Electric Motor Diagnostics

Defect Frequencies and Data Collection Methods

DATA COLLECTION
* Objectives

Identify different defect frequencies related to motors. Describe why different setups are required for electrical defect detection. State how certain defects appear in both the vibration and current domains

DATA COLLECTION
* Calculating
*

Defect Frequencies

Number of Poles:
Where: 7200 /Actual speed (nameplate rpm) = Poles For Hertz divide by 60).

Note: This calculation results in a fractional number. Round to the nearest whole number.

DATA COLLECTION
* Slip

Frequency Sidebands:

The difference in speed (frequency) between synchronous speed and the motor's actual running speed

Induction Motor Faults

* Static

Eccentricity: Exists when the air gap between the stator and the rotor is eccentric (out of round). This defect is not caused by a rotating component in the motor. Therefore, it is considered static or stationary in nature. The soft foot is the most common among many causes.

Induction Motor Faults

* Static

eccentricity appears in the vibration domain at 2xFL and will not vary with respect to speed. It can also show up at FSP with sidebands of 2xFL.
Slot pass frequency (FSP) = number of stator slots times the rotational frequency of the rotor

Induction Motor Faults

Eccentricity: Defined as an uneven rotating air gap. In the vibration domain the defect appears at 2*Fl and at FSP with sidebands spaced at 1*TS * In the current domain dynamic eccentricity appears at Fsp with 1*TS sidebands.
* * Dynamic

Induction Motor Faults

* In

the vibration domain, this defect appears at 2xFL and FSP with sidebands of 1xRPM.

* Electrically,

eccentricity appears in the current domain at FSP with 1xRPM harmonics

Induction Motor Faults

* Note:

The vibration domain harmonics of FSP are even (0, 2, 4, etc.).

* The

current domain harmonics of FSP are odd numbers not divisible by 3 (1, 5, 7 etc.).

Induction Motor Faults

* Rotor

Bar Pass: Defined as the frequency at which the number of motor rotor bars and defects directly related to them appear in the spectrum; (e.g., Open or Broken Rotor Bar(s), cracked end rings appear (No. of Rotor Bars * 1xRPM), etc.).

Induction Motor Faults

* In

the vibration domain, depending on the severity of the defect, the 1xRPM peak exhibits sidebands at a frequency equal to (SL * P). You may possibly see the FRB, or harmonics, exhibit sidebands of 1xRPM.

Induction Motor Faults

* Electrically,

when acquiring current data, this fault shows up as; (SL * P) sidebands around line frequency (60 Hz USA and 50 Hz Europe).
Depending on the defect severity, you may induce eccentricity. The eccentricity (dynamic) is the result spot heating due to the excess current in the rotor bars adjacent to the broken or open bar.

Transducers
* Function

Convert mechanical signal to an analog electrical signal.

* Three

basic types

Displacement transducer Velocity transducer Accelerometer

Displacement probes act much like a transformer

Displacement Xducers
Advantages + Measures relative movement good for sleeve brg. machines very good for heavy machines * Disadvantages permanently installed frequency response : DC to 1KHz power required
*

Velocity Xducer
Connection Case Conductor Coil Spring Magnet Damper

Velocity Xducer
*

Advantages + best signal to severity ratio good signal to noise ratio no power required single dif. / int. needed usually pretty hardy

Disadvantages usually big heavy freq. 10 to 2Kz temperature sensitive comparatively expensive magnetic field sensitive orientation sensitive wear and temp. changes calibration

Accelerometers

Accelerometers
Advantages broad frequency range small, light, rugged ICP needs no signal conditioning easy to mount * Disadvantages poor as a hand held limited signal to noise ratio reads acceleration power required double integration needed
*

Accelerometers
Mounting Response
* Stud

Mount : up to about 16KHz

10

Accelerometers
*Mounting

Response

Quick Lock Mount : up to about 10KHz

Accelerometers
*Mounting

Response

Rare Earth Magnet : linear to @ 7KHz

11

Accelerometers
*Mounting

Response Super Mag. : linear to @ 3KHz

Accelerometers
*Mounting

Response

Hand Held w/2 stinger :linear to @ 800 Hz

12

Accelerometers
*Mounting

Response

Hand Held w/ 8.5 stinger : linear to @ 500 Hz.

Other Sensors

* Current

Transformers

Must have a voltage output

* Flux

coils

Permanent mount or portable

13

Current Transformers

From top to bottom is the 341D, 341B, and 341C.

Current Transformers
* Technical Specifications (341b): 1.0 to 600 A AC (BNC(M) output), 5 mV/A Accuracy: (48 to 1000Hz, load .lt. 40 m ohms 1 to 25A: +/- (1% reading +0.3A) 25 to 100A: +/- (1% reading + 0.2A) 100 to 600A: +/- (1% reading + 0.1A) Div. Transformer: 1000:1 Output Voltage Sensitivity: 5m V/A Working Voltage: 660V max. Max. Conductor Size: 1.18" (30 mm)

14

Current Transformers
*

341c: Typically used on 1Kv to 25Kv motor starters on the installed CTs secondary Technical Specifications:
.50 mA to 150 A AC (BNC(M) output), 5 mV/A Current Range: 50 mA to 150 A AC Accuracy: +/- (1% reading +0.02 A) with noninductive load .ge. 7 ohms Div. Transformer: 1000:1 Output Voltage Sensitivity: 5mV/A Working Voltage: 600V max Max Conductor size: 0.47" (12mm)

Flux Coil

15

Flux Coil
*

Benefits:
Reduces safety concerns by not having to address live power leads. On-line non-intrusive motor diagnostic tool. Easy to mount on the opposite drive end of motor. Eliminates need for current clamp in most cases. Detection of electrical faults in ac induction motors.

Flux Coil
* Technical Description: The CSI Model 343 flux coil is designed for use with CSI machinery analyzers to detect flux generated by electric motors. Except for the initial calibration and possible verification, the use of the 343 flux coil eliminates the need for current clamp measurements. The flux coil captures flux signals which provide an electrical "quality" signature.

16

Flux Coil
* Technical Description cont.: This electrical signature is sensitive to conditions which alter the electrical characteristics of the motor, such as broken rotor bars, eccentricity, voltage imbalance between phases, and stator faults. Flux readings are acquired by consistent placement of the flux coil on the axial outboard end of the motor and automatically stored in the analyzer. Spectra of these measurements may be permanently stored, trended, or analyzed for alarms in CSI MotorView II software.

17

Electric Motor Diagnostics

A.C. INDUCTION MOTORS

A.C. MOTOR THEORY

* Objectives:

Describe the general configuration of an AC Motor. State the process that allows AC induction motors to function. Identify electrical defects in spectral and waveform data.

A.C. MOTOR THEORY

* First

where does the power come from?

3 Phase power is produced at a power plant, transmitted via the power grid to your plant. 3 Phase power generators use a rotating magnetic field inside a 3 phase winding to produce three sinewaves 120o degrees apart.

Rotating Magnetic Field

Rotating Magnetic Field

Rotating Magnetic Field

Rotating Magnetic Field

Rotating Magnetic Field

Rotating Magnetic Field

* Speed

of the rotating field

RPM = 120 * Frequency Poles 120 * 60 = 3600 2

3 PHASE STATOR
* Stator

Core:

Stationary part of the induction motor Cylindrical laminated slotted core Windings that are placed in the core Frame holds the core

3 PHASE STATOR
Magnetic material used for the core is by nature also a conductor. * Voltage induced in the core steel causes a current to flow in the core. This eddy current flow in the core raises stator temperature and lowers motor efficiency. A laminated core offers high resistance to current flow; hence, the eddy currents and resulting losses are reduced.
*

3 PHASE STATOR
* Example

of single stator lamination

3 PHASE STATOR
* Windings

The stator windings are comprised of turns of insulated copper wire that form a coil. These coils are placed in the slots of the core. The coils are separated from each other and the core by insulation. The windings in the stator provide the ability to develop the required magnetic field for motor action to occur.

3 PHASE STATOR
* Example

of motor winding

Types of 3 Phase Motors

* Induction

fabricated

- Barred rotor, cast or

* Synchronous

- Wound rotor, energized with DC, locks on to rotating field Rotor - Variable speed motor

* Wound

INDUCTION MOTORS
* Rotor The rotor is the rotational element of the electric motor. A squirrel cage rotor design is commonly used in most induction motors. This design uses a laminated slotted core in which the conductive material for the rotor bars is placed in the slots. The rotor bars are then shorted together by the end rings.

INDUCTION MOTORS
*

Squirrel cage induction motors have very few maintenance requirements, and they have a rugged and dependable reputation. You can double-wind the squirrel cage with a high and low resistance winding. This configuration combines both high starting torque and excellent constant speed control

INDUCTION MOTORS
* Rotor

INDUCTION MOTORS
Rotor Bar Shapes

INDUCTION MOTORS

10

INDUCTION MOTORS
* SLIP

The difference between synchronous speed and the speed of the rotor. The means by which an induction motor develops torque.

INDUCTION MOTORS

11

INDUCTION MOTORS
= Synchronous speed - Actual speed * Sidebands appear at #Poles * Slip * Vibration Domain SDBDS of Turning speed * Current Domain SDBDS of Line Frequency
* Slip

INDUCTION MOTORS
* Example: 2 pole motor, turns at 3585 RPM
Synchronous speed = 120 * 60 (Lf) / 2 = 3600 rpm Slip = 3600 - 3585 = 15 cpm / 60 = .25 Hz Poles * slip = 2 * .25 Hz = .5 Hz

Bin Width in spectrum Must be < .5 Hz to see sidebands

12

INDUCTION MOTORS
* Rotor

Defect detection
3.5 * Turning Speed 1600 Lines 4 Normal Hanning Accelerometer

Fmax LOR Averages Avg. Mode Window Sensor

*
*

Fmax high enough to see 3 multiples of turning speed

Bin Width of ~ .12 Hz for 2 pole (sufficient to see poles * slip SDBDS)

INDUCTION MOTORS
* Stator

Fault detection
130 * Turning Speed 3200 Lines 4 Normal Hanning Accelerometer

Fmax LOR Averages Avg. Mode Window Sensor

*
*

Fmax high enough to cover # Rotor Bars and # Stator Slots

Bin Width of ~ 2.5 Hz (sufficient to see turning speed SDBDS and 2 * LF SDBDS

13

INDUCTION MOTORS
* Routine

Current Data Collection

Largest benefit realized by comparison to baseline data, indicates rate of change Manual manipulation of the data can be done with any vibration analyzer Automated analysis with an expert system such as MotorView

INDUCTION MOTORS
* Data

Collection Setup
80 Hz 3200 Lines 4 Normal Hanning Current Transformer

Fmax LOR Averages Avg. Mode Window Sensor

14

INDUCTION MOTORS
* Data

Collection Continued:

The output of a current transformer is current and must be converted to a voltage to be used by a Machinery Analyzer Medium Voltage (1KV - 25KV) must be taken from installed CTs for safety Since readings are taken in db (decibels) actual values of current are not critical, but care should be taken to properly scale readings

INDUCTION MOTORS
* Typical
80

Current Spectrum
LCRA - BOILER CIRC WATER PUMPS 1C BCWP 1C -RB1 CURRENT (ROTOR BAR ANA.) PHASE A Spectrum Display 10-OCT-00 07:12 AMPS = 92.17 LOAD = 74%

60

dB Amps

40 RPM = 1772. RPS = 29.54 20

-20 50 52 54 56 58 60 62 Frequency in Hz 64 66 68 70 Freq: Ordr: Spec: Dfrq: 58.16 1.969 5.880 1.841

15

MotorView

An Effective Motor Monitoring Program

Route Based n Similar to Vibration n Routine Monitoring n 3 Phase Motors only
n

Induction Motors Variable Speed Drive Synchronous Motors (in development)

Critical Motors
Process is altered or stopped due to unexpected down-time u Important to:
u

predict faults proactively avoid shortening motor life

Causes of Electric Failures In Electric Motors

Electrical insulation is the single most important part influencing the reliability of electric motors n Three insulation systems
n

Turn insulation Phase insulation Groundwall insulation

Causes of Electric Failures In Electric Motors

60 50 40 30 20 10 0 Turn to Turn Phase Ground Percent of Failures

Results of G.E. Study

Causes of Electric Failures In Electric Motors

n

Thumb Rule

For every 10 deg C above the rated temperature of the motor the life of the insulation is cut in half Temperature Rating is a letter found on nameplate, eg: A, B, F, H or N

Chemically a motor should last approximately 100,000 hours

Causes of Electric Failures In Electric Motors

n

Other Causes of Insulation Failure

Line Disturbances Mechanical Faults Movement in the Windings

What Will MotorView Do?

n

Monitors Condition of Rotor

Broken rotor bars Porosity in aluminum cages Voltage imbalances Rotating Air Gap Uneven Air Gap Magnetic Flux Asymmetry

Detects Changes in Stator Condition

Rotor Condition
Standard 2120 n Current Clamp n Stroboscope or Tachometer n Affected by Load
n

Must be Greater than 50% Load determined by Speed

Stator Condition
Standard 2120 n Flux Coil n Stroboscope or Tachometer n Affected by Load
n

Must be Greater than 50% Load determined by Speed

Data Collection
n

Safety Issues

Working in the vicinity of hazardous voltages Rotating equipment

Current Data Collection

Five minute test n Collects data on all three phases n One phase used for MCSA n Others used for balance
n

Current Data Collection

n

Medium Voltage Motors

Readings taken from installed CTs secondary Readings taken directly from motor T leads

Low Voltage Motors

Flux Data Collection

Taken on the Motor n Repeatability Critical
n

Install permanent Flux Coils

Five minute test n Measures the magnetic flux of the Motor

n

Case History
4160 Volt 200 Hp Compressor n Rotor bar failure
n

Current Spectrum (baseline)

70 LEHI - E-5B BLEND SILO COMP - 590 E-5B COMP -RB1 CURRENT (ROTOR BAR ANA.) PHASE A Spectrum Display 03-JUN-98 13:02 AMPS = 28.28 LOAD = 72% 60

50

dB Amps

40 RPM = 593. RPS = 9.89 30

20

10

0 50 52 54 56 58 60 Frequency in Hz 62 64 66 68 70 Freq: Ordr: Spec: Dfrq: 58.67 5.933 8.561 1.329

Current Spectrum (baseline)

n
n n n n n n n n n n

RESULTS OF ROTOR BAR ANALYS

DATE TIME RPS %LOAD Amps LF - NPxSF SLIP CONFD ---- ---- ---- ----- ------ ---------- ---- ----03-JUN-98 13:02 9.89 72% 28.3 58.67 Hz .111 48% LF - NPxSF LINE FREQ CALC. ADJUSTED ESTIMATED AMPLITUDE AMPLITUDE DELTA DELTA BROKEN BARS ---------- --------- ----- -------- ----------8.56 60.00 51.44 49.80 1.0

Current Spectrum (baseline)

n n n n n n n n

*** ADVISORY RECOMMENDATION *** Rotor shows some indication of high resistance joints? Watch out for progressive degradation on future analyses. Note: For aluminum cast rotors, voids in the rotor castings are equivalent to high resistance joints in fabricated rotors. Note: CONFIDENCE FACTOR ( 48%) of the located NPxSF sideband is marginal! Current Analysis indicates 1 broken rotor bar

Flux Trend
70 60 WARNING 50 ALERT LEHI - E-5B BLEND SILO COMP - 590 E-5B COMP -FC1 FLUX COIL - AXIAL - CENTER Trend Display of Rotor Bar Cond LF-NPxSF Ampl -- Baseline -Value: 56.92 Date: 03-JUN-98

dB Flux-AU

40

FAULT

30

20

10

-10 0 20 40 60 80 100 120 140

Days: 03-JUN-98 To 12-OCT-98

Flux after Repair

70 60 WARNING 50 ALERT LEHI - E-5B BLEND SILO COMP - 590 E-5B COMP -FC1 FLUX COIL - AXIAL - CENTER Trend Display of Rotor Bar Cond LF-NPxSF Ampl -- Baseline -Value: 56.92 Date: 03-JUN-98

dB Flux-AU

40

FAULT

30

20

10

-10 0 30 60 90 120 150 180 210 240

Days: 03-JUN-98 To 06-JAN-99

10

Case History Rotor Bar Fault 6000 GPM Pump

Condition of Rotor trended using Flux only n No current spectrum available
n

Flux Spectrum
70 60 AMPL = 15.01 LOAD = 93% 50 BLFN - 6K PUMP COOL H2O (SOUTH) {4 PMP SOUTH -FC1 FLUX COIL - AXIAL - CENTER Spectrum Display 09-FEB-98 10:23

dB Flux-AU

40

30

RPM = 1187. RPS = 19.78

20

10

-10 50 52 54 56 58 60 Frequency in Hz Label: Multiple Broken Rotor Bars Priority: 2 62 64 66 68 70 Freq: Ordr: Spec: Dfrq: 58.63 2.965 .07213 1.401

11

Analysis
n RESULTS OF ROTOR BAR ANALYSIS
n n n n n
n n n n n n n n n

Station: BLFN --> BLAST FURNANCE Machine: PMP SOUTH --> 6K PUMP COOL H2O (SOUTH) {4 Meas Point: FC1 --> FLUX COIL - AXIAL - CENTER Data Label: Multiple Broken Rotor Bars
SPECTRUM DATE TIME RPS %LOAD FluxAU LF - NPxSF SLIP CONFD -----------------------------------------Reference 09-FEB-98 10:23 19.78 93% 15.0 58.63 Hz .234 99% SPECTRUM LF - NPxSF LINE FREQ CALC. ADJUSTED ESTIMATED (dB) AMPLITUDE AMPLITUDE DELTA DELTA BROKEN BARS ---------------------------------------------Reference 0.07 23.53 23.46 23.11 15.8

Analysis continued
n n n n n n n

*** ADVISORY RECOMMENDATION *** Rotor Analysis indicates presence of multiple broken bars!!! Maintenance actions should be performed immediately. Note: Possibility exist that the end ring is cracked. Perform an electric current evaluation to verify results

12

Trend of Rotor Bar condition

70 60 LEHI - F20A COOLER - RPM 1765 (new) F20A COOL -FC1 FLUX COIL - AXIAL - CENTER Trend Display of Line Freq Ampl

50

-- Baseline -Value: -9.886 Date: 03-JUN-98

dB Flux-AU

40

30

20

10

0 FAULT ALERT -10 0 30 60 90 120 150 180 210 240 Date: 09-NOV-98 Time: 15:05:45 Ampl: -3.370

Days: 03-JUN-98 To 05-JAN-99

Stator Fault
n

Bad connection in motor connection box

13

Stator Fault
Trend of Line Frequency Amplitude
70 60 LEHI - F20A COOLER - RPM 1765 (new) F20A COOL -FC1 FLUX COIL - AXIAL - CENTER Trend Display of Line Freq Ampl 50 -- Baseline -Value: -9.886 Date: 03-JUN-98

dB Flux-AU

40

30

20

10

0 FAULT ALERT -10 0 30 60 90 120 150 180 210 240 Date: 09-NOV-98 Time: 15:05:45 Ampl: -3.370

Days: 03-JUN-98 To 05-JAN-99

Stator Fault (turn to turn short) Baseline

n n n n n n n
n n n n n n n n

RESULTS OF ROTOR BAR ANALYSIS

**************************** Data Label: Motor in good condition Motor ID: WES Stator Ex Rated RPS = 29.42 Frame Size: 445S ( 4 Pole) Rated AMPS = 58.0 Volts/Powr: 440 - 50 Hp Rotor Bars = 54
SPECTRUM DATE TIME RPS %LOAD FluxAU LF - NPxSF SLIP CONFD ----------------- -------------------------Reference 24-MAY-94 13:18 29.36 110% 30.0 57.49 Hz .618 100% SPECTRUM LF - NPxSF (dB) AMPLITUDE ----------------Reference -20.93 LINE FREQ AMPLITUDE --------29.55 CALC. ADJUSTED ESTIMATED DELTA DELTA BROKEN BARS ---------------------50.49 47.01 0.8

14

Stator Fault (turn to turn short) Baseline

n n n n n n n n n
n

*** ADVISORY RECOMMENDATION *** Rotor Analysis indicates presence of high resistance joints. Watch out for progressive degradation on future analyses. Note: For aluminum cast rotors, voids in the rotor castings are equivalent to high resistance joints in fabricated rotors. Perform an electric current evaluation to verify results

Stator Fault (turn to turn short)

n n
n n n n n n n n n n n n n

RESULTS OF FLUX SPECTRA COMPARISONS ***********************************

FREQUENCY ORDER (Hz ) (xRPM) -------------28.084 .96 30.630 1.04 89.344 3.04 118.701 4.04 148.057 5.04 Line Freq ----------59.987 Hz PEAK IDENTIFICATION LIMIT PERCENT VALUE LF/RPS/PxS/SLP VALUE LIMIT ----------------------------13.19 1/ -1/ -1/ 0 -15.49 130.4 -3.35 1/ -1/ 0/ 0 -4.02 108.1 -8.20 1/ 1/ 0/ 0 -15.17 222.9 -13.98 1/ 2/ 0/ 0 -23.01 282.8 -17.67 1/ 3/ 0/ 0 -18.20 106.3 Slip Freq ----------.637 Hz

-> *> ** ->

RPS Poles X Slip -----------------29.357 Hz 2.547 Hz

15

Stator Fault (turn to turn short)

n n n n n n

Total Peak Amplitude (FLUX-AU ) = 17.5576 vs 1.0004 (Ref) Line Freq Amplitude (FLUX-AU ) = 17.5227 vs 30.0381 (Ref) Total Excess Amplitude = -1.43 / -11.68 ( 5 Peaks) Percent Load = 110.5 vs 110.1 (Ref) ** Research has shown growth in the magnitude of this peak to indicate increased change in the voltage balance. Research has also shown that stator faults can cause this peak to change. Research has correlated stator faults with significant change in peak(s) at running speed sidebands about line frequency and/or line frequency.

n n n

Stator Fault (turn to turn short)

n n n n n n n

The amplitude of the peak(s) marked '*> ' have significantly changed. Increase the frequency of data collection in order to watch for further changes in stator condition. Significant change in any peak marked '-> ' indicates a change in stator condition. WARNING: If the flux coil measurement was not acquired at the same location or if the signal is noisy, amplitude values could change significantly. If this occurs, the diagnosis could be incorrect.

n n n

16

Current Test Results

Current test takes less than 5 minutes n Monitors rotor condition n Calibrates Flux data
n

Flux Results
Flux Coil test takes less than 5 minutes n Trends rotor condition n Monitors stator condition n May indicate faults in motor circuit
n

17