SHORT COURSE

MOTOR CURRENT SIGNATURE ANALYSIS FOR DIAGNOSIS OF FAULTS IN INDUCTION MOTOR DRIVES
Prof Bill Thomson
Director and Consultant EM Diagnostics Ltd
EM Diagnostics Ltd 20 Greystone Road, Alford, Aberdeenshire, AB33 8TY, Scotland, UK Tel : +44 (0) 19755 62446 Fax : +44 (0) 19755 62628

e-mail : mcsa@consultant.com

web site : www.mcsainterpreter.com

William T. Thomson EM Diagnostics Ltd 2001 - unauthorised copying, reproduction or amendment of all or part prohibited. 1

MCSA : MOTOR CURRENT SIGNATURE ANALYSIS INDUCTION MOTOR DRIVES DIAGNOSE PROBLEMS PRIOR TO MOTOR DRIVE FAILURE
BROKEN ROTOR BARS ABNORMAL AIRGAP ECCENTRICITY SHORTED TURNS IN LV STATORS ABNORMAL ROTOR DYNAMICS PUMP WEAR MISALIGNMENT

William T. Thomson EM Diagnostics Ltd 2001 - unauthorised copying, reproduction or amendment of all or part prohibited

INDUCTION MOTOR DRIVE SYSTEMS

WHY SO IMPORTANT?
USA 800,000 MW GENERATING CAPACITY 40-50% CONSUMED BY INDUCTION MOTORS 320,000MW PLANT SYSTEMS 328 MILLION HORSEPOWER
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Power Utilities

Pulp & Paper

Shipping

Nuclear

MOD

Oil & Gas

Uptime of Induction Motor Drive Systems

Wind Power

Chemical Refineries

DuPont Kodak

Mining

Transport

Ford
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8 CW Induction Motor Drives

8 PA Induction Motor Drives

8 ID Induction Motor Drives

26 Mill Motors Induction Motor Drives

2000 MW Coal Fired Power Station

Numerous other Induction Motor Drives

8 Coal Conveyor Induction Motor Drives 8 FD Induction Motor Drives

8 Compressor Induction Motor Drives

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3 PHASE, SCIM, 6.6kV, 2800kW/3753H.P., 2-POLE, 3570r.p.m., 60Hz, (Full-load slip = 0.00833 or 0.833%)

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William T. Thomson EM Diagnostics Ltd 2001 - unauthorised copying, reproduction or amendment of all or part prohibited

MOTOR CURRENT SIGNATURE ANALYSIS CONDITION MONITORING TECHNIQUE INSURANCE POLICY TO PREVENT FAILURES REDUCE DOWNTIME AND REPAIR COSTS PREVENT LOST PRODUCTION INCREASE RELIABILITY - PRODUCT DELIVERY
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MCSA
MCSA : On-Line Monitoring and Analysis of Current to Assess the Condition of an Induction Motor Drive System

APPLICATION OF CURRENT TRANSFORMER CT

MCSA Instrumentation

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Time Domain signals and Current Spectra

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CURRENT SIGNATURE DUE TO BROKEN BARS

f1 =SUPPLY FREQUENCY (60 Hz)
UPPER SIDEBAND

dB
LOWER

SIDEBAND

Hz

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SIGNATURE PATTERN DUE TO BROKEN BARS

TWICE SLIP FREQUENCY SIDEBANDS : 2sf1
dB

f1
-2sf1

fsb = f12sf1

+2sf1

Hz

IDEALISED
Current Spectrum Due to Broken Rotor Bars 13

MCSA ON GM3802A (January, 2002) 3-PH, HV, SCIM, 4155HP/3.1MW, 11kV, 2974r.p.m., 195A 50 Hz BROKEN ROTOR BAR LIFTED OUT OF THE SLOT

N=46 dB

William T. Thomson EM Diagnostics Ltd 2001 - unauthorised copying, reproduction or amendment of all or part prohibited

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3-PH, HV, SCIM, 4155HP/3.1MW, 11kV, 2974r.p.m., 195A BROKEN ROTOR BAR LIFTED IN THE SLOT SECONDARY DAMAGE TO HV STATOR

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William T. Thomson EM Diagnostics Ltd 2001 - unauthorised copying, reproduction or amendment of all or part prohibited

3-PH, HV, SCIM, 4155HP/3.1MW, 11kV, 2974r.p.m., 195A BROKEN ROTOR BAR LIFTED IN THE SLOT SECONDARY DAMAGE TO HV STATOR OFFSHORE OIL PRODUCTION PLATFORM TOTAL REPAIR COSTS : $270,000.00

(Removal, transport, repair & re-installation costs)

THE BOSS IS NOT HAPPY PREVENT THIS HAPPENING AGAIN YOUR JOB IS ON THE LINE
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Case History : Large Sea Water Injection Pump 3-Phase SCIM, 6600V, 60Hz, 3.6MW/4285h.p.,376A, 3580r.p.m., Star connected

Full-load slip? s=(Ns-Nr)/Ns = 0.0055(0.55%)

Sidebands = 2*0.0055*60 = 0.67 Hz (at full load) or Pole Pass Sidebands = 2 *(60 - 59.667) = 0.67 Hz
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1985 : 20 BARS BROKEN OUT OF 46

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INDUCTION MOTOR GEARBOX COMPRESSOR

3 phase, 415 V, 134 kW/180 H.P., 210 A, 1485 r.p.m., 50 Hz R = 58

1982

150 A

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INSPECTION FOLLOWING ON-LINE MCSA

DIE CAST ROTOR

FAULTY END RING

William T. Thomson EM Diagnostics Ltd 2001 - unauthorised copying, reproduction or amendment of all or part prohibited

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