827.840
Phase 3
0.979
85.810
1414.700
1328.700
1120.400
Avg/Total
1.4
32.0
% dev
Demand Pwr = 1501.83 HP [Load:75.1 %, Motor Eff.:99.8 %, Output Pow.:1118.1 KW, Imp.Unb.Eff.Reduc.:98.99 %, Output
Trq.:4427.9 Ft.Lb]
Summary of Rotor Bar Health
Se, fund
Se, harm
Level %
1.398
1
0.0
Measured
Severity level
Rotor Condition Assessment
Excellent
1
Harmonic Distortion Results:
Voltage input, from 59.994 Hz harmonics
THD Odd %
THD Even %
5.136
0.984
Current 1
5.742
0.005
Current 2
5.733
0.853
Current 3
4.009
0.803
Voltage 1
3.992
0.768
Voltage 2
4.033
0.176
Voltage 3

FR-ADM-060.07 (EL CERREJON Motores elctricos)

+ve%
1.887
1.049
1.745
1.306
1.358
1.114

(Ao 2008)

Power line dB diff.

Rotor bar
Health index
Upper SB
Lower SB
100.0
100.0
0.0029
Recommended Corrective Action
None

-ve %
9.036
9.283
12.756
9.863
40.738
8.019

Zero %
0.393
0.737
0.351
0.313
0.848
0.095

THD All %
1.773
1.785
1.853
3.008
3.650
3.253

Pgina 17 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

Figure- 1: Current Harmonic distortion graph

Figure- 2: Voltage Harmonic distortion graph

Hz
60
120
180
240
300
360
420
480
540
600
660
720
780

Cur1
115.7
0.5
0.4
0.0
1.2
0.1
1.3
0.2
0.2
0.1
8.7
0.8
6.8

Harmonic distortion table

Vlt1
Cur2
Vlt2
6567
116.4
6441
0.3
0.8
0.3
0.2
0.5
0.2
0.1
0.1
0.1
0.2
1.4
0.2
0.4
0.1
0.4
0.8
1.9
0.8
0.2
0.2
0.2
0.4
0.6
0.4
0.5
0.2
0.5
8.8
7.5
8.8
1.8
0.4
1.8
3.6
7.5
3.6

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Cur3
116.2
0.4
0.2
0.1
1.6
0.6
0.6
0.3
0.2
0.2
7.6
0.8
6.2

Vlt3
6555
0.3
0.2
0.1
0.2
0.4
0.8
0.2
0.4
0.5
8.8
1.8
3.6

Pgina 18 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

CORRIENTE DE CARGA (A) Vs TIEMPO (s).

ESPECTRO DE CORRIENTE

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 19 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

VOLTAJE RMS DE ALIMENTACIN (V) Vs TIEMPO (s)

ESPECTRO DE VOLTAJE

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 20 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

ANEXO 3
Empath 2000 4.4 Analysis Results
PERFORMANCE SUMMARY
Bottom Line
X

This motor is operating normally, no action is required.

This motor exhibits suspicious operation, trending of the motor is warranted.
This motor exhibits abnormal indications, action is warranted, NOW.

Power Factor Commentary

X

Power factor exceeds 0.85.

Power factor is below 0.85, see detailed report.

Current Commentary
X

Current variation is within normal limits.

Current variation is beyond normal limits, see detailed report.

Voltage Commentary
X

Voltage variation is within normal limits.

Voltage variation is beyond normal limits, see detailed report.
RMS voltage differs from nameplate by more than 5%.

Load Commentary
X

Load on the motor is consistent with nameplate values.

Load on the motor exceeds nameplate values, see detailed report.
Load on the motor is less than 25%.

Phase Connection Commentary

X

Connections are normal.

Voltage ground reference is NOT neutral.
Loose connection.

Rotor Commentary
X

Rotor bar health is normal.

Rotor bar health is questionable, see detailed report.
Load is insufficient to determine rotor bar health, at this time.

Stator Commentary
X

Stator health is normal.

Stator mechanical health is questionable.
Turn to turn short.

Rotor/Stator Air-gap Characteristics

X

Dynamic or static eccentricity indications do not exist.

Indications of static eccentricity exist.
Indications of dynamic eccentricity exist.

Harmonic Distortion Commentary

X

There is no evidence of harmonic distortion.

There is evidence of harmonic distortion, see detailed report.

Misalignment Indications
X

There are no indications of mechanical problems like misalignment or unbalance.

There are indications of mechanical problems like misalignment or unbalance. Perform vibration survey to
identify and correct the cause.

Bearing Commentary
X

There is no evidence of bearing problem.

Indications of potential bearing problems, perform vibration survey to verify.

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 21 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

INPUT SUMMARY
INFORMACION DE PLACA [Palm TX-Series]]
Units
Manufacturer
Serial Number
Model Number
Motor type
Power
RPM
AC/DC
Poles
Phases:
Voltage
Full Load Current
Number Stator Slots
Rotor Bars
Torque (ft-lbs):
CT Ratio
PT Ratio
Duty Cycle
Service Factor
Frame Size
Insulation Type
Ambient Temperature
Motor efficiency
Power factor

ABB
4578450
AMA500L4ABAXYH
Induction
1943.60
1767
AC
4
3
7200.0
140.00
1
68
5774.7
35.000
15.000
S1
115
****
F
80.0
1.000
1.000

HP
Rpm

Volt
Amp

Ft.Lb

Detailed Calculations
LEGENDS:
Impedance
CF
CFC
THDF
VDF
Se, fund
Se, harm
Level
Slip %

= Complex Impedance = vi/ci

= Crest Factor = (waveform peak)/(waveform rms)
= Carrier Frequency Content = 10^(x/20)/frms, %
= Transformer Harmonic De-rating Factor = sqrt(2)/CF, %
= Voltage De-rating Factor = 100 - (voltage unbalance, %)^2, %
= Location of pole pass frequency fundamental, Hz
= Number of pole pass frequency harmonics
= Sum of spectral amplitudes of pole pass frequency fundamentals and harmonics
= SRSS sum of slip and harmonic "levels" divided by RMS level of RMS DEMOD spectra
between 0 and 65 Hz.
Upper sb
= dB level of upper slip sideband of power line peak
Lower sb
= dB level of lower slip sideband of power line peak
Rotor bar health = Estimate of the percent of broken or cracked rotor bars
Thd
= Total harmonic distortion
+Ve
= Positive sequence harmonic
-Ve
= Negative sequence harmonic
Zero
= Zero sequence harmonic
FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 22 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

Running Speed
= 29.825 Hz / 1790 Rpm
Pole pass frequency = 0.665 Hz
Load
= 43.8 %
Time
Current 1
Current 2
Current 3
Average
% dev
THDF = 81.7

RMS
123.930
132.030
129.960
128.640
3.7

Peak
216.130
224.850
227.060
222.680
2.9

CF
1.744
1.703
1.747
1.731
1.6

RMS
3954.100
3982.400
3974.800
3980.500
0.9

Peak
4343.000
4330.300
4388.300
4353.900
0.8

CF
1.470
1.452
1.460
1.461
0.6

Time
Voltage 1
Voltage 2
Voltage 3
Average
% dev
VDF = 99.2

Power factor
0.985
Phase 1
0.989
Phase 2
0.978
Phase 3
Avg/Total 0.984
0.6
% dev
Demand Pwr = 875.84 HP

Impedance
23.837
22.590
23.121
23.183
2.8

App. Power
kVA
210.950
225.960
227.260
664.170

Summary of Rotor Bar Health

Se, fund
Se, harm
Level %
0.665
1
Measured
Severity level
Rotor Condition Assessment
1
Excellent

Harmonic Distortion Results:

Voltage input, from 60.017 Hz harmonics
THD Odd %
THD Even %
5.529
0.761
Current 1
5.479
0.740
Current 2
5.232
0.954
Current 3
2.143
0.241
Voltage 1
1.505
0.246
Voltage 2
1.963
0.303
Voltage 3

FR-ADM-060.07 (EL CERREJON Motores elctricos)

Real Power
kW
207.690
223.490
222.200
653.380

Reac. Power
kVARS
36.926
33.356
47.692
117.970

Power line dB diff.

Rotor bar
Health index
Upper SB
Lower SB
100.0
100.0
0.0031
Recommended Corrective Action
None

+ve%
3.984
2.910
4.484
0.640
0.504
0.817

(Ao 2008)

-ve %
3.757
4.653
2.808
2.051
1.428
1.797

Zero %
1.079
0.672
0.540
0.193
0.173
0.216

THD All %
5.581
5.529
5.318
2.157
1.525
1.986

Pgina 23 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

Figure- 1: Current Harmonic distortion graph

Figure- 2: Voltage Harmonic distortion graph

Hz
60
120
180
240
300
360
420
480
540
600
660
720
780

Cur1
132.2
0.5
0.2
0.0
1.3
0.0
1.0
0.4
0.4
0.1
0.6
0.0
3.0

Harmonic distortion table

Vlt1
Cur2
Vlt2
3935
132.1
3976
3
0.5
3
3
0.3
5
3
0.1
3
50
0.9
47
0
0.0
0
9
0.4
9
5
0.6
6
3
0.3
2
0
0.1
1
3
0.6
3
0
0.0
0
13
2.8
16

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Cur3
132.0
0.5
0.3
0.0
1.3
0.0
1.0
0.8
0.1
0.2
0.6
0.1
3.4

Vlt3
3968
3
5
3
56
0
12
6
2
1
3
0
15

Pgina 24 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

CORRIENTE DE CARGA (A) Vs TIEMPO (s).

ESPECTRO DE CORRIENTE

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 25 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

VOLTAJE RMS DE ALIMENTACIN (V) Vs TIEMPO (s)

ESPECTRO DE VOLTAJE

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 26 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

ANEXO 4
Empath 2000 4.4 Analysis Results
PERFORMANCE SUMMARY
Bottom Line
X

This motor is operating normally, no action is required.

This motor exhibits suspicious operation, trending of the motor is warranted.
This motor exhibits abnormal indications, action is warranted, NOW.

Power Factor Commentary

X

Power factor exceeds 0.85.

Power factor is below 0.85, see detailed report.

Current Commentary
X

Current variation is within normal limits.

Current variation is beyond normal limits, see detailed report.

Voltage Commentary
X

Voltage variation is within normal limits.

Voltage variation is beyond normal limits, see detailed report.
RMS voltage differs from nameplate by more than 5%.

Load Commentary
X

Load on the motor is consistent with nameplate values.

Load on the motor exceeds nameplate values, see detailed report.
Load on the motor is less than 25%.

Phase Connection Commentary

X

Connections are normal.

Voltage ground reference is NOT neutral.
Loose connection.

Rotor Commentary
X

Rotor bar health is normal.

Rotor bar health is questionable, see detailed report.
Load is insufficient to determine rotor bar health, at this time.

Stator Commentary
X

Stator health is normal.

Stator mechanical health is questionable.
Turn to turn short.

Rotor/Stator Air-gap Characteristics

X

Dynamic or static eccentricity indications do not exist.

Indications of static eccentricity exist.
Indications of dynamic eccentricity exist.

Harmonic Distortion Commentary

X

There is no evidence of harmonic distortion.

There is evidence of harmonic distortion, see detailed report.

Misalignment Indications
X

There are no indications of mechanical problems like misalignment or unbalance.

There are indications of mechanical problems like misalignment or unbalance. Perform vibration survey to
identify and correct the cause.

Bearing Commentary
X

There is no evidence of bearing problem.

Indications of potential bearing problems, perform vibration survey to verify.

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 27 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

INPUT SUMMARY
INFORMACION DE PLACA [Palm TX-Series]]
Units
Manufacturer
Serial Number
Model Number
Motor type
Power
RPM
AC/DC
Poles
Phases:
Voltage
Full Load Current
Number Stator Slots
Rotor Bars
Torque (ft-lbs):
CT Ratio
PT Ratio
Duty Cycle
Service Factor
Frame Size
Insulation Type
Ambient Temperature
Motor efficiency
Power factor

ABB
4578451
AMA500L4ABAXYH
Induction
1943.60
1767
AC
4
3
7200.0
140.00
1
64
5774.7
35.000
15.000
S1
115
****
F
70.0
1.000
1.000

HP
Rpm

Volt
Amp

Ft.Lb

Detailed Calculations
LEGENDS:
Impedance
CF
CFC
THDF
VDF
Se, fund
Se, harm
Level
Slip %

= Complex Impedance = vi/ci

= Crest Factor = (waveform peak)/(waveform rms)
= Carrier Frequency Content = 10^(x/20)/frms, %
= Transformer Harmonic De-rating Factor = sqrt(2)/CF, %
= Voltage De-rating Factor = 100 - (voltage unbalance, %)^2, %
= Location of pole pass frequency fundamental, Hz
= Number of pole pass frequency harmonics
= Sum of spectral amplitudes of pole pass frequency fundamentals and harmonics
= SRSS sum of slip and harmonic "levels" divided by RMS level of RMS DEMOD spectra
between 0 and 65 Hz.
Upper sb
= dB level of upper slip sideband of power line peak
Lower sb
= dB level of lower slip sideband of power line peak
Rotor bar health = Estimate of the percent of broken or cracked rotor bars
Thd
= Total harmonic distortion
+Ve
= Positive sequence harmonic
-Ve
= Negative sequence harmonic
Zero
= Zero sequence harmonic
FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 28 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

Running Speed
= 29.991 Hz / 1799 Rpm
Pole pass frequency = 0.115 Hz
Load
= 55.3 %
Time
RMS
Peak
CF
166.040
251.690
1.603
Current 1
166.540
265.770
1.596
Current 2
164.080
259.170
1.580
Current 3
162.550
258.870
1.593
Average
2.4
2.7
0.8
% dev
THDF = 88.8
Time
Voltage 1
Voltage 2
Voltage 3
Average
% dev
VDF = 98.9

RMS
5957.400
5991.200
5015.700
5988.100
1.0

Peak
6322.100
6340.800
6378.000
6346.900
0.7

CF
1.461
1.451
1.452
1.455
0.5

App. Power
Real Power
Reac. Power
Power factor
Impedance
kVA
kW
kVARS
0.979
18.833
267.330
261.820
53.967
Phase 1
0.986
17.960
285.660
281.610
47.921
Phase 2
0.974
18.380
288.460
281.090
64.786
Phase 3
18.391
841.450
824.530
166.670
Avg/Total 0.980
0.6
2.4
% dev
Demand Pwr = 1105.26 HP [Load:55.3 %, Motor Eff.:96.4 %, Output Pow.:795.2 KW, Imp.Unb.Eff.Reduc.:2.60 %, Output
Trq.:3110.1 Ft.Lb]
Summary of Rotor Bar Health
Se, fund
Se, harm
Level %
0.115
1
Measured
Severity level
Rotor Condition Assessment
Rotor bar crack may be developing or
4
problems with high resistance joint

Harmonic Distortion Results:

Voltage input, from 60.040 Hz harmonics
THD Odd %
THD Even %
1.732
0.325
Current 1
1.748
0.337
Current 2
1.785
0.402
Current 3
2.138
0.167
Voltage 1
1.556
0.161
Voltage 2
2.004
0.131
Voltage 3

FR-ADM-060.07 (EL CERREJON Motores elctricos)

+ve%
1.145
1.000
1.429
0.252
0.515
0.617

(Ao 2008)

Power line dB diff.

Rotor bar
Health index
Upper SB
Lower SB
-100.0
-12.7
0.8249
Recommended Corrective Action
Reduce survey intervals, trend closely

-ve %
1.173
1.321
1.129
2.103
1.438
1.888

Zero %
0.647
0.652
0.175
0.335
0.336
0.296

Pgina 29 de 44

THD All %
1.762
1.781
1.830
2.144
1.564
2.008

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

Figure- 1: Current Harmonic distortion graph

Figure- 2: Voltage Harmonic distortion graph

Hz
60
120
180
240
300
360
420
480
540
600
660
720
780

Cur1
155.7
0.1
0.5
0.0
1.4
0.0
0.4
0.4
0.8
0.0
0.2
0.0
1.5

Harmonic distortion table

Vlt1
Cur2
Vlt2
2948
164.7
2995
2
0.2
2
8
0.7
9
1
0.0
2
53
1.0
50
0
0.0
0
9
1.2
16
4
0.4
3
7
0.8
4
0
0.1
0
1
0.1
1
0
0.0
0
6
0.9
7

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Cur3
162.3
0.5
0.1
0.1
1.2
0.0
1.4
0.4
0.1
0.0
0.2
0.0
1.7

Vlt3
2984
2
8
1
60
0
11
4
4
0
2
0
8

Pgina 30 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

CORRIENTE DE CARGA (A) Vs TIEMPO (s).

ESPECTRO DE CORRIENTE

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 31 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

VOLTAJE RMS DE ALIMENTACIN (V) Vs TIEMPO (s)

ESPECTRO DE VOLTAJE

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 32 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

ANEXO 5
Empath 2000 4.4 Analysis Results
PERFORMANCE SUMMARY
Bottom Line
X

This motor is operating normally, no action is required.

This motor exhibits suspicious operation, trending of the motor is warranted.
This motor exhibits abnormal indications, action is warranted, NOW.

Power Factor Commentary

X

Power factor exceeds 0.85.

Power factor is below 0.85, see detailed report.

Current Commentary
X

Current variation is within normal limits.

Current variation is beyond normal limits, see detailed report.

Voltage Commentary
X

Voltage variation is within normal limits.

Voltage variation is beyond normal limits, see detailed report.
RMS voltage differs from nameplate by more than 5%.

Load Commentary
X

Load on the motor is consistent with nameplate values.

Load on the motor exceeds nameplate values, see detailed report.
Load on the motor is less than 25%.

Phase Connection Commentary

X

Connections are normal.

Voltage ground reference is NOT neutral.
Loose connection.

Rotor Commentary
X

Rotor bar health is normal.

Rotor bar health is questionable, see detailed report.
Load is insufficient to determine rotor bar health, at this time.

Stator Commentary
X

Stator health is normal.

Stator mechanical health is questionable.
Turn to turn short.

Rotor/Stator Air-gap Characteristics

X

Dynamic or static eccentricity indications do not exist.

Indications of static eccentricity exist.
Indications of dynamic eccentricity exist.

Harmonic Distortion Commentary

X

There is no evidence of harmonic distortion.

There is evidence of harmonic distortion, see detailed report.

Misalignment Indications
X

There are no indications of mechanical problems like misalignment or unbalance.

There are indications of mechanical problems like misalignment or unbalance. Perform vibration survey to identify
and correct the cause.

Bearing Commentary
X

There is no evidence of bearing problem.

Indications of potential bearing problems, perform vibration survey to verify.

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 33 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

INPUT SUMMARY
INFORMACION DE PLACA [Palm TX-Series]]
Units
Manufacturer
Serial Number
Model Number
Motor type
Power
RPM
AC/DC
Poles
Phases:
Voltage
Full Load Current
Number Stator Slots
Rotor Bars
Torque (ft-lbs):
CT Ratio
PT Ratio
Duty Cycle
Service Factor
Frame Size
Insulation Type
Ambient Temperature
Motor efficiency
Power factor

ABB
4574643
AMA500L4ABAXYH
Induction
1943.60
1767
AC
4
3
7200.0
140.00
1
64
5774.7
35.000
72.000
****
115
****
****
65.0
0.950
0.880

HP
Rpm

Volt
Amp

Ft.Lb

Detailed Calculations
LEGENDS:
Impedance
= Complex Impedance = vi/ci
CF
= Crest Factor = (waveform peak)/(waveform rms)
CFC
= Carrier Frequency Content = 10^(x/20)/frms, %
THDF
= Transformer Harmonic De-rating Factor = sqrt(2)/CF, %
VDF
= Voltage De-rating Factor = 100 - (voltage unbalance, %)^2, %
Se, fund
= Location of pole pass frequency fundamental, Hz
Se, harm
= Number of pole pass frequency harmonics
Level
= Sum of spectral amplitudes of pole pass frequency fundamentals and harmonics
Slip %
= SRSS sum of slip and harmonic "levels" divided by RMS level of RMS DEMOD spectra
between 0 and 65 Hz.
Upper sb
= dB level of upper slip sideband of power line peak
Lower sb
= dB level of lower slip sideband of power line peak
Rotor bar health = Estimate of the percent of broken or cracked rotor bars
Thd
= Total harmonic distortion
+Ve
= Positive sequence harmonic
-Ve
= Negative sequence harmonic
Zero
= Zero sequence harmonic

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 34 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

Running Speed
= 29.642 Hz / 1779 Rpm
Pole pass frequency = 1.330 Hz
Load
= 70.6 %
Time
RMS
Peak
CF
114.610
187.040
1.691
Current 1
114.730
187.530
1.683
Current 2
114.990
186.960
1.696
Current 3
114.770
187.310
1.690
Average
0.8
0.6
0.4
% dev
THDF = 83.7
Time
Voltage 1
Voltage 2
Voltage 3
Average
% dev
VDF = 98.9

RMS
7123.180
7123.250
7122.980
7123.130
0.6

Peak
7186.370
7186.490
7186.820
7186.510
0.4

CF
1.537
1.441
1.440
1.473
4.4

App. Power
Real Power
Reac. Power
Power factor
Impedance
kVA
kW
kVARS
0.996
133.180
1001.330
796.950
83.710
Phase 1
0.980
125.240
1001.350
797.800
212.370
Phase 2
0.984
129.840
1001.330
797.820
167.030
Phase 3
129.420
3004.010
2392.400
463.110
Avg/Total 0.987
1.0
3.2
% dev
Demand Pwr = 1379.97 HP [Load:70.6 %, Motor Eff.:95.0 %, Output Pow.:2306.2 KW, Imp.Unb.Eff.Reduc.:3.84 %, Output
Trq.:5768.0 Ft.Lb]
Summary of Rotor Bar Health
Se, fund
Se, harm
Level %
1.330
3
0.0
Measured
Severity level
Rotor Condition Assessment
1
Excellent

Power line dB diff.

Rotor bar
Health index
Upper SB
Lower SB
-100.0
-100.0
0.0044
Recommended Corrective Action
None

Harmonic Distortion Results:

Voltage input, from 60.017 Hz harmonics
THD Odd %
THD Even %
5.157
1.267
Current 1
4.932
1.567
Current 2
4.569
1.635
Current 3
3.279
8.861
Voltage 1
2.809
8.922
Voltage 2
3.794
9.988
Voltage 3

+ve%
2.139
2.215
2.743
3.682
3.324
4.025

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

-ve %
4.690
4.571
3.954
8.365
8.421
9.611

Zero %
1.275
0.987
0.623
2.397
2.348
2.362

THD All %
5.310
5.175
4.853
9.449
9.353
10.684

Pgina 35 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

Figure- 1: Current Harmonic distortion graph

Figure- 2: Voltage Harmonic distortion graph

Hz
60
120
180
240
300
360
420
480
540
600
660
720
780

Cur1
114.61
1.2
0.5
0.1
1.0
0.1
1.7
0.5
1.2
0.4
4.3
0.2
1.5

Harmonic distortion table

Vlt1
Cur2
Vlt2
7123,18
114.73
7123.25
1262
1.5
1305
322
0.2
302
508
0.1
512
180
0.9
199
94
0.0
90
133
1.6
153
69
0.3
100
111
1.1
131
62
1.0
68
167
4.7
217
42
0.2
39
94
1.6
78

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Cur3
114.99
1.6
0.3
0.1
1.2
0.1
2.4
0.8
0.1
0.6
2.9
0.2
1.7

Vlt3
7122.98
1303
322
522
276
93
207
95
89
83
173
42
10

Pgina 36 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

CORRIENTE DE CARGA (A) Vs TIEMPO (s).

ESPECTRO DE CORRIENTE.

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 37 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

VOLTAJE RMS DE ALIMENTACIN (V) Vs TIEMPO (s)

ESPECTRO DE VOLTAJE

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 38 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

ANEXO 6
Empath 2000 4.4 Analysis Results
PERFORMANCE SUMMARY
Bottom Line
X

This motor is operating normally, no action is required.

This motor exhibits suspicious operation, trending of the motor is warranted.
This motor exhibits abnormal indications, action is warranted, NOW.

Power Factor Commentary

X

Power factor exceeds 0.85.

Power factor is below 0.85, see detailed report.

Current Commentary
X

Current variation is within normal limits.

Current variation is beyond normal limits, see detailed report.

Voltage Commentary
X

Voltage variation is within normal limits.

Voltage variation is beyond normal limits, see detailed report.
RMS voltage differs from nameplate by more than 5%.

Load Commentary
X

Load on the motor is consistent with nameplate values.

Load on the motor exceeds nameplate values, see detailed report.
Load on the motor is less than 25%.

Phase Connection Commentary

X

Connections are normal.

Voltage ground reference is NOT neutral.
Loose connection.

Rotor Commentary
X

Rotor bar health is normal.

Rotor bar health is questionable, see detailed report.
Load is insufficient to determine rotor bar health, at this time.

Stator Commentary
X

Stator health is normal.

Stator mechanical health is questionable.
Turn to turn short.

Rotor/Stator Air-gap Characteristics

X

Dynamic or static eccentricity indications do not exist.

Indications of static eccentricity exist.
Indications of dynamic eccentricity exist.

Harmonic Distortion Commentary

X

There is no evidence of harmonic distortion.

There is evidence of harmonic distortion, see detailed report.

Misalignment Indications
There are no indications of mechanical problems like misalignment or unbalance.
There are indications of mechanical problems like misalignment or unbalance. Perform vibration survey to identify
X
and correct the cause.

Bearing Commentary
X

There is no evidence of bearing problem.

Indications of potential bearing problems, perform vibration su

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 39 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

INPUT SUMMARY
INFORMACION DE PLACA [Palm TX-Series]]
Units
Manufacturer
Serial Number
Model Number
Motor type
Power
RPM
AC/DC
Poles
Phases:
Voltage
Full Load Current
Number Stator Slots
Rotor Bars
Torque (ft-lbs):
CT Ratio
PT Ratio
Duty Cycle
Service Factor
Frame Size
Insulation Type
Ambient Temperature
Motor efficiency
Power factor

ABB
4578597
AMA500L4ABAXYH
Induction
1943.60
1767
AC
4
3
7200.0
140.00
1
64
5774.7
35.000
72.000
S1
115
****
F
65.0
1.000
0.870

HP
Rpm

Volt
Amp

Ft.Lb

Detailed Calculations
LEGENDS:
Impedance
CF
CFC
THDF
VDF
Se, fund
Se, harm
Level
Slip %

= Complex Impedance = vi/ci

= Crest Factor = (waveform peak)/(waveform rms)
= Carrier Frequency Content = 10^(x/20)/frms, %
= Transformer Harmonic De-rating Factor = sqrt(2)/CF, %
= Voltage De-rating Factor = 100 - (voltage unbalance, %)^2, %
= Location of pole pass frequency fundamental, Hz
= Number of pole pass frequency harmonics
= Sum of spectral amplitudes of pole pass frequency fundamentals and harmonics
= SRSS sum of slip and harmonic "levels" divided by RMS level of RMS DEMOD spectra
between 0 and 65 Hz.
Upper sb
= dB level of upper slip sideband of power line peak
Lower sb
= dB level of lower slip sideband of power line peak
Rotor bar health = Estimate of the percent of broken or cracked rotor bars
Thd
= Total harmonic distortion
+Ve
= Positive sequence harmonic
-Ve
= Negative sequence harmonic
Zero
= Zero sequence harmonic
FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 40 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

Running Speed
= 29.986 Hz / 1778 Rpm
Pole pass frequency = 0.073 Hz
Load
= 56.9 %
Time
RMS
Peak
CF
92.653
122.470
1.109
Current 1
93.213
128.760
3.067
Current 2
92.459
125.480
3.064
Current 3
92.775
125.570
3.653
Average
1.3
2.5
1.5
% dev
THDF = 68.9
Time
Voltage 1
Voltage 2
Voltage 3
Average
% dev
VDF = 86.7

RMS
7200.200
7253.400
7269.900
7274.600
1.1

Power factor
0.711
Phase 1
0.739
Phase 2
0.668
Phase 3
Avg/Total 0.706
5.4
% dev
Demand Pwr = 1017.20 HP

Peak
8723.300
8721.620
8723.490
8723.040
1.6

Impedance
94.861
92.729
91.985
92.240
3.4

CF
1.399
1.665
1.546
1.592
1.49

App. Power
kVA
343.980
343.970
343.950
921.290

Summary of Rotor Bar Health

Se, fund
Se, harm
Level %
0.057
3
0.0
Measured
Severity level
Rotor Condition Assessment
Three or more rotor bars likely cracked
7
or broken and problem with high
resistance joints likely.

Real Power
kW
311.330
337.480
334.560
983.380

Reac. Power
kVARS
747.350
0.499
609.290
1357.100

Power line dB diff.

Rotor bar
Health index
Upper SB
Lower SB
-103.2
-103.2
0.0069
Recommended Corrective Action
Perform vibration tests to confirm problem source
and severity

Harmonic Distortion Results:

Voltage input, from 60.113 Hz harmonics
THD Odd %
THD Even %
4.953
1.569
Current 1
4.816
1.567
Current 2
4.754
1.635
Current 3
3.967
8.861
Voltage 1
3.968
8.922
Voltage 2
3.941
8.922
Voltage 3

+ve%
2.469
2.215
2.743
3.682
3.324
3.123

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

-ve %
4.572
4.570
3.967
9.365
9.461
9.458

Zero %
1.182
0.987
0.848
2.397
2.348
2.347

THD All %
5.327
5.255
4.842
9.494
9.413
9.912

Pgina 41 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

Figure- 1: Current Harmonic distortion graph

Figure- 2: Voltage Harmonic distortion graph

Hz
60
120
180
240
300
360
420
480
540
600
660
720
780

Cur1
108.6
1.7
0.2
0.1
0.3
0.1
2.2
0.9
0.1
0.6
0.8
0.2
0.5

Harmonic distortion table

Vlt1
Cur2
Vlt2
6987
109.3
7039
34
1.1
59
3
0.1
20
13
0.1
11
66
0.3
72
2
0.0
5
79
1.4
126
27
0.8
31
4
0.1
4
14
0.3
22
29
0.8
30
2
0.1
4
10
0.5
11

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Cur3
114.0
1.3
0.4
0.1
0.3
0.0
1.9
0.5
0.1
0.6
1.2
0.1
0.5

Vlt3
7018
45
14
12
70
4
101
28
4
17
27
2
10

Pgina 42 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

CORRIENTE DE CARGA (A) Vs TIEMPO (s).

ESPECTRO DE CORRIENTE.

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 43 de 44

Applus Norcontrol Colombia Ltda.

Bogot
Carrera 11 No. 73-32,
PBX: (571) 3765000 - FAX: (571) 3765006
Barranquilla
Carrera 55 No. 72-109 Piso 8
PBX: (575) 3301800 - FAX: (575) 3301836
www.appluscorp.com..co

VOLTAJE RMS DE ALIMENTACIN (V) Vs TIEMPO (s)

ESPECTRO DE VOLTAJE.

FR-ADM-060.07 (EL CERREJON Motores elctricos)

(Ao 2008)

Pgina 44 de 44