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2008 was rough on the U.S. economy, but a goodyear for IPS. We completed three acquisitions, significantly increasing our service offerings. We expanded our capabilities (wind, hydro, CNC, motorsales) and geographic presence to better serve customers on a local, regional and national scale.And we forged important new relationships with customers and OEMs.

In 2009, we continue to focus on where we are as acompany and where we want to be. Our vision is tobecome nationally recognized as the premier providerof electrical and mechanical services. Our objective isto continue building IPS as both a business and abrand by accomplishing the following:

Tel: 864.451.5600Fax: 864.451.5601

Integrated Power Services3 Independence PointeSuite 100Greenville, SC 29615

www.integratedps.com

• Aggressively penetrating targeted industry segments

• Making it easier for customers to do business with us

• Strengthening our operational infrastructure (i.e., People, Systems, Alliances)

Today, IPS consists of almost 1,000 employees support-ing a total of 16 individual service centers throughoutthe US. Even though each facility has its own capabilities,we share a common set of values—so we should remem-ber to leverage our regional and national resources tobetter serve our customers.

There’s more to tell, of course, so I’ll turn it over to mycolleagues. This edition of TIPS has more news from the field—your stories and your pictures—to give you abetter idea of what’s happening coast to coast. Have yousent in a story yet? We’re looking for stories for the Summer edition. We want to know what you’re doing at your service center. Email story ideas to Jay Kirkman (jkirkman@radiillc.com) or Megan Thompson (mcthompson@integratedps.com) and send a picture or two.

Best Wishes,

Brian BrehmerPresident & CEO

Winning locally with regional and national resources

IInn tthhiiss iissssuuee......• IPS news from the field• Monarch turns 50• Spotlight on Cleveland Service Center• Ron Brook has a feel for vibration analysis• IPS Tech Council holds first meeting• IPS Houston delivers reliability—and

Christmas gifts

SERVICE CENTERS

Birmingham, AL800.978.2212

Chicago, IL800.978.4559

Cincinnati, OH800.998.8447

Cleveland, OH800.433.7801

Denver, CO800.448.0899

Detroit, MI800.992.9466

Glassport, PA800.394.7366

Houston, TX800.221.3698

Indiana, PA800.537.0097

Litchfield, MN888.694.6200

Philadelphia, PA800.451.5718

Portland, OR800.366.4951

Rock Hill, SC800.868.3702

Rock Springs, WY866.256.4798

Shreveport, LA800.366.6030

Washington, PA800.441.2553

WIND POWER FIELD SERVICE

Lake Benton, MN507.368.4015

REBABBIT SHOP

Cleveland, OH877.880.5600

Dallas Drietz, On-Site Services Manager, standing on top of a GE1.5 MW wind turbine in Blairsburg, Iowa.

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d. Tim Baldwin, Salesman with the Rock Springs

and Denver Regional Service Centers, sent usthese updates on delivering reliability 24/7...Technicians from the Rock Springs shop worked about15 hours Christmas Day at a power customers CO2plant in Baroil, Wyoming. Tim also sends out a bigthanks to the IPS Portland technicians who handledin-place machining of a 5000HP compressor motor atthe same plant over the New Year holiday.

Tim had more news...I’m working with Bryan Klontz, IPS Senior Project Engineer based in Greenville, on replacing a generatorat the Ouray Hydro Plant. The existing GE generatorwas put into service in 1904 and is supposed to be oneof—if not the oldest—operating generators in thecountry. It’s a 432 KW, 360 RPM, 2300 V unit and theywant to upgrade to 750-1000 KW, 4160 V 300 RPM125 DC Excitation. Just to keep things interesting,they want to maintain the historical footprint of theold generator.”

Ouray also has a Westinghouse generator that was built sometime in the early 1890s and is still usable. Want more details? Give Tim a call at 720.937.6100 or drop him a line at atbaldwin@integratedps.com.

Mike Renfro has good news…Shreveport was awarded a contract with LuminantPower, formerly TXU, for all of their business—50 HPand above in their five lignite plants (Martin Lake, Big Brown, Monticello, Sandow and the newly builtOak Grove).

Mike also adds…We’re in the process of rewinding our second 7000 HPCWP from one of our nuclear customers. The units aretoo large for IPS VPI tanks, so we’re installing B-stagehard coils.

Larry Tygart writes from Denver with newsabout Flender Motox…IPS Denver is now one of two stocking build centersfor Flender Motox in the U.S. We’re also the Flender

Motox Master Distributor for Colorado, Utah,Wyoming, Arizona and southern Montana.

The new IPS distribution territory is enormous, whichis important because Flender Motox has a large installed base in the Denver area and Western part ofthe U.S. The IPS Western Sales Region has a high concentration of agg and cement plants.

The IPS commitment includes dedicated resources, toprovide quotes in 10-15 minutes. We can handle awide range of gear motors and reducers, from small tolarge, complicated units. We’re building locally, so de-liveries should be quicker than normal replacementsfrom the manufacturer.

Walt Dryburg gives us the scoop on the Dodge TXTAdvanced Repair and Remanufacture Program...

IPS now offers customers its exclusive Dodge TXT Advanced Exchange and Remanufacture Program.This is an important complement to the company’sability to repair and/or sell motors for the aggregateand grain handling industries.

The program offers the quick turn time operators needto replace repairable failed units, as IPS can ship re-manufactured TXTs from participating service centers.

We have ready-to-ship remanufactured inventory in TXT sizes 1 to 10. All remanufactured units havebeen rebuilt to original specifications using genuineDodge renewal parts—and they’re backed by a fullone-year warranty. We also offer Level I and Level IIrepair kits for TXT units, and carry output shaft hubsand carcasses in our inventory.

All 16 regional service centers participate in the program and are able to repair Dodge TXTs.

News from the IPS network

Flender Motox Gearmotor

Dodge TXTs side-by-side, before and after remanufacture.

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Wayne Whiting sent in some great photos and anupdate on an 8500 HP compressor motor RockSprings is rewinding for a local oil company…

This was a project I puttogether with HaroldCampbell, one of ourservice engineers. We hadto remove the roof of theplant and use a crane tolift the motor out, overgas and electrical lines,and put it on a flatbed.The stator’s being re-wound in Houston andwe’re handling the rotorin the Rock Springs serv-ice shop.

Mary “Cookie” Anderson sends the following pictures of the 14’ VPI tank in Houston.

Wyoming Wind SockStrength of wind from chain angle:0° Broken-notify meteorolgist

30° Fresh breeze45° Gentle zephyr60° Hurricane in area75° Beware of low flying trains90° Welcome to big wonderful Wyoming

Houston recently applied its MegaSeal high-voltage insulation system to the above 36 MW generator stator.

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The Monarch Group turned 50 on December 8, 2008.The company, founded by George Roller in 1959, includes three large electric apparatus service centersin Cleveland, Detroit and Pittsburgh,sales offices in Cincinnati and Buffalo,PennCoil, its coil manufacturing opera-tion in Pittsburgh, and Cleveland Rebab-bitting, a dedicated rebabbitting facility.

The company is a leader in the high-voltage market, offering repairs, rewindsand remanufacturing of extremely largemotors and generators around theworld. Monarch has projects and coil orders from allfifty states, with customers in Canada, Mexico, Cen-tral and South America, England, Israel, South Africa,China, the Philippines, the United Arab Emirates,Australia and New Zealand.

Did we mention Monarch does a lot of nuclear powerplant work? The company is highly regarded for bothnon-safety and safety motor repair.

So they’re busy, which is the way Ken Roller, GeorgeRoller’s son, former President of Monarch and cur-rent Sr. VP of the IPS Midwest Region, likes it. Kenhas his father’s drive and entrepreneurial spirit, andlooking ahead, he sees all kinds of opportunities.

“One of the reasons we joined IPS was to expand ourinfluence and I can see it happening already,” Ken saidrecently. “Cleveland is the Houston Service Center ofthe North and we’re well situated to extend our reachinto markets like Chicago, Cincinnati and Philadelphia.

“Plus, we’re looking at things in new ways. We’relearning more about the VPI technologies, for exam-ple, because there are some high-voltage motors,

some Siemens models, where B-Stagefully cured coils don’t work. Or howabout this? We’d trained ourselves notto look at small motors—200 HP andbelow. Now we can offer small motorservices and sales through Electro-Mecand leverage their CNC capabilities too.Becoming a top-level new motor dis-tributor for Siemens, TECO Westing-house, Baldor/Reliance and General

Electric opens up all kinds of possibilities.

“Here’s another opportunity—we do a lot of business inpower generation. Those com-panies are starting to ask ques-tions about wind energy. I canbring in the guys from TRICOTCWIND, which is good forthem, us and our customers, andit all stays in the IPS family.”

Ken’s a busy man, so we didn’t have a lot of time, butwe asked him to look ahead. What’s in store forMonarch and IPS, we wondered, considering thestate of the economy and industry in general? “Thisorganization has never been affected by the econ-omy. We’ve built a reputation for reliability, on-timedelivery and customer service. We’re taking that rep-utation into new markets and going back to our oldcustomers with a new story. There’s a lot of work outthere and as part of a larger network, we can go aftermore of it.”

Congratulations, Ken and George (George is no longeractive in the business, but according to Ken, he likesto know what’s going on). Here’s to many more yearsof success for Monarch as an IPS company.

Monarch turns 50

Ken Roller—Sr. VP of theIPS Midwest Region

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d.SPOTLIGHT ON:

Cleveland Regional Service Center, Cleveland, OH

Snapshot• Sr. VP of Midwest Region—Ken Roller• VP of Sales—Bill Oros• VP of Engineering—Don Dolence• Service Center Controller—Judy Boldt• 100 employees• 72,000 SF facility• Full load testing to 1,750 HP• Run testing to 13,800VAC/1,000VDC• 70-ton lift capacity• Stator rewinds to 15kV/80,000 HP• 10-ft. VPI system• Nuclear repair per 10CFR50 Appendix B• On-site Hydro electric generator rewind• Bearing rebabbitting

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d. A few thoughts on rotor dynamics

and support stiffness—from an IPSexpert in vibration analysisBy Ron BrookField Services ManagerPhiladelphia Regional Service Center

If you’re in field services, you’ve probably seen it—amotor operates for hours on a shop floor after recon-ditioning, only to demonstrate high vibration levelsonce it’s back in the field—and uncoupled, too!

What’s up with that?

If you’ve been in this situation, you’ve probably hada consultant or company reliability engineer tell yousomething is operating at a critical frequency or “inresonance.” It’s at this point that a critical piece ofinformation is usually overlooked, one that can prob-ably explain your problem.

An induction motor rotor is simple. Solid steel shaft,thousands of thin laminations and either solid or castbars connected to end rings. Modeling this rotor toidentify its natural frequencies is easy, as a simpli-fied 2D finite element program uses shaft lengths,diameters and material properties.

Shaft- only model of a 1000 hp 2 pole motor

You should choose a support stiffness that mostclosely approximates the structure that supports themotor—for example, a motor bolted to a 2 inch soleplate embedded in grout that’s part of a 16 inch thicksubstrate. The customer and those responsible forthe equipment foundation must ensure that the rigidbody modes don’t end up near major forcing func-tions, such as 1x and 2x running speed. Also, theconcrete floor must have been properly poured, withtwo feet of crushed stone underneath, for an equiv-

alent support stiffness of approximately 400,000lbs/inch. Obviously, most equipment sits on foundations that aren’t this robust. Most industrialapplications utilizing I-beam base construction havean equivalent support stiffness of approximately100,000 lbs/inch.

When discussing lateral modes, remember—there arerigid body modes and bending modes. The motor design engineer is responsible for making certain thatthe bending modes are higher in frequency thantwice running speed. The end user and those re-sponsible for the foundation need to insure the rigidbody modes don’t end up near major forcing func-tion vibrations, such as 1x and 2x operating speed.

First Rigid Body Mode

Second Rigid Body Mode

These are the rigid body modes, with no bending inthe shaft. You can see from the response of themode that the bearing phases will be in phase for thefirst mode and out of phase for the second mode.

First Bending Mode

This is the first bending mode. You can see its fre-quency is 21,556 cpm or more than 3x operating speedfor this 2-pole motor. You can also see that the bend-ing crosses the center line, indicating true bending. Thephases are also out-of-phase for this mode.

Critical Speed Map

The critical speed map results are the key to under-standing what’s happening in our “good” motor, nowvibrating back on its foundation. Note that a basestiffness somewhere between 50,000 lb/inch and100,000 lb/inch is ideal for this motor. If the foun-dation is such that the equivalent support stiffness isclose to 30,000 lb/inch, then the second rigid bodymode of this motor would be excited and the result-ing motor vibration severe. For this particular motor,the first rigid body mode is excited by an equivalentsupport stiffness near 200,000 lb/inch.

Equivalent support stiffness is the total stiffness inseries from the bearing down to the earth. The weak-est link in that stiffness chain largely determines theequivalent support stiffness. Also note that the rigidbody modes curve downward near 200,000 lb/inchand the bending mode curves upward above 100,000

lb/inch. This area is where the system changes frombeing support stiffness-dependent to shaft stiffness-dependent.

This example also illustrates that no matter what youchange in a typical support setting, the first bendingmode will be unchanged. The NEMA standard fortesting motors on isolation pads is based on under-standing the critical speed map. The isolationpadding lowers the equivalent support stiffness tothe 1000-10,000 lb/inch range, moving both rigidbody modes well below running speed. It’s also crit-ical that the deflection of the isolation pad is tospecification—too soft or too hard and you could endup on a rigid body mode on the test stand with veryhigh vibration results.

So the next time a motor demonstrates more vibration than you expect—and you’ve eliminated unbalance, misalignment, soft foot and every otherpossibility, consider the stiffness of the support. Whatchanged? It could be something as simple as shortershims that support the entire motor foot, or usingcorroded shims that don’t supply full surface supportwhen restacked. If the motor had no problems whenit came out, but does when it goes back in, it may notbe the reconditioning work that’s the problem.

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About the authorRon Brook is a “Level 5” vibration expertwith 34 years of vibration experience. He can be reached at 1-866-FIX-VIBE.

What constitutes Level 5 vibration experience?The important component of Level 5 vibration experienceis time in the field—fifteen years minimum. During thattime, the vibration specialist must have seen and dealtwith a range of issues—complete analysis of any vibration issue plus the ability to teach it, modal analysisand operating defection shapes, rotor dynamics modeling, isolation and damping of vibration, finite element analysis, root cause failure analysis, the ability to recommend structural modifications for machinery supports, and the ability to serve as an expert witness inarbitration and court proceeding.

In my 34 years in this field, which I love, I’ve worked 260miles off the coast of St. Johns, Newfoundland, on an oil drilling platform, 20 miles upriver in Nigeria at an oilpumping station, and solved a noise problem in a $4 million condo in Philadelphia (it turned out to be industrial exhaust fan noise from four blocks away!).Sometimes the problems are easy. Sometimes the problems are incredibly complex. The satisfaction in solving the tough ones is most gratifying, especially whencustomers express their thanks.

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d. The IPS Technology Council held its first meeting

December 2-3, at Monarch Electric’s headquarters in Cleveland. The meeting, chaired by Tom Reid, IPS Sr. VP for Engineering and Quality, and hosted by Don Dolence, Monarch’s VP of Engineering, gavesome of the network’s leading technical specialists a chance to discuss critical next-generation technologies and how to leverage the group’s collective experience throughout the IPS network.

As Tom Reid said, the meeting was important as somany of the participants had never met each other.“We have incredible resources and experience, butwe need to start getting the word out. In our currentstate, an IPS sales engineer who typically handles repairs on a utility’s 500-1000HP pump motorswouldn’t necessarily talk to that customer about repairing their 40,000 HP generators.

“When he finds out what Monarch is capable of and that they’re ready to support him, suddenly he’s looking at a $500K-plus repair opportunity. That’sgood for him, good for his customer and good for IPS.”

The Council met all day Tuesday, December 2, review-ing capabilities across the network and discussingthe best diagnostic for motors and generators. Later,a presentation on the shape of things to come wasgiven by Dr. Rich Schiferl, Manager of Advanced De-velopment for Baldor/Reliance. Dr. Schiferl gave us alook at next generation motor technologies and theirrequired support services.

The next day’s discussions began with talk aboutemerging and next-generation repair technologies,and what’s on the horizon for field services and diag-nostics. The Tech Council will be supporting the com-pany’s work in repair services and field services, andfocusing on how to leverage capabilities across thecompany in the months ahead.

Questions about a specific technology or engineeringassignment? Email Tom Reid at rtreid@integratedps.com.If he can’t help you, chances are he knows someone onthe IPS Technology Council who can.

IPS Technology Council holds first meeting

IPS Houston delivers reliability—and Christmas gifts for girls and boys.CT Miller, SalesEngineer, andhis colleaguesin LaPorte, TX,are at it again.IPS Houstonheld its 1stAnnual Boysand Girls Har-bor Toy Drive, filling boxes with toys from IPS asso-ciates and vendors. CT, who evidently likes to arrivein style, showed up at Boys and Girls Harbor in La-Porte on December 17, wearing a Santa Suit anddriving an IPS service truck.

The IPS associatescapped off the toydrive by joining theboys and girls fortheir Christmas partyon the 19th. Theyhung out with thekids and watchedthem open the gifts—CT says Michelle Brown, Financial Analyst, did a great job pulling people together for a gift-wrapping party.

Looks as ifeverybody had a great time.Have you sentus pictures fromyour location’sc o m m u n i t y involvement?We’ll look forthem in theSummer issue of TIPS.