Starting Failure Analysis on Fresh Feed

Charge Pump Motor GM-3-01C

On Job Training Report in PT Pertamina (Persero) Refinery Unit V Balikpapan

Arjuna
School of Electrical Engineering and Informatics
Institut Teknologi Bandung
Bandung, Indonesia
arjunagbt@gmail.com

Abstract An induction motor is the most

II. THEORY
common machine used for industrial purposes.
Induction motor is usually coupled with a rotating A. Induction Motor Construction
equipment such as pumps, valves, fans, and other
An induction motor has the same physical stator as
auxiliary equipments. This paper will discuss an
a synchronous machine, with a different rotor
induction motor starting failure in PT Pertamina
construction. A typical two-pole stator is shown in
(Persero) Refinery Unit V Balikpapan, GM-3-01C
induction motor coupled with Fresh Feed Charge Figure 2.1. It looks (and is) the same as a
Pump in Hydro-Cracking Complex plant. This synchronous machine stator. There are two different
types of induction motor rotors which can be placed
Motor failed to start three consecutive times. All
inside the stator. One is caned a cage rotor, while
data and chronology of events leading to the starting
the other is called a wound rotor.
failure will be presented along with the analysis for
turn-to-turn fault probability.

Keyword induction motor, pump,

starting, turn-to-turn fault

I. INTRODUCTION
An induction motor is one of the most
commonly used machine for industrial purposes.
Induction motor is usually coupled with a rotating
equipment such as pumps, motor operated valves, Figure 2.1 Induction machine stator
and other auxiliary equipment.
At PT Pertamina (Persero) RU V
Balikpapan, a rotating equipment is coupled with
either a three phase induction motor or turbine.
Every equipment in the refinery always have one
spare induction motor and one steam turbine if the
motor fails. The induction motors in PT Pertamina
(Persero RU V Balikpapan numbers around two Figure 2.2 Induction machine rotor.
hundred because of the ease of maintenance and
durability. Induction motor starting does not Figure 2.2 show cage induction motor
produce high starting current and does not use rotors. A cage induction motor rotor consists of a
carbon brushes, hence induction motor is very series of conducting bars laid into slots carved in the
suitable for oil refineries face of the rotor and shorted at either end by large
shorting rings. This design is referred to as a cage
However, every machine has a probability rotor because the conductors, if examined by
of encountering a problem. For example: voltage dip themselves, would look like one of the exercise
on the system, starting failure, excessive vibration wheels that squirrels or hamsters run on. [8]
and noises, overheating, and winding faults.
B. Relay
This paper will discuss failure analysis on
GM-3-01C, a 6,6kV induction motor coupled with a
pump that failed to start three consecutive times.

FIgure 2.3 Digital Relay (left) and Electromechanic
Relay (Right)
Relay is the main protection component
used to prevent damage to electrical equipment.
Basically, relay is a switch operated electrically.
Reley is an electromechanic component with two
main parts. That is the electromagnets and
mechanical switches. Relay is used for isolating an
electric equipment from disturbances with the help
of circuit breakers. The most common relay is an
electromagnetic relay with a coil and moving parts
to detect abnormal operating conditions such as over
voltages, over currents, and abnormal frequencies.
As a main protection component, relay needs to
fulfill some requirements:
1. Sensitivity The relay needs to indentify
disturbance in its area of protection.
machine is manufactured by a Netherlands
company Holec Ridderkerk.
Table 3.1 is the specification sheet of GM-
3-01C, published by Holec Ridderkerk on
January 1993rd. We can observe the rated
current (184A) and starting current (1177.6 A).
We can also see that the specification sheet
includes an explosion-proof standard on the
machine enclosure that prevents the machine to
trigger an explosion in the event of sparks inside
the machine. The code for this standard is Ex-n-
T3 where the Ex-n means non incentive and/or
notmally no sparking circuits. This type of
standard suits well for a zone 2 area such as oil
refineries. T3 means the enclosure surface can
withstand temperatures until 200 degrees
celcius
B. History Report
1. First trip GM-3-01C
Date: Thu, 25 Feb 2016
Time: 08.58 WITA
Indication:
a. Earth fault relay

2. Selectivity The relay only activates the

right switch to isolate the disturbance.
Figure 3.1 Earth Fault Relay MICOM P220
3. Security The protection system works readings
when needed, and idle when there is no
disturbance.

4. Speed When a fault occurs, relay

responds accordingly with a timely
manner.
III. DATA AND CHRONOLOGY OF
EVENTS
A. Equipment Data Figure 3.2 current waveform read by MICOM
P220

Table 3.1 Specification sheet of GM-3-01C

GM-3-01C Fresh Feed Charge Pump is
one of the induction motor in HCC unit plant 3.
This induction motor is coupled with the fresh
feed pump. This machine is one of the largest
motor in this oil refinery with an output of
Figure 3.3 Phase diagram and current
1890kW and 6600V terminal voltage. This
magnitudes
b. Differential relay a. Earth fault relay

Gambar 3.4 Differential relay MICOM P123R

readings Figure 3.7 MICOM P220 readings

Gambar 3.5 Differential relay waveform

readings Figure 3.8 Per phase current waveform

The chronology of events:

At 9:00 AM in the morning, HCC area
reported a trip of induction machine while
being started for routine testing as a
standby pump motor.
A high insulation testing (megger) is
performed. MCC and protection relay is
examined, along with wiring control and Figure 3.9 Phase diagram and current
terminal connection. magnitude
The results are normal, the megger testing b. Differential relay
yields an acceptable result of around 2000
M.
2. Second trip GM-3-01C
Date: Thu 25 Feb 2016
Time: 14.55 WITA
Indikasi:

Figure 3.6 Alarm on MICOM P220 (left) and

MICOM P123R (right) Figure 3.10 MICOM P123R readings
Figure 3.11 Current waveform and magnitude
The chronology of events:
About 3:00 PM, test run is performed on
the machine, but the result is also a filure.
The protection relay working was the
differential relay and earth fault relay.
Re-examination of the MCC, protection
relay, wiring control, and terminal
connection is performed. All of the results
show normal conditions. Visual check is
performed on the power terminal of the
machine. Results are favorable. High
insulation testing is performed. The lowest
value is 800 M.
c. Third trip GM-3-01C
Date: Thu, 25 Feb 2016
Time: 20.55 WITA
Chronology of events:
The machine is started again without load.
Power loss and voltage dip on 61B busbar
is detected. Transformer, fin-fan motors,
and compressor motors power loss
detected. Lighting is dimmed.
Feeder bus protection examined, working
relay was differential relay from the
substation. Differential relay on the
machine is bypassed..
C. Examination Data

Test Current: 10 Amp

Burn-In: 5 seconds
109 m
213.40 m
110.82 m
Table 3.2 Low Resistance Test 26/02/16
 Winding have a very low resistance to conduct an electric
current. Although there is one phase with a
R-G 1.7 G R-T 1.15 G much different value that the others, it is still
acceptable, but this is also a sign of a fault
S-G 1.6 G S-T 633 M because the three conductors are supposed to
T-G 800 M R-S 1.82 G have the same characteristics.
Table 3.3 Insulation Resistance measurements
on Winding Motor

Cable
U-G 2.92 G
V-G 1.13 G
Table 4.1 recommendation on
W-G 1.166 G insulation resistance value (IEEE std 43-
Table 3.4 Insulation Resistance on Kabel
2013)
Incoming Feeder
We can compare the result from table 3,3
and table 3.4 to table 4.1. table 4.1 shows the
IV. ANALYSIS minimum recommended value of insulation
resistance. We can conclude that the value of
The third chapter of this paper shows the
testing is already good and has a value above
data that can be used for the basis of root cause
the minimum recommended value which is
problem finding. We can observe the readings
100M. But, there is still and indication of
of protection relays. The machine is shown to
failure in one of the windings because the value
work normally for around 900ms. We can also
is different. And megger test only shows
see in the readings of earth fault relay that the
insulation resistance between the phases, not
current magnitude of the phases exceeds the
the insulation resistance of the phase itself.
starting current threshold (1544,25A). The
ground phase also has current values which is a Most conditions that cause machine
sign of faults. In normal operating condition, failures are manifested in the form of vibration
there should be no current in ground phase. If or excessive temperature. The failure is caused
we observe the phase diagram, we can see that by a combination of failure modes (stresses)
the current is not isolated 120 electric degrees. that act on the various machine components.
The phases are unbalanced and there is a value The failure modes can be grouped as:
on neutral current. The R, S, and T phase have
a value of 244.5, 123.2, 39.8 respectively. Thermal
We can see in figure 3.4 that the faulty Electrical
phase is phase C. this means that the differential
relay sensed a discrepancy on incoming and Electromagnetic
output current. This is also evident on the LED Mechanical
indicator on MICOM P123R. the fault current
value is 254.25A. We can also see in figure 3.5 Environmental
that there is a form for neutral current wave
Residual
even though the value is very small.
Dynamic
In the second event where the machine is
restarted, there is no noticeable change on the From the above causes, we can specify
relay alerts. Faulty phase is still the C phase. But even further the cause of failure as below:
the phase diagram shifted a little bit even
though it still showed a sign of unbalanced Stator
phase. Rotor
In the third event, the machine is started Vibration and noise
with no load. But, the machine still failed to
start. This proves that the machine is not shorted Shaft
because of the pump jamming.
Lubricants and bearing
In table 3.2, we can observe the result of a
Structure
low resistance tes and insulation resistance
testing. The low resistance test shows a Ventilation
favourable result. A conductor is supposed to
Accesory
 Aplications and environmental
In regards to IEEE Std 1415-2006, IEEE
Guide to Induction Machinery Maintenance
Testing and Failure Analysis, also the event
chronology, we can conclude that this failure is
of single phase winding failure. These failures
are usually the easiest of all to identify because
of their unique patterns. Depending on whether
wye- or delta-connected, either one or two
phases may overheat and usually fail due to
turn-to-turn shorting within the overheated
phases. If the cause is internal to the winding,
the unheated phase or phases will have an open
circuit. The machine controls and protection
equipment, or some other element of the power
distribution system may also show signs of
single phasing or unbalanced voltage
Keeping all of the facts above in mind, we
can limit our analysis to the causes below:
A. Aging on the windings
Windings are typically designed for a life
of 20 years or longer, if properly maintained.
Anti-friction bearings generally have a 5 to 10
year life. The expected life of sleeve and plate
(hydrodynamic) bearings is considered to be
infinite with correct application and care.
From the specification sheet of GM-3-01C,
we can see that the machine is manufactured on
January 1993rd. The machine is already 23 years
old at the time of the failure (25th Feb 2016).
Keeping in mind that GM-3-01C is a high
voltage machine with terminal voltage of
6,6kV, the probability of the winding to
experience partial discharges is very high. A
breakdown of the insulation is a probable cause
of inter-turn short circuits. GM-3-01C has never
had a rewinding overhaul. Only cleaning of the
insides.
Gambar 4.1 Contoh penuaan pada
winding stator
B. Excessive Starting
Large, squirrel cage, induction motors have
limited capability for repetitive starts. The
machine manufacturer designs the starting
capability for the machine. When OEM
information is not available, NEMA MG 10
offers limits for starting frequency. Exceeding
starting limitations can lead to failure of rotor
bars, rotor short circuit rings, or stator windings.
During starting, a machine will draw many
times the normal rated current required to run
under full-load conditions. If the machine is
subjected to repeated starts within a short period
of time, the rotor winding temperature will
escalate based upon the acceleration heating
during starting. The mass of the rotor material
per power ratio affects the cooling of the rotor
and insulation components of the equipment.
Therefore, typically smaller machines have
more effective starts per hour or day than a
larger machine each with their appropriate
loads.
An additional weakening effect of this
cycling is the thermal expansion and
contraction of the insulation system. Over time,
the insulation materials will tend to become
brittle and crack and the windings become
loose. Full voltage starting will also cause
mechanical flexing of the stator coils reducing
the insulation mechanical life.
C. Tracking
Contamination tracking is a phenomenon
caused by accumulation of conductive
environmental particulate onto the stator
winding insulation that becomes electrically
reactive once it has adhered. Conductive
contaminantion can produce a potential
difference between the insulation surface and
the coil strands forcing the electrical
functionality of the stator to be interrupted.
Depending where it accumulates, it can create a
conductive path for current flow causing turn
faults, phase faults, or even ground faults if the
accumulation is close enough to the stator core.
The primary root cause of electrical tracking
failures is in the precence of any contamination
build up on the stator winding insulation
Gambar 4.2 Tracking/conductive
contamination pada stator winding
 D. Voltage Surges
Voltage surges are high voltage spikes
absorebed by the stator winding from the power
source that typically surpass the electric stress
limits of the insulation system. They can inflict
gradual or immediate degradation of turn,
ground wall and phase insulations. Once the
winding insulation is weakened, it is extremely
vulnerable to electrical faults. Typical root
causes for this failure are: power system ground
faults, circuit breaker reclosure, lightning
strikes, impedance mismatch, and drives with
unfiltered output.
Gambar 4.3 Turn-to-turn fault karena
surja tegangan
Gambar 4.4 Efek surja tegangan pada
insulasi
E. Poor Impregnation
Poor impregnation yields inadequate
encapsulation of the stator winding leaving
voids and uncoated areas exposed to electrical
stresses. The purpose of stator impregnation is
to create an electrically sealed system by
allowing the winding insulation to obtain
maximum resin absorption. It provides
protection against contamination and improves
heat transfer between the end winding and the
stator core. If the impregnation process is
poorly executed there will be portions of
winding insulation that were left uncoated or
did not properly absorb the resin. These weak
portions of the winding insulation will be highly
susceptible to erosion of insulation material due
to partial electrical discharges which frequently
lead to turn and/or ground faults. Typical root
causes of poor impregnation are: incompatible
epoxy resin and insulation tapes, poor insulation
taping, improper resin viscosity, insufficient
resin curing time.
Gambar 4.4 Rongga udara karena resin
belum menyerap
V. CONCLUSION AND SUGGESTION
A. Conclusion
From the analysis above, we can conclude
that:
1. From the readings of the relay and high
insulation test, it is evident that the failure
is not phase to phase failure or ground
faults. Because the value of all the
insulation testing showed good results
according to IEEE std 43-2013.
2. From the readings of differential relay and
earth fault relay, and the absence of
supporting data from the machine at normal
condition, and winding temperatures. Also
with the absence of visual data, the failure
can not be proved with certainty. But we
can safely assume that the failure is a turn-
to-turn fault. This argument is supported by
a statement that the inter-turn fault in the
stator has a high percentage of occurrence
if we compare it with other electrical
faults.[10][11]
3. With the assumption that the fault
occurring in said machine is indeed an
inter-turn fault, we can classify the root
cause as following: misalignment, partial
discharge of aged winding, excessive
starting, tracking/conductive
contamination, voltage surges, and partial
discharge caused by poor impregnation.
The most probable cause is conductive
contamination, but we dont have enough
data to prove so with certainty
B. Suggestions
1. Visual inspection is a must when there are
faults in the machine so the root cause can
be hastily determined.
2. Equipment for induction machine testing
on IEEE std 112-2004 should be readily
available, with the most important
equipment being surge comparison tester
according to IEEE std 522-2004.
3. Routine maintenance on the machine machines, IEEE Trans. Ind. Electron.,
should be done according motor sebaiknya vol. 55, no. 12, pp. 4109-4126, Dec. 2008
mengacu kepada standar IEEE std 1068-
[11] S. Grubic, J. M. Aller, B. Lu, and T.
2015.
G. Habetler, A survey on testing and
4. Adding new protection device and starting monitoring methods for stator insulation
device for induction machine such as soft systems of low-voltage induction
starters see IEEE std C37.96-2012. machines focusing on turn insulation
problems, IEEE Trans. on Ind. Electron.,
REFERENCE
vol. 55, no. 12, pp. 4127-4135, Dec. 2008.
[1] IEEE Standard 43 2013, IEEE
Recommended Practice for Testing
Insulation Resistance of Electric
Machinery, The Institute of Electrical and
Electronics Engineers, New York.
[2] IEEE Standard 112 2004, IEEE
Standard Test Procedure for Polyphase
Induction Motors and Generators, The
Institute of Electrical and Electronics
Engineers, New York.
[3] IEEE Standard 522 2004, IEEE
Guide for Testing Turn Insulation of
Form-Wound Stator Coils for Alternating-
Current Electric Machines, The Institute
of Electrical and ElectronicsEngineers,
New York.
[4] IEEE Standard 1068 2015, IEEE
Standard for the Repair and Rewinding of
AC Electric Motors in the Petroleum,
Chemical, and Process Industries, The
Institute of Electrical and Electronics
Engineers, New York.
[5] IEEE Standard 1415 2006, IEEE
Guide for Induction Machinery
Maintenance Testing and Failure
Analysis, The Institute of Electrical and
Electronics Engineers, New York.
[6] IEEE Standard C37.96 2012, IEEE
Guide for AC Motor Protection, The
Institute of Electrical and Electronics
Engineers, New York.
[7] Chapman, Stephen J., Electric
Machinery Fundamentals, 5th ed.,
McGraw-Hill, New York (2012).
[8] Fitzgerald, A.E., Jr., Charles Kingsley,
dan Umans, Stephen D., Electric
Machinery, 6th ed., McGraw-Hill, New
York (2003).
[9] Gaerke, Tyler R. dan Hernandez,
David C., Root Cause Analysis of Motor
Stator Failures, Proceedings of IEEE
PPIC, 2013.
[10] A. Bellini, F. Filippetti, C. Tassoni,
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diagnostic techniques for induction