Chuck Yung
EASA Senior Technical Support Specialist

Redesigning electric motors has become commonplace for motor repair service centers. By changing one or more motor characteristics, service centers often can adapt motors to meet new requirements faster and more economically than they can obtain new ones.

This paper explains how to make any changes in the ratings of AC electric motors that are possible within design limitations. Examples of each redesign are included as a guide for making your own redesigns. Besides mathematical formulas, this section provides guidelines on the limitations for each type of redesign. These guidelines will also help you determine whether a desired new rating is possible before you strip a motor.

In most service centers, there are rules regarding what winding changes can be made, who can make them, and who must approve them. Make sure that redesigns are not made without going through the proper channels.

This paper gives a brief review of AC motor theory and operation that includes flux pattern, types of losses, NEMA design designations and test procedures. It also covers:

• Design considerations for slip-ring and synchronous motors
• Requirements for reduced starting voltage
• Formulas for redesigning polyphase and single-phase AC equipment.

Chuck Yung
EASA Senior Technical Support Specialist

This paper covers:

• Interpreting AC and DC drop test results (Is that coil really shorted?)
• Differentiating between interpole and armature problems
• Locating an armature short/ground
• Locating shorted/open equalizers in an armature
• Working neutral: Did that motor arc when it left the factory? Let’s cure that problem!

Gene Vogel
EASA Pump & Vibration Specialist

This technical paper was presented at the 2014 EASA Convention.

The impeller is generally the most difficult pump component to repair and the most expensive to replace. This paper looks at case histories of failed pumps and the steps to determine the cause of failure.

• Erosion, corrosion, cavitation or wear. What happened to this impeller?
• How to spot the tell-tale signs
• What operational conditions led to impeller damage

Welcome by 2019-2020 EASA Chairman Brian Larry
Presentation by Tom Bishop, P.E., EASA Senior Technical Support Specialist

In 2003, EASA and AEMT (Association of Electrical and Mechanical Trades in the UK) issued a report that proved rewinding motors in accordance with prescribed good practices would maintain efficiency and reliability. But in recent years, claims abounded that premium efficient motors could not be rewound without degrading efficiency.

This recording discusses the latest EASA/AEMT research that included independent, third-party testing.

Jerry Lipski
Jerry Lipski, LLC
Scheerville, IN

Ever run across brush arcing or vexing commutation issues? This paper, presented at the 2013 EASA Convention, covers:

• Definition of commutation
• Basic magnetism
• Commutation and AC in a DC armature core
• Brush construction
• The basic commutator and placement of carbon brushes
• Carbon brush arcing; what are the brushes telling you? + field case studies
• Sanding brushes
• Most common surface conditions
• Field experiences with drives
• Brushholders
• Slip ring application
• Field settings (neutral, tape method)
• Field/service center testing

Vicki Warren — Iris Power - Toronto, Ontario
Brian F. Moore – Georgia Power - Atlanta, Georgia
Jim Williams – Bradley’s Motors - Corpus Christi, Texas 
Special thanks to Gary Castle at Bradley’s Motors

Traditional tests of insulation resistance, polarization index (IEEE 43) and the controlled DC high voltage test (IEEE 95) have been effective in evaluating certain aspects of global vacuum pressure impregnation (GVPI) stator windings; however, they have not proven adequate for determining whether or not the insulation system is well-consolidated. Recently there has been the development of an IEC standard (IEC 60034-27) that defines the test procedures for performing off-line partial discharge testing as part of quality assurance testing. In addition, globally there has been a move towards using a dielectrics characteristic test, either power factor or dissipation factor, as part of the QA testing for GVPI systems. Partial discharge tests have proven to be effective in locating isolated problems that could lead to failure; whereas, the dielectrics characteristic tests provide a more general condition assessment. Based on experience to date, both are needed to fully evaluate how well the winding is consolidated. 

This paper, presented at the 2014 EASA Convention, describes research done by EASA service shops on the effectiveness and practicality of using offline partial discharge combined with a dielectrics characteristic test to evaluate the consolidation of stator windings in medium voltage machines manufactured by GVPI. Advantages and disadvantages of each test and industrial standards will be described as appropriate.

Brian Beaulieu
ITR Economics

This highly-rated economist will discuss the leading economic indicators, which continue to be in chaos given the worldwide pandemic. He will recommend the best course of action for the most important part of the economy – you and your business.

Chuck Yung
EASA Senior Technical Support Specialist

Although the rotating equipment repair industry has been around for over a century, technology continues to introduce new test instruments and procedures. Some of these are good: surge test, growler, core loss test; some are bad: core testing a rotor at 60 times its operating frequency, or performing a Hipot at several times the prescribed value; and some are just plain ugly.

This paper will help you to sort out which are which, and help educate your customers as to the reasons why. Standards organizations (IEEE, ANSI, IEC) have developed specific tests, with much scientific thought as to how stringent a test should be. ANSI/EASA AR100: Recommended Practice for the Repair of Rotating Electrical Apparatus consistently references the relevant standard(s) for each test.

This paper, presented at the 2013 EASA Convention, summarizes the accepted and other electrical tests required by motor and generator end users. It covers:

• Various standards (IEEE, IEC, NEMA, ANSI and API) that describe and legitimize most of the tests used by our industry
• Other tests, not supported by any recognized standards, that end users request repairers to perform
• An outline of these tests, with supporting standards, which should be useful when discussing testing requirements with end users

Sam Richter
SBR Worldwide, LLC

During times of uncertainty, you have three choices as it relates to sales:

1. Curl up, feel sorry for yourself and hope things get better soon
2. Identify prospects and start building relationships so when we return to some sense of normalcy, your business development efforts are ready to hit the ground running
3. Identify opportunities that need your solutions right now, and reach out in a highly relevant and highly differentiated way. 

Option 1 is not really an option. For Options 2 and 3: What worked in the past won’t necessarily work today and might never work again. The answer: Leverage sales intelligence to locate the right prospects at the right time with the right message. 
In this dynamic program, discover: 

• How to generate opportunities using sales trigger events and powerful introductions so that you’re calling on the prospects who most likely need your solution, right now. 
• How to use search engines, social media and the Invisible Web as powerful sales and competitive “intelligence agents,” ensuring you know how to align your value proposition to what prospects care about. 
• How to leverage information to make a great impression, ensure relevancy, gain permission to ask challenging questions and provide ongoing value to both prospects and customers. 

The Evolution of Sales is not a new sales process – so you’re not starting over. Rather, it’s an evolution of how to identify opportunities and approach prospects in ways where your message is welcomed and appreciated – even in tumultuous times. Plus, what you learn and implement today will work even better when our world returns to some sense of normalcy.

Neville Sachs, P.E.
Applied Technical Services, Inc.,
Syracuse, NY

This technical paper, presented at the 2014 EASA Convention, will help you understand how and why shafts and fasteners fail. This paper covers:

• Discussion of material properties typically found in motor shafts, machine shafts and common fasteners
• Differentiating between overload and fatigue failures
• Understanding and identifying the difference between ductile and brittle materials, and how their fracture appearances differ
• A detailed explanation of how to identify fatigue failures, including the rate and direction of force application and the effect of stress concentrations
• Examples of several failure analyses

Craig MacKay & Glenn Tofil
England & Company, LLC

Prior to the downturn, many business owners were looking to raise capital for internal growth initiatives, acquisitions, or to buy out a family member or partner, while others were considering an outright sale to an outside acquirer, management or employees. While the current economic slowdown may have delayed those plans, this presentation is designed to help business owners understand: 

1. Current private capital markets conditions
2. Alternative transaction structures available to middle market business owners
3. How financial and strategic investors and acquirers have changed their outlooks given the economic dislocation caused by social distancing measures

Despite the economic downturn, there is an abundance of private capital and continuing long-term interest from financial and strategic acquirers in quality businesses. As part of this session, England & Co. will ask a panel of non-control and control investors and acquirers along with a well-known ESOP attorney to explain key aspects of their particular transaction focus and provide their views on how the current downturn is likely to impact overall levels of transaction activity.

Bill Finley and Tyler Gaerke
Siemens Industry, Inc., Norwood, OH

There is always a need to push to higher and higher efficiencies. This can be seen in the revisions to IEEE 841 which pushed efficiencies up to NEMA premium levels. DOE has continued to pass legislation increasing efficiencies to higher levels up to 500 HP. There has also been action recently to establish higher minimum efficiency levels on machines as large as 2500 HP. Motor manufacturers have been motivated to find creative ways to increase efficiency levels through optimization of manufacturing processes, designs, active material increase and better more efficient materials such as magnetic sticks.

To better understand the steps required, it is helpful to understand, how losses are generated and to identify the levers that reduce these significantly, all at an acceptable cost for the investment of the motor. Life cycle costs should also be investigated. 

This paper investigates the impact on the motor performance during starting and normal operation by employing magnetic wedges versus non-magnetic wedges and other potential design changes. The type of induction motor, open (ODP, WPII) or enclosed (TEFC), along with the number of poles, influences the effect on the motor these design changes may have.

Magnetic forces (stresses) acting on the wedges are also investigated in this paper. This paper also discusses qualification processes that are necessary in order to avoid failures and ensure reliable magnetic wedge systems.

This paper covers:

• Designing and testing for NEMA and IEC premium efficiency levels
• History of high efficiency standards activities
• Industrial facility opportunities
• Magnetic wedges (purpose)
• Impact of magnetic wedges on motor performance
• Experimental data for different magnetic wedges
• Qualification of magnetic slot wedges
• Designing with magnetic wedges

Gene Vogel
EASA Pump & Vibration Specialist
and
Walter Barringer
Mobius Institute, Knoxville, TN

Temperature is hot or cold, pressure may be high or low and a tank may be full or empty. But vibration cannot be adequately described by a single parameter. Vibration is composed of amplitude, frequency and phase. Overall amplitude may be used as a simplistic indicator of machinery condition; much like a noise could be described as loud or soft, even though there is a big difference between the scream of a siren and the roar of a train. And so it is with vibration.

The siren sounds different than the train because they are different frequencies. In the same way, the vibration from a failing rolling element bearing can be distinguished from coupling misalignment. This combination of vibration amplitude and frequency is the most common and useful vibration data for determining machinery condition, and analyzing machinery vibration problems. The phase angle of the vibration plays an important role in dynamic balancing and advanced analysis. The analysis of vibration amplitude and frequency as represented in the vibration spectrum, is the topic of this paper.

This paper covers how to get the vibration spectrum and what it means, including:

• Wave form
• Displacement
• Velocity
• Demodulation

Vicki Warren, Iris Power
Mississauga, Ontario
Brian F. Moore, Georgia Power
Atlanta, Georgia

Surveys have shown that stator winding insulation failure account for about 40% of motor failures in motors rated 2300V and above. In addition, the work force in general is losing its technical experience. This impacts both the customers we serve and our own internal work force that fixes the equipment.  Lastly, there seems to be a shift toward a more political type customer base that is less likely to own up to their contribution to motor failures. These reasons combine to force motor shops into better testing to know that a more reliable product is being shipped.

Several old and new test methods have recently gained popularity with AC induction motor maintenance specialists.  This paper, presented at the 2013 EASA Convention, will examine Power Factor Tip-up and Partial discharge testing to assess stator winding conditions for motors rated 2300V and above. Both tests will be evaluated for: effectiveness; which windings/types of machines the test is effective; set-up; interpretation and limitations.

Topics discussed include:

• Brief review of stator winding failure mechanisms
• Brief review of power factor and power factor tip-up
  • The theory/math behind it
  • Georgia Power’s use as a sorting tool
• Partial discharge terms that apply to power factor and tip-up testing
  •   Inception and extinction voltage
  •   Magnitude
  •   Polarity
• Reading actual power factor and test data sheets
  •   Advantages and limitations of off-line tests
  •   Deciding if there is a problem or not
• Case studies: What to do next (if you suspect a problem)
  • Partial discharge testing (brief theory and expected results)
  • Dynamometer testing or full-load testing at the customer’s plant us

Clint Swindall,
Verbalocity, Inc., San Antonio, TX

Leaders often lead employees based on the way they’ve been led in the past. As leaders, we can all think of good bosses and bad bosses from our past. Good or bad, there were lessons to be learned. In this 15-minute session, the speaker discusses what makes bad leaders bad and good leaders good, with an eye on person introspection of our own leadership abilities.

Clint Swindall
Verbalocity, Inc.

The pandemic of 2020 is creating change in virtually all organizations. From changes in work routines to uncertainty of security in the future, employees are faced with change (both professionally and personally). In this 15-minute recording, the speaker addresses a very specific thing you can do to help employees through these changing times.

Clint Swindall
Verbalocity, Inc.

Employees need help getting through these uncertain and unprecedented times. While it’s our job to provide guidance and encouragement, who is guiding and encouraging us? In order to stay strong for our employees, we need to be inspiring ourselves. In this 15-minute session, the speaker will discuss some things you can do to take care of yourself during these tough times in order to take care of others.

Clint Swindall
Verbalocity, Inc.

As a professional, you are contributing to your organization with exceptional skills required for your area of expertise. As a leader, you are contributing based on your ability to successfully fill four specific roles of leadership. In this 15-minute recording, the speaker takes a look at those four roles and how to fill the right role for each leadership situation.

Craig MacKay & Glenn Tofil
England & Company, LLC

Solid middle-market businesses are vulnerable to revenue surprises and market volatility as the impact of COVID-19 on the economy is currently demonstrating. While the long-term prospects of your business may not be materially impaired by temporary decreases in customer demand, delayed projects or supply chain disruptions, the earnings impact can potentially trigger a default under performance-linked financial covenants with a lender.

As part of this presentation, the speakers discuss: 

• Steps business owners should take if the breach of a financial covenant is a possibility  
• The range of how different lenders might work with borrowers that are in default
• Actions that can be taken if a breach leads to the need to amend an existing credit facility, seek a new credit facility or lending relationship, or possibly raising additional third-party junior capital to shore up a company’s balance sheet

The presenters have helped numerous business owners obtain long-term funding to allow their companies to thrive and grow. In addition, England & Co. will be joined by representatives of leading debt capital providers to discuss how companies can best handle short-term liquidity challenges and prepare for a resumption of long-term growth.

Adam Willwerth (deceased)
AEGIS, Electro Static Technology, Mechanic Falls, ME
and
Hilton Hammond
Fluke Corporation, Everett, WA

Get a better understanding of the working principles of motor and drive measurements with test equipment, analysis tools and best practices. This paper presents valuable services you can incorporate to increase services and profits. It also covers:

• Safety practices related to test equipment
• Overview of the system drive train covering measurement protocols for:
  • Drive input and output
  • Motor and drive
  • Shaft voltage measurement and assessment

Not only is the measurement protocol explained but also the technology behind the systems under discussion, such as the inverter and motor. Measuring devices discussed will include:

• ScopeMeter
• Shaft voltage test kit
• Vibration analyzer
• Insulation tester
• Thermal imager

Mike Howell
EASA Technical Support Specialist

Most service centers do not routinely rewind stators in the voltage range of 11-13.8 kV (13.8 kV will be used throughout the discussion for simplicity). These machines represent a small percentage of machines repaired and typically present significant financial exposure in the event of an in-process or warranty related failure. Organizational efforts to enter this product line should be carefully planned to minimize risk to the service center and to assure customer requirements are met.

This paper, presented at the 2013 EASA Convention, presents a generic product quality planning process for industrial motor stator windings rated 13.8 kV. Emphasis is placed on analyzing gaps between a 4 kV rewind and a 13.8 kV rewind as they relate to stator winding design, insulation system validation and process control. The process analysis model considers materials, equipment, people, environment and methods.

Machines rated in the 6 kV class are excluded from the discussion with exception to a short explanation near the end of the paper providing rationale for the exclusion.

• Stator winding design
• Insulation system validation
• Process control

The process analysis model will consider materials, equipment, people, environment and methods.

Rick Hoadley
ABB

Whenever an application engineer is planning on installing adjustable speed drives for AC motors, line current harmonics and reflected waves are two factors that need to be addressed. Four basic questions should be answered in order to successfully commission the drive system:

1. What is my power system like today
2. What impact will the additional drives have on the power quality for the other equipment
3. If needed, what harmonics mitigation method should be used
4. How long and what type of cable is used between the drive and motor

This paper, presented at the 2013 EASA Convention, deals with understanding IEEE Std 519 and various mitigation methods in order to meet those recommendations. It also reviews the types of filtering that is available to reduce the reflected waves seen at the motor terminals.

Topics covered include:

• Overview of drives topologies
• The differences between 6,12,18 pulse and active front end drives
• How the differences in drives relate to harmonics generated
• Filters on either end of the drive to mitigate the effects of harmonics, as well as voltage spikes and other potential damaging effects on the motor

Rick Hoadley
ABB, Inc.
New Berlin, WI

Whenever an application engineer is planning on installing adjustable speed drives for AC motors, line current harmonics and reflected waves are two factors that need to be addressed. Four basic questions should be answered in order to successfully commission the drive system:

1. What is my power system like today
2. What impact will the additional drive(s) have on the power quality for the other equipment
3. If needed, what harmonics mitigation method should be used
4. How long and what type of cable is used between the drive and motor

This paper, originally presented at the 2014 EASA convention, deals with understanding IEEE Std 519 and various mitigation methods in order to meet those recommendations. It also reviews the types of filtering that is available to reduce the reflected waves, first turn insulation stress, and common mode voltages seen at the motor terminals.

• Overview of drives topologies
• The differences between 6,12,18 pulse and active front end drives
• How the differences in drives relate to harmonics generated
• Filters on either end of the drive to mitigate the effects of harmonics, as well as voltage spikes and other potential damaging effects on the motor

Chuck Yung
EASA Senior Technical Support Specialist

Concerns about partial discharge (PD) used to be limited to repairers and users of machines rated over 7 kV – and PD was a common consideration for machines rated 11 kV and higher. Since the advent of variable frequency drives (VFDs), PD activity is a major contributing cause to winding failures in 460v and (especially) 575v motors. This paper will describe PD, explain how to detect it, and offer repair solutions.

Topics covered include:

• Explanation of partial discharge (PD)
• Description of damage mechanism
• PWM drive and PD
• How to evaluate PD
• Repair tips

Craig MacKay & Glenn Tofil
England & Company, LLC

Raising capital or selling a business is time consuming and requires significant preparation well before the first potential financing partner or acquirer is contacted. This session will provide attendees with: 

1. An understanding of how to best prepare your business to fully explore your options while minimizing the distraction from running the business
2. An overview of a “typical” transaction timeline
3. Techniques for maximizing the value created through a transaction
4. An outline of key economic and legal terms that can often leave a business owner exposed to significant unexpected liabilities following the close of a transaction

Moderated by England & Company, this presentation includes a panel of leading control and non-control investors and a corporate securities attorney that have many years of experience in dealing with business sales and acquisitions. This experience will be helpful as the presenters share insights and observations regarding the larger, non-financial questions owners must ask themselves as they prepare to transition or finance their businesses.

Jim Bryan
EASA Technical Support Specialist (retired)

Reclosure occurs when power to a motor is briefly interrupted and restored before the magnetic field has fully collapsed in the motor’s winding. If this occurs while the applied power is out of phase with the collapsing field, significant damage can result. This paper, presented at the 2014 EASA Convention, addresses how this can happen and what measures can mitigate damage potential. Topics covered include:

• Reclosing a switch or breaker before the magnetic field collapses
• Utilities’ automatic reclosure
• Contactor “chatter”
• Determining the time constant
• Remedies
• Time delay
• Zero crossing

Revisit EASA's 2022 Convention & Solutions Expo by buying access to recordings of the general sessions and education events streamed from EASA's website! These recordings provide almost 44 hours of training. Downloadable PDFs of slides and technical papers are included!
 

General sessions

• Keynote - Recalibrate: 7 Choices to Live a Radically Inspired Life
• EASA Industry Research - State of the EASA Industry: Service Center Trends
• The Post-Pandemic Industrial Economy & How To Plan
• Opening Remarks and Presentation of the EASA Award

Technical presentations

• In-Depth: Converting an Application from DC to AC with VSD/VFD - Matthew Conville, MBA, PE, EASA Technical Support Specialist
• DC Motors: Theory, Design, Field Types and Testing - Chuck Yung, EASA Senior Technical Support Specialist
  • DC Theory and Design 101
  • DC Field Types
  • DC Final Testing
  • Drilldown into DC Design
• Industrial Pumps, Applications and Opportunities - Gene Vogel, EASA Pump & Vibration Specialist
• Centrifugal Pump Impellers  - Gene Vogel, EASA Pump & Vibration Specialist
• Tips & Tricks for Submersible Pump Repair  - Gene Vogel, EASA Pump & Vibration Specialist
• Understanding Corrosion in Pumps  - Gene Vogel, EASA Pump & Vibration Specialist
• Fundamentals of Surge Comparison Testing and Results - Jacob Beck, Electrom Instruments
• Visions on IIoT for Industrial Maintenance  - Gene Vogel, EASA Pump & Vibration Specialist
• Tips and Tricks of Vertical Pump Repair  - Gene Vogel, EASA Pump & Vibration Specialist
• What Else Can Remote Condition Monitoring Sensors Tell Us? - Vijay Anand, ABB
• Catching Common Winding Errors to Minimize Loss - Mike Howell, EASA Technical Support Specialist
• Testing Options for Squirrel Cage Induction Motors from Cradle to Grave - Austin Bonnett, Austin Bonnett Engineering LLC
• Electric Motor Bearing Lubrication Frequency and Quantity - Tom Bishop, EASA Senior Technical Support Specialist
• Open Forum: Industrial Internet of Things (IIoT) - Facilitated by Members of EASA's Emerging Technologies Committee

En Español

• La Placa de Datos de los Motores Trifáicos de CA: Que Información Revela - Carlos Ramirez, EASA Especialista de Soporte Técnico
• Idenitificando Transitorios de Voltaje que Pueden Causar Fallos Prematuros al Motor - Carlos Ramriez, Especialista de Soporte Técnico de EASA

Sales/marketing presentations

• Crushing Price Objections - Paul Reilly, Tom Reilly Training, Inc.
• Value Added Selling - Paul Reilly, Tom Reilly Training, Inc.
• Establishing Your Ideal Customer and Crafting a Message that Resonates - Joe Sullivan, Gorilla 76 Marketing
• How to Build an Expert Content Marketing Program - Joe Sullivan, Gorilla 76 Marketing
• Measuring Marketing Success in a Digital Era - Joe Sullivan, Gorilla 76 Marketing

Management presentations

• Non-Family Executives/Employees - Stephen McClure, Ph.D., The Family Business Consulting Group
• Succession Planning - Stephen McClure, Ph.D., The Family Business Consulting Group
• Family Conversations about Ownership and Leadership Succession - Stephen McClure, Ph.D., The Family Business Consulting Group
• Alternatives to Selling Your Family Business - Stephen McClure, Ph.D., The Family Business Consulting Group
• Great Ideas Session - Paul Gullickson, L&S Electric; Dale Hamil, Illinois Electric Works; Blake Parker, Hi-Speed Industrial Service; Javier Portos, Integrated Power Services
• Attract and Retain Employees While Fostering a Productive Culture Across Generations - Dan Lester, Sr., MCA & Burnea Lester, MA, M.Ed; The Art of Adaption
• European Market Trends and More - Frederic Beghain, EASA Region 9 General Manager & Derry Sheehan, Avonmore Electrical Co.

Ron Widup
Shermco Industries
Irving, TX

Learn from an industry veteran about safety topics you may think you know but that can cost your firm substantially if you’re not diligent.

• Fall protection
• Fork lift hazards and relevant regulations
• Material handling/lifting
• Cranes and hoists
• Machine shop hazards
• Cautions regarding abrasive blasting
• Painting irritants

Mike Weinberg
Speaker, Consultant, Best-Selling Author

The title says it all!! Last year’s highly rated speaker on sales is back by popular demand.

Besides convention papers and handouts, the 2019 Select Presentations includes audio recordings of most sessions with synchronized slide presentations where applicable.

Sessions included are:

Technical Presentations

• DC Machines: The Basics and Beyond • Thermal Imaging and Non-Contact Measurement: What Every Supervisor, Engineer and Technician Should Know
• Final Assembly and Testing of DC Machines
• Máquinas de CA: Procedimientos de Inspección y Prueba 
• Emerging and Disruptive Technologies
• Squirrel Cage Induction Motor Starting Methods
• Ultrasonic Cleaning: Applications for Motor Repair
• Descripción General del Programa de Certificación de EASA y la Norma ANSI/EASA AR 100
• Case Studies in Failure Analysis
• High-Potential Testing of AC Stator Windings 

Management Presentations

• How to Build a Marketing Team of Winders, Machinists and Mechanics 
• Industry Research: New Insights from Plant Maintenance Customers 
• Recruiting & Retaining Top Talent 
• Industrial Economy 2019 and Beyond 

Sales Presentations

• New Sales. Simplified
• Sales Calls. Simplified
• Sales Management. Simplified

NOTE:
The USB Flash Drive version of this product was mailed free of charge to Full Business registrants who attended the 2019 EASA Convention in Las Vegas.
*Includes technical paper

Gene Vogel
EASA Pump & Vibration Specialist

Increasingly, it is not enough to just “fix” that pump. Customers want and need to understand the “why” behind the failure. This pump failure case study looks at:

• Failure methodology and how it was used
• The possible causes of failure
• The final analysis
• How the analysis impacted the repair approach

Ron Widup
Shermco Industries, Inc.

This paper, presented at the 2013 EASA Convention, provides an overview of NFPA 70E.

The hazard of electrical shock has been known since the first electrical devices were designed in the 1800s. Arc flash and arc blast have also been recognized, but due to the inability to quantify these two hazards, there was nothing that could be done to effectively protect the worker from them.

That began to change in 1996, when the first arc testing took place. As the industry was then able to determine the hazard created by an electrical arc flash, protective equipment was designed to provide that protection, and NFPA 70E (in the 2000 edition) provided the first generally available guide to choosing PPE to protect workers from the arc flash hazard. 

Advancements have been made, both in our understanding of the arc flash hazard, as well as how to design more effective PPE and clothing that provides a higher level of protection and is more comfortable to wear. This includes lighter weight arc flash clothing and arc-rated windows and face shields that have better light transmission through them. These two factors increase the acceptance by workers of the provided arc-rated PPE and clothing and has increased their usage. 

Topics covered in this paper include:

• The latest changes and the reasoning behind them
• Important wording changes concerning energized work
• How to implement the changes
• Personal protective equipment requirements
• How to avoid costly mistakes that could put your employees and company at risk

Charles LeMone
LeMone Technical Services
Roanoke, VA 

Is the induction motor the preferred answer in industrial drive applications? What is happening to the synchronous, DC and wound rotor motor (WRM) in those applications? This paper discusses:

• Observations as customers replace synchronous, WRM and DC machines with the induction motor
• Why synchronous motors are used in industrial applications
• Issues with WRM and soft starters
• A case study of a 12,000 hp 4-pole synchronous motor and a soft starter
• What needs to be done to modernize the older synchronous motor starter?
• How a brushless synchronous motor operates
• Brushless synchronous motor protection

Chuck Yung
EASA Senior Technical Support Specialist

This paper, presented at the 2014 EASA Convention, covers theory of operation, inspection, operation, and troubleshooting tips for AC generators. For the supervisor, field service technician or service center personnel, generators can present unique challenges. Topics covered include:

• Theory of operation
• Testing tips
• Stator winding cautions
• How to interpret the exciter rotor connection
• In-shop and on-site testing methods
• How to test the voltage regulator
• How to test a generator without the regulator

Gene Vogel
EASA Pump & Vibration Specialist

Vibration has three primary parameters; amplitude, frequency and phase. Previous presentations and papers have focused on the two most common parameters, amplitude and frequency. These two are the primary tools for determining if a machine vibration is a problem, and what the cause of the vibration might be. This paper, presented at the 2013 EASA Convention, focuses on the third parameter: phase angle.

While vibration phase angle has several perspectives, this paper focuses on the most straightforward aspect — the angular relationship between vibratory motions of two different locations on a machine. Inherently, then, phase angle is based on two different inputs and measuring phase requires two input signals. The two signals can be two vibration transducers, or a single vibration transducer and a reference pulse signal from a photo tach, laser tach, key phasor or such. For those who are familiar with using a strobe light and a single transducer to measure phase angle, your eye and the reference mark on the shaft provide the second input.

Phase angle is seldom used to detect when a problem occurs on a machine. But it is a powerful tool for diagnosing vibration in many common situations. It also provides necessary data for dynamic balancing. For phase to be useful in any situation, it must be coupled with the corresponding vibration amplitude. Together, phase and amplitude constitute a vector. A basic understanding of vectors is fundamental to vibration analysis.

This paper covers:

• Amplitude and phase concepts
• Shaft alignment vector analysis
• Planar shape sketches
• Animated Operating Deflection Shape (ODS)
• ODS instrumentation and software

Vibration data from field measurements can tell a great deal about the health of machine components and required follow-up action. Beyond acquired time waveform or spectral frequency pattern data, several tools are available in most portable vibration instruments to determine natural frequencies, shaft centerline motion, and the relative movement of machine components. Drawing on practical examples, this paper will also cover:

• Startup/coast down analysis
• Bump tests
• Cross-channel phase measurement
• Demodulation techniques
• Orbital plots

Tom Bishop, P.E.
EASA Senior Technical Support Specialist

For most service centers the traditional repair services such as electric motor rewinding have been and will continue to be in a state of decline over time. Among the factors leading to this reduction in business are conversions to more efficient motors, improved maintenance of existing motors, incentives to replace with more efficient motors and in some regions a reduction in the industrial customer base. A consequence of this is that there is more competition for a “shrinking pie”. Service center reaction can be to make a comparable reduction in size or become pro-active and seek new business. The objective of this paper is to suggest and detail some of these alternatives, namely value-added repair and service opportunities for service centers that carry with them the added benefit of contributing to optimizing motor reliability.

The opportunities for value-added repairs and services are ever-increasing. Topics covered here are:

• Bearing isolators, increased winding wire area, ball-to-roller/roller-to-ball bearing conversions
• Preventive and predictive maintenance (PM & PdM) services: vibration analysis, condition monitoring, bearing lubrication, electrical testing (IR, amps, volts, kW)
• Motor management
• New premium efficient motors vs. repair and retrofitting of existing motors

Chuck Yung
EASA Senior Technical Support Specialist

Vertical motors differ from horizontal motors in numerous ways, yet some view them as “just a horizontal motor turned on end.” The obvious differences are the (usually) thrust bearings, with arrangements varying from single- to three-thrust bearings with different orientations suited for specific load, rpm and applications.

Less obvious differences are in the ventilation arrangements, shaft stiffness, degrees of protection and runout tolerances. This session will include:

• Bearing systems: Single, double or more?, Thrust direction, Angle of contact and rpm, Spherical thrust bearings, hydrodynamic
• Ventilation and cooling
• Operating environment, and enclosures: Enclosures (degrees of protection), ODP, TEFC, WPI, WPII (IP equivalents)
• Oil types and quantity: Bearing load and operating temperature, Consideration of speed, Sizing and adding cooling tubes
• Runout tolerances and repair methods: Upper bearing housing, Bearing carrier and shaft, Bottom bracket flange, Best practice methods for re-machining

This recording will benefit the service center owner, supervisor, technicians, sales personnel and customer.

Gene Vogel
EASA Pump & Vibration Specialist

The ability to measure machinery vibration is essential to machinery repair. But vibration is a complex phenomenon, with multiple parameters; specifically, amplitude, frequency and phase. So unlike temperature, pressure or other single parameter indicators, to use vibration as an effective machine condition indicator, technicians need more than simple meter and 5 minutes of instruction. The most common vibration related task for EASA service centers is acceptance testing for repaired machines. Even this basic task requires:

• Knowledge of vibration fundamentals
• Adequate vibration instrumentation
• Documented acceptance criteria
• Proper mounting methods
• An awareness of advance analysis techniques

This paper addresses the concerns related to insuring the service center has adequate vibration instrumentation. While needs vary among service centers, the basic instrument required is a portable vibration analyzer. In order to qualify as a vibration analyzer, the most basic instrument functions are the ability to measure vibration amplitude and frequency, and common tools for analyzing a vibration spectrum. There are a number of instruments that meet these basic requirements, and most offer additional useful capabilities. Choosing an instrument that meets a specific service center’s needs should involve all of the stakeholders, which includes owners, managers, engineers and technicians. For smaller service centers, it may be one person who wears all those hats, and the decision process is simplified. For larger service centers, input from a dozen people may be needed, and there will be trade-offs on costs vs. benefits. In either case, and those in between, it’s important that considerations include:

• Features and capabilities
• Cost
• Convenience
• Durability
• Support
• Training

This paper focuses on features and capabilities. Not to diminish the importance of the other components, but those are best left to discussion between the service center and the various instrument vendors.

This paper covers:

• Heritage instruments
• Spectrum analyzers
• Balancing instruments
• Online monitors
• Portable vibration level meters
• Proximity probes and instruments
• Accelerometer transducers

Gene Vogel
EASA Pump & Vibration Specialist

Centrifugal pump failures are most commonly attributed to seal failure, impeller damage and bearing failures. A good understanding of failure modes for seals, impellers and bearings is essential to providing customers with reliable pump repairs. This presentation will explore various failure modes and provide some direction on ways to avoid them.  

• How mechanical pump seals operate, the importance of seal face material selection and proper installation techniques 
• Impeller damage examples and causes 
• General rolling element bearing failure modes 
• Bearing failure modes unique to vertical turbine pumps and associated vertical motors 

This recording will be useful for service center engineers, pump technicians and operations managers.

Chuck Yung
EASA Senior Technical Support Specialist

Even though they comprise a small portion of electric motors in service, wound rotor motors are disproportionately represented in EASA’s tech support call volume. There are several misconceptions about how they work. This paper will describe how they are applied and explain several simple but critical tests for the repairer.

• What are the rotor leads used for?
• What is the purpose of the steps/resistance changes?
• How should you evaluate the completed repair?
• Common causes of failure and how to prove them to your customer
• Considerations and cautions for retrofitting a wound rotor motor with a VFD
• Identifying wave wound rotor connections