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

1
 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

2
 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

* Staticeccentricity 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

3
 Induction Motor Faults
* Dynamic 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.
*

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

4
 Induction Motor Faults
* Note: The vibration domain harmonics of
FSP are even (0, 2, 4, etc.).

* Thecurrent 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.).

5
 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.

6
 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

7
 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

8
 Velocity Xducer
* Advantages + * Disadvantages -
best signal to severity
ratio
good signal to noise
ratio
no power required
single dif. / int.
needed
usually pretty hardy
Accelerometers
usually big
heavy
freq. 10 to 2Kz
temperature sensitive
comparatively expensive
magnetic field sensitive
orientation sensitive
wear and temp. changes
calibration
9
 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
*MountingResponse
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 non-

inductive 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.

1
 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

2
Rotating Magnetic Field

Rotating Magnetic Field

3
Rotating Magnetic Field

Rotating Magnetic Field

4
 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

5
 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

6
 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

7
 Types of 3 Phase Motors
* Induction - Barred rotor, cast or
fabricated

* Synchronous - Wound rotor, energized

with DC, locks on to rotating field

* Wound Rotor - Variable speed motor

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.

8
 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

9
 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
* Slip= Synchronous speed - Actual speed
* Sidebands appear at #Poles * Slip
* Vibration Domain SDBDS of Turning speed
* Current Domain SDBDS of Line Frequency

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
Fmax 3.5 * Turning Speed
LOR 1600 Lines
Averages 4
Avg. Mode Normal
Window Hanning
Sensor Accelerometer
* 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
Fmax 130 * Turning Speed
LOR 3200 Lines
Averages 4
Avg. Mode Normal
Window Hanning
Sensor Accelerometer
* 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
Fmax 80 Hz
LOR 3200 Lines
Averages 4
Avg. Mode Normal
Window Hanning
Sensor Current Transformer

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 Current Spectrum
LCRA - BOILER CIRC WATER PUMPS 1C
BCWP 1C -RB1 CURRENT (ROTOR BAR ANA.) PHASE A
80
Spectrum Display
10-OCT-00 07:12

AMPS = 92.17
60 LOAD = 74%

40
dB Amps

RPM = 1772.
RPS = 29.54
20

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

15
MotorView

An Effective
Motor Monitoring Program
n Route Based
n Similar to Vibration
n Routine Monitoring
n 3 Phase Motors only
Induction Motors
Variable Speed Drive
Synchronous Motors (in development)

1
Critical Motors
u Process is altered or stopped due to
unexpected down-time
u Important to:
predict faults
proactively avoid shortening motor life

Causes of Electric Failures

In Electric Motors
n Electrical insulation is the single most
important part influencing the reliability of
electric motors
n Three insulation systems
Turn insulation
Phase insulation
Groundwall insulation

2
Causes of Electric Failures
In Electric Motors
60

50

40

30
Percent of
20 Failures

10

0
Turn to Phase Ground
Turn

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
n Chemically a motor should last
approximately 100,000 hours

3
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
n Detects Changes in Stator Condition
Voltage imbalances
Rotating Air Gap
Uneven Air Gap
Magnetic Flux Asymmetry

4
Rotor Condition
n Standard 2120
n Current Clamp
n Stroboscope or Tachometer
n Affected by Load
Must be Greater than 50%
Load determined by Speed

Stator Condition
n Standard 2120
n Flux Coil
n Stroboscope or Tachometer
n Affected by Load
Must be Greater than 50%
Load determined by Speed

5
Data Collection
n Safety Issues
Working in the vicinity of hazardous voltages

Rotating equipment

Current Data Collection

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

6
Current Data Collection
n Medium Voltage Motors
Readings taken from installed CTs secondary
n Low Voltage Motors
Readings taken directly from motor T leads

Flux Data Collection

n Taken on the Motor
n Repeatability Critical
Install permanent Flux Coils
n Five minute test
n Measures the magnetic flux of the Motor

7
Case History
n 4160 Volt 200 Hp Compressor
n Rotor bar failure

Current Spectrum (baseline)

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

50
dB Amps

40
RPM = 593.
RPS = 9.89
30

20

10

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

8
Current Spectrum (baseline)

n RESULTS OF ROTOR BAR ANALYS

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

Current Spectrum (baseline)

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

9
Flux Trend
LEHI - E-5B BLEND SILO COMP - 590
E-5B COMP -FC1 FLUX COIL - AXIAL - CENTER
70
Trend Display
of
60 Rotor Bar Cond
LF-NPxSF Ampl
WARNING
50 -- Baseline --
Value: 56.92
ALERT Date: 03-JUN-98
40
FAULT
dB Flux-AU

30

20

10

-10
0 20 40 60 80 100 120 140
Days: 03-JUN-98 To 12-OCT-98

Flux after Repair

LEHI - E-5B BLEND SILO COMP - 590
E-5B COMP -FC1 FLUX COIL - AXIAL - CENTER
70
Trend Display
of
60 Rotor Bar Cond
LF-NPxSF Ampl
WARNING
50 -- Baseline --
Value: 56.92
ALERT Date: 03-JUN-98
40
FAULT
dB Flux-AU

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

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

40
dB Flux-AU

RPM = 1187.
30
RPS = 19.78

20

10

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

11
Analysis
n RESULTS OF ROTOR BAR ANALYSIS
n Station: BLFN --> BLAST FURNANCE
n Machine: PMP SOUTH --> 6K PUMP COOL H2O (SOUTH) {4
n Meas Point: FC1 --> FLUX COIL - AXIAL - CENTER
n Data Label: Multiple Broken Rotor Bars
n
n SPECTRUM DATE TIME RPS %LOAD FluxAU LF - NPxSF SLIP CONFD
n -------- ---- ---- ---- ----- ------ ---------- ---- -----
n Reference 09-FEB-98 10:23 19.78 93% 15.0 58.63 Hz .234 99%
n
n SPECTRUM LF - NPxSF LINE FREQ CALC. ADJUSTED ESTIMATED
n (dB) AMPLITUDE AMPLITUDE DELTA DELTA BROKEN BARS
n -------- ---------- --------- ----- -------- -----------
n Reference 0.07 23.53 23.46 23.11 15.8
n

Analysis continued

n *** ADVISORY RECOMMENDATION ***

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

12
Trend of Rotor Bar condition
LEHI - F20A COOLER - RPM 1765 (new)
F20A COOL -FC1 FLUX COIL - AXIAL - CENTER
70
Trend Display
of
60 Line Freq Ampl

50 -- Baseline --
Value: -9.886
Date: 03-JUN-98
40
dB Flux-AU

30

20

10

0
FAULT
ALERT
-10
Date: 09-NOV-98
0 30 60 90 120 150 180 210 240
Time: 15:05:45
Days: 03-JUN-98 To 05-JAN-99 Ampl: -3.370

Stator Fault
n Bad connection in motor connection box

13
 Stator Fault
Trend of Line Frequency Amplitude
LEHI - F20A COOLER - RPM 1765 (new)
F20A COOL -FC1 FLUX COIL - AXIAL - CENTER
70
Trend Display
of
60 Line Freq Ampl

50 -- Baseline --
Value: -9.886
Date: 03-JUN-98
40
dB Flux-AU

30

20

10

0
FAULT
ALERT
-10
Date: 09-NOV-98
0 30 60 90 120 150 180 210 240
Time: 15:05:45
Days: 03-JUN-98 To 05-JAN-99 Ampl: -3.370

Stator Fault (turn to turn short)

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

14
 Stator Fault (turn to turn short)
Baseline
n *** ADVISORY RECOMMENDATION ***
n Rotor Analysis indicates presence of high resistance joints.
n Watch out for progressive degradation on future analyses.
n
n Note: For aluminum cast rotors, voids in the rotor castings are
n equivalent to high resistance joints in fabricated rotors.
n
n Perform an electric current evaluation to verify results
n
n

Stator Fault (turn to turn short)

n RESULTS OF FLUX SPECTRA COMPARISONS
n ***********************************
n FREQUENCY ORDER PEAK IDENTIFICATION LIMIT PERCENT
n (Hz ) (xRPM) VALUE LF/RPS/PxS/SLP VALUE LIMIT
n --------- ------ ----- -------------- ----- -------
n 28.084 .96 -13.19 1/ -1/ -1/ 0 -15.49 130.4
n -> 30.630 1.04 -3.35 1/ -1/ 0/ 0 -4.02 108.1
n *> 89.344 3.04 -8.20 1/ 1/ 0/ 0 -15.17 222.9
n ** 118.701 4.04 -13.98 1/ 2/ 0/ 0 -23.01 282.8
n -> 148.057 5.04 -17.67 1/ 3/ 0/ 0 -18.20 106.3
n
n Line Freq RPS Poles X Slip Slip Freq
n ----------- ------- ------------ -----------
n 59.987 Hz 29.357 Hz 2.547 Hz .637 Hz
n

15
Stator Fault (turn to turn short)
n Total Peak Amplitude (FLUX-AU ) = 17.5576 vs 1.0004 (Ref)
n Line Freq Amplitude (FLUX-AU ) = 17.5227 vs 30.0381 (Ref)
n Total Excess Amplitude = -1.43 / -11.68 ( 5 Peaks)
n Percent Load = 110.5 vs 110.1 (Ref)
n
n ** 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.
n
n Research has correlated stator faults with significant change in peak(s)
n at running speed sidebands about line frequency and/or line frequency.

Stator Fault (turn to turn short)

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

16
Current Test Results
n Current test takes less than 5 minutes
n Monitors rotor condition
n Calibrates Flux data

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

17