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I
In recent years, intensive research [3-7] effort
nduction motors are a critical component of has been focused on the technique of monitoring
many industrial processes and are frequently and diagnosis of electrical machines and can be
integrated in commercially available equipment summarized as follows,
and industrial processes. Motor-driven • Time and frequency domain analysis.
equipment often provide core capabilities
• Time domain analysis of the
essential to business success and to safety of
electromagnetic torque and flux phasor.
equipment and personnel. There are many
• Temperature measurement, infrared
published techniques and many commercially
recognition, radio frequency (RF)
available tools to monitor induction motors to
emission monitoring,
insure a high degree of reliability uptime. In spite
of these tools, many companies are still faced • Motor current signature analysis
with unexpected system failures and reduced (MCSA)
motor lifetime. The studies of induction motor • Detection by space vector angular
behavior during abnormal conditions and the fluctuation (SVAF)
possibility to diagnose these conditions have • Noise and vibration monitoring,
been a challenging topic for many electrical • Acoustic noise measurements,
machine researchers. The major faults of • Harmonic analysis of motor torque and
electrical machines can broadly be classified as speed,
the following [1]: • Model, artificial intelligence and neural
network based techniques.
Of all the above techniques, MCSA is the best
possible option: it is non-intrusive and uses the
stator winding as the search coil; It is not
affected by the type of load and other
M anuscript Received April 16, 2007; Revised
Received August 14, 2007. The authors are with the
National Institute of Technology, Kurukshetra, Haryana,
asymmetries.
India
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INTERNATIONAL JOURNAL OF SYSTEMS APPLICATIONS, ENGINEERING & DEVELOPMENT Volume 2, Issue 1, 2007
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INTERNATIONAL JOURNAL OF SYSTEMS APPLICATIONS, ENGINEERING & DEVELOPMENT Volume 2, Issue 1, 2007
V. CASE STUDIES
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INTERNATIONAL JOURNAL OF SYSTEMS APPLICATIONS, ENGINEERING & DEVELOPMENT Volume 2, Issue 1, 2007
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INTERNATIONAL JOURNAL OF SYSTEMS APPLICATIONS, ENGINEERING & DEVELOPMENT Volume 2, Issue 1, 2007
and thus disregard these slopes from the analysis the gearbox at full load conditions is 18.46 rpm
thereby correctly identifying the current and the individual shaft speeds internal to the
components due to broken rotor bars. gearbox are 48.60 rpm and 135.78 rpm at full
load conditions.
Case IV: Fault in gear box The fundamental rotational speed
Figure 4 shows part of the frequency resolved frequencies for these shafts at full load
current spectrum for coal mill rated 440 V, 240 conditions are 0.28 Hz, 0.75 Hz and 2.68 Hz
HP operating in a utility plant. The full load respectively. Since part of the spectrum, which
speed is 885 rpm yielding a frequency interval of may contain current components due to broken
48 Hz to 52 Hz for detection of broken rotor rotor bars, span from 48Hz to 52 Hz, only the
bars. The motor is driving a coal mill through a last two reduction stages may give rise to a series
three-stage reduction gearbox, i.e. the gearbox of current components in the part of the current
thus contains three shafts. The output speed of
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INTERNATIONAL JOURNAL OF SYSTEMS APPLICATIONS, ENGINEERING & DEVELOPMENT Volume 2, Issue 1, 2007
spectrum where broken rotor bar components means for online monitoring of a wide variety of
may be present. Specifically, two components heavy industrial machinery. It has been used as a
may be found in the upper and lower search test method to improve the motor bearing wear
band. assessment for inaccessible motors during plant
The motor was operating at 200 Amp operation. This technique can be fairly simple, or
corresponding to approximately 80% load. Based complicated, depending on the system available
on the gearbox name-plate data, the instrument for data collection and evaluation. MCSA
was able to correctly identify the current technology can be used in conjunction with other
components caused by the shafts in the gearbox. technologies, such as motor circuit analysis, in
The positions of these components are displayed order to provide a complete overview of the
in Figure 4. As can be seen, the two current motor circuit. The result of using MCSA as part
components in each search band are indeed of motor diagnostics program is a complete view
caused by the gearbox. Specifically, the two of motor system health.
components in each search band are a 4th This paper discusses the fundamentals
harmonic from the 3rd reduction stage and the of MCSA and demonstrates through industrial
2nd harmonic from the 2nd reduction stage. case studies, how motor current signature
Since the current components in the search band analysis can reliably diagnose rotor cage
are caused by the gearbox and not by the problems in induction motor drives. Traditional
presence of broken rotor bars, the motor was methods of measurements can result in false
diagnosed as not being subjected to broken rotor alarms and/or misdiagnosis of healthy machines
bars. This example clearly demonstrates that due to the presence of current frequency
gearbox components need be correctly identified components in the stator current resulting from
and omitted from the analysis. If the influence of non-rotor related conditions such as mechanical
gearbox components is not considered when load fluctuations, gearboxes, etc. Theoretical
identifying the, presence of broken rotor bar advancements have now made it possible to
current components in the current spectrum, predict many of these components, thus making
otherwise healthy machines may be incorrectly MCSA testing a much more robust and less error
diagnosed as unhealthy. prone technology. Based on these theoretical
developments, case studies are presented which
demonstrate the ability to separate current
VI. CONCLUSION components resulting from mechanical
gearboxes from those resulting from broken rotor
Motor Current Signature Analysis is an electric bars. The case studies show that MCSA can
machinery monitoring technology. It provides a effectively detect broken rotor bars and other
highly sensitive, selective, and cost-effective high resistance faults.
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INTERNATIONAL JOURNAL OF SYSTEMS APPLICATIONS, ENGINEERING & DEVELOPMENT Volume 2, Issue 1, 2007
Transactions on Energy Conversion, Vol 13, No [12] J Penman, H G Sedding, B A Lloyd and W
4, December 1998, pp 347-357 T Fink: “Detection and Location of Interturn
[10] S Fruchenecht, E Pittius and H Seinsch: “A Short Circuits in the Stator Windings of
Diagnostic System for Three-Phase Operating Motors”, IEEE Transactions on
Asynchronous Machines”, Proc IEE Conf, Energy Conversion, Vol. 9, No 4, December
EMDA’89, Vol. 310, IEE Savoy Place, London, 1994
1989, pp 163-171. [13] W T Thomson: “On-Line MCSA to
[11] J Penman, J G Hadwick and B Barbour: Diagnose Shorted Turns in Low Voltage Stator
“Detection of Faults in Electrical Machines by Windings of 3-Phase Induction Motors Prior to
Examination of the Axially Directed Fluxes”, Failure”, IEEE, PES&IAS IEMDC, MIT,
Proceedings ICEM’78, Brussels Boston, June, 2001.
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