Ending a Recurring Million-Dollar Motor Failure
Industry
Chemical Manufacturing
Focus
The Challenge
A high-pressure ethylene copolymer facility had been running with a persistent drive system issue for nearly 15 years. A 1150HP DC motor powering a critical extruder was suffering repeated failures traced to its variable speed drive (VSD). Over the years, the problem had become “normal” to the team — a source of frustration, lost productivity, and rising maintenance costs.
The complexity of the VSD system, combined with incremental process changes over time, made the root cause difficult to pinpoint. Vendor visits hadn’t resolved the issue, and operators had grown accustomed to living with the failure risk.
Our Approach
Red Rock Reliability was brought in to work alongside the facility’s maintenance and engineering teams to investigate. We:
1. Listened First
Spent time with operators, electricians, and supervisors to understand the history of the problem, prior troubleshooting attempts, and how the fault typically presented.
2. Checked the Fundamentals
Verified VSD wiring, parameters, and integration with the extruder’s control logic.
3. Dug into the Details
Reviewed historical maintenance logs and operational changes, uncovering that small process adjustments over time had created a mismatch between the VSD’s tuning and the motor’s operational profile.
4. Collaborated with Vendors
Coordinated with the drive manufacturer’s technical support, using field data to validate potential fixes before implementation.
5. Implemented and Verified
Applied parameter changes, monitored performance over several production cycles, and confirmed the fault condition no longer occurred.
The Outcome
Resolving the VSD fault removed a problem that had cost the facility over $1.2 million in lost production every time it occurred. Each failure meant pulling a 1150HP motor, rushing a rebuild of the commutator and armature, and enduring 36–48 hours of downtime that disrupted schedules and strained customer commitments.
The breakdowns also drove costly overtime, placed stress on operators working long hours to clear the unit and prepare equipment for maintenance, and introduced safety risks tied to rushed repairs and harsh startup/shutdown cycles. Over time, these repeated events wore down both the equipment and the people who kept it running.
By eliminating the fault for good, the facility avoided a seven-figure loss every 12–18 months, stabilized production, improved safety, and strengthened customer trust — turning a long-accepted “cost of doing business” into a permanent win.
Key Insight
Even long-standing equipment issues can be solved when you combine field-tested troubleshooting, collaboration with operators, and a willingness to question “the way it’s always been.”
Turning a Small CoGen into a Top Producer
Industry
Onsite Cogeneration
Focus
Loop Tuning
Efficiency Optimization
Emissions Compliance
Grid Protection
The Challenge
A 375kW onsite cogeneration plant powered by a CATERPILLAR 3412 Series engine with two CAIN heat exchangers was running at around 80% efficiency — a solid number on paper, but the plant was only marginally profitable. While it provided roughly 24 MMBTU of thermal energy without burning additional fossil fuel, the control loops weren’t optimized for peak performance. The risk was that any tuning changes might push emissions above strict CARB-mandated limits (9 ppm NOx, 53 ppm CO) or cause operational conflicts with utility grid protection settings.
Our Approach
Red Rock Reliability worked alongside the plant owner, local agencies, and the utility to ensure improvements met both regulatory and grid safety requirements
1. Assessed Current Operation
Verified engine, heat recovery, and emissions performance against benchmarks.
2. Collaborated with the Utility
Reviewed and adjusted the reverse power protection settings (ANSI 67) to allow optimal unit operation while maintaining the protection needed for the grid.
3. Optimized Loop Tuning
Adjusted control setpoints to balance efficiency gains with emissions compliance.
4. Validated with Regulators
Coordinated with local environmental agencies to confirm post-tuning emissions met CARB requirements.
5. Monitored Results
Tracked efficiency, emissions, and output over multiple operational cycles to lock in the improvements.
The Outcome
By working closely with the local utility to adjust the reverse power protection settings (ANSI 67) and with regulators to validate emissions compliance, the plant was able to operate at its full potential without compromising grid safety or environmental limits. Optimized setpoints and loop tuning improved total plant efficiency, allowing more power to be generated each year without burning additional fuel. Emissions consistently stayed well below 9 ppm NOx and 53 ppm CO, satisfying CARB mandates. What had once been a marginally profitable facility became the top-producing plant in the owner’s portfolio — proving that even smaller cogeneration units can deliver exceptional returns when safety, compliance, and performance are approached together.
Meeting Emissions and Heat Rate in a Misconfigured Natural Gas Peaking Plant
Industry
Power Generation – Natural Gas Reciprocating Engine
Focus
Emissions Compliance
Heat Rate Optimization
Loop Tuning
The Challenge
A natural gas reciprocating peaking plant in Alberta, Canada, was struggling to meet emissions requirements due to the configuration of its CO and NOx catalysts and the type of emissions control system installed. The system design made it difficult to balance environmental compliance with the plant’s performance targets, particularly heat rate. The narrow operating window left little margin for error — small changes to improve efficiency risked pushing emissions out of compliance.
Our Approach
Red Rock Reliability worked alongside the plant owner, local agencies, and the utility to ensure improvements met both regulatory and grid safety requirements
1. Evaluated Catalyst and Control Configuration
Verified engine, heat recovery, and emissions performance against benchmarks.
2. Mapped Performance Trade-offs
Reviewed and adjusted the reverse power protection settings (ANSI 67) to allow optimal unit operation while maintaining the protection needed for the grid.
3. Precision Loop Tuning
Adjusted control setpoints to balance efficiency gains with emissions compliance.
4. Collaborative Implementation
Adjusted control setpoints to balance efficiency gains with emissions compliance.
The Outcome
By working closely with the local utility to adjust the reverse power protection settings (ANSI 67) and with regulators to validate emissions compliance, the plant was able to operate at its full potential without compromising grid safety or environmental limits. Optimized setpoints and loop tuning improved total plant efficiency, allowing more power to be generated each year without burning additional fuel. Emissions consistently stayed well below 9 ppm NOx and 53 ppm CO, satisfying CARB mandates. What had once been a marginally profitable facility became the top-producing plant in the owner’s portfolio — proving that even smaller cogeneration units can deliver exceptional returns when safety, compliance, and performance are approached together.