MAY 2004
TORQUE REPORT
TWMC Delivers 60,000 HP Motors to U.S. Air Force
TECO-Westinghouse Motor Company delivered one of the largest pairs of synchronous
motors built at its Round Rock, Texas plant to
the Arnold Engineering Development Center
(AEDC) at Arnold Air Force Base in
Tennessee in December.
The nation's largest aerospace ground test
facility complex, AEDC uses its ground test
facilities to support propulsion, aerodynamic,
reentry, trans-atmospheric and space-flight
systems testing. Within the complex, the
advanced Propulsion Wind Tunnel (PWT)
Facility holds four electric motors built to
drive five compressors that generate wind
speeds (airflow) in excess of 2,000 miles per
hour in the PWT’s supersonic and transonic
wind tunnels.
The two new 60,000 HP TWMC synchronous motors replaced two existing 50-year-old,
35,000 HP, Westinghouse wound rotor induction motors at the facility. The new dual 3phase motors will start the two existing 83,000
HP Westinghouse motors, as well as re-power
the supersonic and transonic wind tunnels, providing a substantial upgrade in the facility’s
overall testing capabilities. Continued on page 2
Top: The first of two 60,000 HP Propulsion Wind Tunnel (PWT) motors undergoing factory acceptance testing at TWMC’s Round Rock plant. Bottom: A complete 100+ ton rotor assembly and jackshaft undergoing final machining.
TWMC Copper Bar Rotor Motors Save
Feed Mills Time, Labor, Production Costs
Hill's Electric Motor Service, Inc. is a family-owned and operated EASA repair and
new equipment sales company that is helping to introduce TECO-Westinghouse products
to the Maryland and Delaware area. Having built a reputation on providing outstanding
service, Hill’s has been working successfully with area poultry producers to put TWMC
motors to work on tough applications.
Four major poultry producers on the Delmarva
Peninsula - Mountaire Farms, Allen Family Foods,
Tyson Foods and Perdue Farms - have similar
demanding feed requirements. The pelletizers at their
feed mills compress the feed into pellets, and, in most
cases, run six to seven days a week.
Large TEFC motors, ranging from 250 HP to 450 HP,
350 HP, 4 pole, TWMC copper bar
run all of the pelletizers, and only motors with cast alurotor motors (as shown above) that
run the pelletizers in many feed mills minum rotors were used in the mills until Hill’s introduced
have helped to save time, labor and TWMC motors with copper bar rotors. Continued on page 2
production costs.
INSIDE THIS ISSUE:
* Time-Critical Repair Puts Plant
“Back into Production” .................... 2
* TWMC Tradeshow Tracks ............. 3
* Safety Achievements Increase
TWMC Acceptance ....................... 3
* MAX-SE, MAX-HT “Stand Up” to
Demanding Applications ................ 3
* PAM Motors Supply Efficient
Generation Capabilities ............... 4
* eTorque Report ............................ 4
* TECO Tech Tip .............................. 4
* EPRI Motor/Generator Seminar... 5
* Comanche Peak Replaces
Synchronous Motor...................... 5
* PA7300 Inverter Introduced ........ 5
TORQUE REPORT 1
Copper Bar Rotor Motors Bring Mills Substantial Savings
"Hill's was consistently seeing motor
failures from open aluminum rotors and
needed a solution," said Hill's Electric
Motor Service Vice President, Mark Hill.
When an existing motor failed at a
feed mill, Hill’s replaced it with a 300
HP, 1800 RPM, standard efficiency,
TEFC, TWMC motor with copper bar
rotors. After starting the new TWMC
motor, the feed mill manager called
Hill’s asking if the new motor was a
faster speed. Hill's confirmed the 4 pole
rating was the same as that of the failed
motor, and asked why he was concerned. The mill manager replied that
the tons of feed per hour had increased
over 10% while operating the new
motor at the same load/amps as the
failed unit.
"The extra feed produced in the same
amount of time was so great that the
mill ordered another TWMC motor for
their second pelletizer, even though the
existing motor was still operational,"
said Hill.
The same scenario occurred at numer-
Continued from page 1
ous other feed mill locations in the area.
In some cases the increased tons per
hour of feed were enough to eliminate
Saturday production of feed, saving the
customer overtime labor and production
costs. This increase in feed was produced at the same amp draw as the
failed units, meaning that there were no
increases in energy costs.
"The end results were problems
solved, happy customers, and TWMC
motors proving their excellence in
design," said Hill.
Time-Critical Repair Puts Chemical
Plant “Back into Production”
TWMC Synchronous Motors Power
Air Force Wind Tunnels
Continued from page 1
Engineers from ABB and TWMC began working together in the fall of 2000 to explore the requirements for this
upgrade project. The contract was subsequently awarded in
October of 2001. A wide range
of complex engineering studies, ventilation additions,
spare jackshafts and new bearing upgrades were integral
parts of the overall system's
performance upgrade.
Undoubtedly the most difficult engineering task was to
Preparations for the installation of
one of two 60,000 HP TWMC physically design the new
motors into the Propulsion Wind 60,000 HP motors to drop into
Tunnel (PWT) building at the AEDC.
the exact space occupied by
the original 35,000 HP machines. Due to the substantial
increase in horsepower, the shaft and bearing journal sizes
were increased while retaining the original overall span.
With the system’s variable frequency drives, the 12 pole synchronous motors have the ability to run at variable speeds.
With a rotor weight of over 200,000 pounds these 6500
volt motors represent some of the largest synchronous
motors ever built in the history of Westinghouse. The new
TWMC motors are the centerpiece of the supersonic / transonic wind tunnel power train upgrade, now with a total
output capability of over 300,000 HP.
TWMC recently completed a successful repair in record
time for a major global chemical company's critical process
plant. The 15,000 HP, 4 pole, 13.2 KV compressor drive motor,
manufactured by a European OEM, had been rewound by
another repair shop due to impending failure from partial discharge damage. However, an unexpected failure occurred on
the rewound stator at final AC hipot after completion of the
VPI process. With the maintenance outage well past the
halfway point, timing was crucial as the failed rewind threatened to delay the restart of plant production.
The customer approached TWMC to solve the problem in
21 days or less. After initial meetings with the customer at the
plant site, TWMC's engineering department began designing
stator coils that were essentially duplicates of the original
OEM design, except for the incorporation of the TECOWestinghouse Thermalastic Epoxy insulation system.
New coils were manufactured in four days in TWMC's onsite coil shop, and coil insertion in the stator began as soon as
the first new coils were completed. Rigorous in-process testing
in the coil shop, plus fit checks in wooden stator fixtures
assured the manufacture of top quality coils that would fit right
the first time. Customer representatives were present 24 hours
a day to observe progress and to help make in-process decisions as needed.
After successful final
testing, the motor was
returned to the customer
in 16 days, beating the
target of 21 days and
enabling the chemical
plant to go back into production on schedule per Fit checks for coils that were manufactured in
the original maintenance TWMC’s on-site coil shop assured correct fitting before insertion in the stator.
outage schedule.
Editorial Statement: “Torque Report” is a periodical publication of TECO-Westinghouse Motor Company. Its editorial mission is to inform our readership in the areas of motor application industries,
as well as business and world affairs that have an impact on our mutual concerns. Comments, inquiries and suggestions should be directed to: Torque Report, TECO-Westinghouse Motor Company,
5100 N. IH-35, Round Rock, TX 78681 USA. Phone: 1-800-451-8798. FAX: 512-244-5512. E-mail: torquereport@tecowestinghouse.com. Website: www.tecowestinghouse.com.
2 TORQUE REPORT
TWMC Tradeshow Tracks
In January, TWMC
participated in the 2004
International AHR EXPO
(Air-Conditioning, Heating,
Refrigerating Exposition)
in Anaheim, CA, and
showcased the new
PA7300 AC Fan and
Pump Inverter (see page 5).
Many visitors were
impressed by the new
PA7300 line and learned
about its features firsthand with the demo units that were exhibited. Success
with the PA7300 product will help to further establish
TWMC in the HVAC market.
In March,
TWMC hosted
its second EPRI
(Electric Power
Research Institute)
sponsored Motor
and Generator
Rewind seminar
at its Round
Rock, TX plant.
Seventeen participants attended the three-day seminar
conducted by Jim Oliver of JARSCO Engineering,
Jim Michalec of AEP, and Elton Floyd of TXU, with
additional topics taught by TWMC engineers.
Safety Achievements
Increase TWMC Acceptance
Recently, TWMC surpassed
1.1 million man-hours without a
lost time injury, which is due in
part to the implementation of an
improved HS&E (Health, Safety
& Environmental) Management
System. In 2003, the company’s
Total Recordable Case Rate
dropped 24%, Lost Workday
Case Rate dropped 100%, and
Number of Recordable Injuries
dropped 27%. For these safety
achievements, TWMC received
an Award of Merit from the
Texas Safety Association, of
which it has been a member for
over 30 years.
Moreover, after meeting
t h e ri g o ro u s HS & E an d
security requirements of the
Northrop Grumman Newport
News Navy ship building program, TWMC is now an
approved vendor for new motor
sales and onsite service.
A member of Clean Texas,
Energy Star, and the former
ClimateWise program, TWMC
has thus far reduced hazardous
chemical levels by 72%, reduced
energy usage by 45%, and
reduced hazardous waste levels
by 91%. These reductions not
only help the environment, but
have also helped to reduce the
amount of chemical exposures
and potential health effects associated with these chemicals.
Since its recognition in 2000
as one of ten companies nationwide to receive the EPA and
DOE’s ClimateWise Outstanding
Achievement Award, TWMC
has received other honors including recognition in 2003 from the
TCEQ (Texas Commission on
Environmental Quality) for its
waste reductions.
TWMC's philosophy is that
safety involves a commitment
from everyone to work together
towards a common goal for
health and safety, and to create
an environment that everyone
can enjoy. TWMC has worked
to develop this commitment, as
is reflected in the company's
HS&E performance.
MAX-SE, MAX-HT “Stand up” to Demanding Crusher Applications
CEMCO, Inc. is located in
Albuquerque, New Mexico, and has
manufactured CEMCO TurboTM vertical
shaft impact (VSI) crushers since 1967
for industries including the aggregate,
mining and recycling industries. Each
VSI crusher is designed to exact customer needs for processing material.
When it comes to choosing a motor
to drive the CEMCO TurboTM VSI
crusher, CEMCO proudly chooses
TECO-Westinghouse.
“The TECO-Westinghouse MAX-SE
and MAX-HT products have proven to
be rugged enough to stand up to such a
demanding application,” said CEMCO
Vice President Jennifer Hise.
CEMCO has been pleased with the
standard features on the MAX-HT, such
as the 4140 steel shafting, all cast iron
CEMCO’s Turbo Model 54 features a 100 HP, 1800
RPM, TECO-Westinghouse MAX-SE motor.
construction, oversized conduit box,
breathers and drains on each end bracket and along the horizontal plane of the
motor, and NEMA design C torques.
“It is clear that TECO-Westinghouse
did their homework when they designed
their motors,” said Hise.
TWMC has worked closely with
CEMCO to insure that the products they
order have the features and mountings
that they need for their crushers.
“We use very little of our shop time
to modify the TECO-Westinghouse
product to fit our needs, as compared to
what we had done in the past with the
other brands,” said Hise.
“In using TECO-Westinghouse we
have had no problems in the field with
warranty claims. Their customer service
is unsurpassed and their sales, engineering and overall after-sale support is very
good,” Hise said. “Our decision to standardize on the TECO-Westinghouse
product line further enhances the quality of our VSI crushers.”
TORQUE REPORT 3
PAM Motors Supply
Efficiently-Tailored
Generation Capabilities
EPRI Motor/Generator
Rewind Seminar
July 20 - 22, 2004
Round Rock, Texas
TECO-Westinghouse Motor Company recently
shipped a total of 52,000 horsepower in motors to
Southern Company's Plant Wansley facility in
Roopville, GA. The eight PAM (Pole Amplitude
Modulation) motors that shipped are rated 6500 HP /
3500 HP, 900 RPM / 720 RPM, 4000 volts.
The motors are being used with Plant Wansley's ID
(Induced Draft) Fans. These fans supply air flow for the
completion of combustion in the plant's coal fired furnace, which provides the controlled release and efficient
transfer of heat to the facility's
steam generator and downstream
turbine generator.
Demand-side utility management requires that these motors
be able to run at dual speeds,
which
enables
Southern
Company to efficiently tailor
generation capabilities to meet
customer requirements.
eTorqueReport:
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e-mail. Sign up today to receive
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TWMC recently shipped
eight PAM motors (a total of
52,000 HP), including the
unit shown above, to
Southern Company’s Plant
Wansley facility. Below: One
of the new TWMC PAM
motors coupled to an ID Fan
at the plant facility.
TECO Tech Tip
Sleeve bearings provide a frictionless support for the motor
shaft. Yet, these bearings can
fail even though there is ample
oil in the sump. The cause for
failure could be an oil
ring that is worn, outof-round or dragging
against the housing.
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4 TORQUE REPORT
Correction:
An article on page 4 of the Sept. 2003
issue of the Torque Report discussing
Wk2 vs. Gd2 gave an incorrect equation.
The equation should have read:
Wk2 (lbf-ft2) / 5.93 = Gd2 (kgm-m2)
where
1 kgf = 2.205 lbf,
1 kgm produces 1 kgf, and
1 m2 = 10.764 ft2
Gd is larger by a factor of 4 since d =
(k/2), and d is then squared. Therefore
Seminar Registration
Please complete the response form
below, and return the form and a check
or credit card payment to Jim Oliver,
18901 State Street, Corona, CA
92881; phone/fax (909) 735-5239.
Seminar Fees
The fee for the Rewind Seminar is
$795.00 (USD) per attendee, and it
includes materials and lunches.
Registration Response Form
I am registering for the Motor Rewind
Seminar: July 20 - 22, 2004.
Method of Payment:
___ Check enclosed
(payable to JARSCO Engineering Corp.)
___ Purchase Order
___ Master Card
___ VISA
___ American Express
Cardholder's name
______________________________
Card number ___________________
Expiration date _________________
Signature of cardholder
______________________________
Attendee Information:
Name of Attendee
______________________________
Title/Department
______________________________
Organization
______________________________
Address _______________________
______________________________
City/State/Zip __________________
______________________________
Phone (______)_________________
2
2.205 * 10.764 = 5.93
4
FAX (______)__________________
E-mail Address _________________
______________________________
Comanche Peak Replaces
Synchronous Motor
EPRI Motor/Generator
Rewind Seminar
July 20 - 22, 2004
Round Rock, Texas
What You Will Learn
Included in the program is new material on increasing the capacity of nuclear
power plant motors, industry standards
including IEEE, NEMA, and API, insulation materials, processes, coil design
and coil manufacturing, stator cores,
rotors and bearings. In addition, there is
material on motor testing, VPI resins
and tiered motor maintenance.
Information will also be presented on
purchasing new motors.
Who Should Attend
This three-day Motor/Generator
Rewind Seminar is for specialists and
non-specialists who specify, contract
and accept motor or generator repairs
and rewinds.
Seminar Instructors
Instructors for the seminar will be Mr.
Jim Oliver (JARSCO Engineering),
Mr. Jim Michalec (AEP) and Mr. Elton
Floyd (TXU), who have a combined
total of over 100 years of experience in
the electric utility and rotating machinery industry.
Location
TECO-Westinghouse Motor Company
5100 N. IH-35, Round Rock, TX 78681
(A tour of this 500,000 square foot large
motor and generator manufacturing and
repair facility is included with the seminar.)
Sponsors
EPRI & TECO-Westinghouse Motor Co.
Registration
Fax or mail the perforated registration
form on the back of this sheet,
visit www.tecowestinghouse.com/epri.htm,
or contact:
Marian Wu (512-218-7235)
wumarian@tecowestinghouse.com
Jim Oliver (909-735-5239)
jaoliver@mindspring.com
The Comanche Peak Steam Electric
Station is located in Somervell
County, less than 200 miles northwest
of Round Rock, Texas. The only
nuclear power plant operated
by TXU, the plant was
designed in the 1980’s by
Westinghouse Electric
Corporation and was
placed in service in the
1990’s. It has an
operating capacity
of
2,300
megawatts.
To help cool
the steam turbines (as well
as condense the
steam), a large
bank of eight circulating water
pumps
and
motors are located near the power
plant. Cooling water for the pumps
comes from, and is discharged back
TWMC recently designed a drop-in synchronous
motor to replace a failed circulating water pump
motor at the Comanche Peak Steam Electric
Station. The plant was designed in the 1980’s by
Westinghouse Electric Corporation.
to, the Squaw Creek Reservoir nearby. When both Comanche Peak units
are at full power, 2.2 million gallons
of water are pumped through the
plant’s main and auxiliary condensers per day.
According to the U.S.
Department of Energy, in
2001, Unit 1 had a capacity
factor of 93.5 percent and
supplied 9.42 billion kilowatthours of electricity. Unit 2 generated 8.9 billion
kilowatthours of
electricity in
2001, and had a
capacity factor
of 88.3 percent.
The original circulating
water
pump motors were
designed by a TWMC competitor in
the 1960’s. After a few years in service the motors had to have a “shroud”
welded over their exciters and stators
to prevent the ongoing problem of
rainwater entering the windings. TXU
was having constant maintenance
problems with one of the existing
motors and requested that TWMC
come up with a drop-in replacementdesign, synchronous motor that would
use the existing excitation system.
The new TWMC 2500 HP, 28 pole,
6600 volt synchronous motor was
originally purchased to serve as a
“spare” motor.
TWMC I ntr oduces PA7300 I n v erter
The new TECO-Westinghouse PA7300 AC
Fan and Pump Inverter was introduced at the
AHR Expo in Anaheim, CA in January.
Complete with vertical bypass packages, the
PA7300 is designed specifically for variable
torque, fan, and pump applications. Its features
include PID, an English language keypad, energy savings, and communication protocols.
The PA7300 is offered in a wide rage of
230V/460V models from 5 to 500 HP. UL versions began arriving in April of 2004.
TORQUE REPORT 5
T ORQUE R EPORT
M AY 2004
Come see TWMC at these
upcoming conferences:
EASA Convention
Washington, DC
June 20 - 23, 2004
Booth 330
IEEE-PCIC Conference
San Francisco, CA
September 13 - 16, 2004
San Francisco Marriott Hotel
MINExpo International 2004
Las Vegas, NV
September 27 - 30, 2004
Booth 5125
5100 N. IH-35
Round Rock, TX 78681
1-800-451-8798
If you are interested in receiving future
issues of T ORQUE R EPORT , please visit
www.tecowestinghouse.com/torquereport.htm
or send an e-mail to
torquereport@tecowestinghouse.com.
TWMC Auxiliary Propulsion Motors Provide Fuel
Savings for U.S. Navy Amphibious Assault Ship
TECO-Westinghouse is supplying the
auxiliary propulsion motors for the U.S.
Navy's newest amphibious assault ship,
the Makin Island, Wasp Class LHD-8.
Two TWMC 5000 HP, 1800 RPM,
590 volt, TEWAC motors (one per propeller shaft) are part of the auxiliary
propulsion system that is used for lowspeed vessel operation (up to 12 knots).
The auxiliary system provides substantial fuel savings when compared to operating the main gas turbines at slow speeds.
The TWMC motors were procured by TWMC is supplying two 5000 HP TEWAC motors
Alstom Power Conversion’s Marine for the U.S. Navy’s new Wasp Class LHD-8
amphibious assault ship to be launched in 2006
Division, and will be supplied to (above). The LHD-8 follows seven sister vessels in
Northrop Grumman Ship Systems - the Wasp Class including the LHD-3 USS
Kearsarge pictured below.
Ingalls Shipyard in Pascagoula,
Mississippi. The new LHD-8 is the center
of a study by the U.S. Navy to incorporate
cost-effective design changes into current
ship construction techniques.
LHD Class vessels typically carry a
Marine Expedition Unit of 2,000 marines,
with supporting main battle tanks, trucks,
artillery and ammunition. The ship also
carries Harrier and MV-22 tilt-rotor aircraft and a complement of transport and attack helicopters. Air cushion and conventional landing craft are used to transport troops and equipment to the battle zone.
The LHD-8 will be launched in 2006 and delivered to the Navy in 2007.
EPRI Motor/Generator
Rewind Seminar
July 20 - 22, 2004 Round Rock, Texas
See Inside for Seminar Details
and Registration Materials!
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