A

Project Report on
INDUCTION MOTOR MAJOR CAUSES OF FAILURE AND PREVENTIVE
MEASURES
PRESENTED
By
ELECTRICAL AND ELECTRONICS ENGINEERING

A.N.V.L.LAVANYA 09A31A0202
Y.J.S.SRINIVAS 09A31A0260
R.JAYA CHANDRA 10A35A0203
G.V.RAMAKRISHNA 09A31A0226
M.S.N.P.B.SURYA TEJA 09A31A0238
 Induction Motor
• Most popular motor today in the low and medium
horsepower range
• Very robust in construction
• Speed easily controllable using V/f or Field Oriented
Controllers
• Have replaced DC Motors in areas where traditional
DC Motors cannot be used such as mining or explosive
environments
• Of two types depending on motor construction:
Squirrel Cage or Slip Ring
• Only Disadvantage: Most of them run with a lagging
power factor
 INTRODUCTION
 The electric motor is the item of equipment most widely
used by man in his pursuit of progress, as virtually all
machines and many renowned inventions depend upon
it
 By virtue of the prominent role the electric motor plays
in the comfort and welfare of mankind, it must be
regarded and treated as a prime power unit embodying
features that merit special attention, including its
installation and maintenance.
 They have wide range of applications and each one
needs certain changes in design aspect choice of motor
plays a major role in satisfactory operation of the motor.
• The motors the 3-phase induction motors are simple,
rugged in construction, low cost, and easy to maintain.
They run at essentially constant speed from zero-to-
full load. Therefore, they are the motors most
frequently encountered in industry
• They have wide range of applications and each one
needs certain changes in design aspect choice of motor
plays a major role in satisfactory operation of the
motor.
• The extensive use of these machines for long durations
may cause malfunctioning of the motor. But most
malfunctions affecting the normal running of electric
motors can be prevented by maintenance and the
appropriate precautions
• There is a need for regular maintenance and protection of
motors against these faults without which they may end up
with severe faults which may even permanently damage the
motor causing huge loss of economy.
• While ventilation, cleanliness and careful maintenance are
the main factors ensuring long motor life, a further
essential factor is the prompt attention to any
malfunctioning as signalled by vibrations, shaft knock,
declining insulation.
• When failures of an electric or mechanical nature arise, the
first step to be taken is to stop the motor and subsequent
examination of all mechanical and electrical parts of the
installation. In the event of fire, the installation should be
isolated from the mains supply.
CONSTRUCTION AND WORKING
OF INDUCTION MOTOR
Construction of Induction Motor
IT HAS MAINLY TWO PARTS
1)STATOR
2)ROTOR
STATOR:
 The stator of an induction motor consists of a stator
frame, stator core, poly phase or two phase distributed
winding, two end covers, bearings etc..
 The stator core is a stack of cylindrical steel
laminations which are slotted along their inner
periphery for housing the winding. The two end covers
made of cast iron and the stator frame, provide only
mechanical support to the stator core and are not
designed to carry the stator flux.
 Large size motors use open slots so that already
prepared and properly insulated coils can be inserted in
open slots. Small size induction motors use semi closed
slots so as to reduce the effective gap length between
stator and rotor.
 The air gap between stator and rotor should be as small
as is mechanically possible: this will
 Reduce the leakage flux between stator and rotor
 Lead to better operating power factor of the
induction motor.
construction Of the stator
 Construction

Stator windings of practical machines

are distributed

a 120o
120o
c’ Coil sides span can be less than
180o – short-pitch or fractional-
b’ pitch or chorded winding
If rotor is wound, its winding the same
as stator

b c

a’

120o
Stator – 3-phase winding
Rotor – squirrel cage / wound
ROTOR:
 The induction motor has two types of rotors; the
squirrel cage rotor and the wound rotor .both type of
rotors make use of circular laminations tightly
assembled on the shaft or on the cast iron spider carried
by the shaft.
 For the squirrel cage type, the rotor winding consists of
un insulated conductors, in the form of copper or
aluminum bars embedded in the semi closed slots.
 Rotor bars form a uniformly distributed winding in the
rotor slots. As the rotor bars are short circuited by the
two end rings, no external resistance can be inserted in
the rotor circuit of a squirrel cage induction motor.
 PRINCIPLE OF OPERATION
 Operation of 3-phase induction motors is based upon
the application of Faraday’s Law and the Lorentz Force
on a conductor.
 faraday’s law:-
when ever there exist a relative speed between the
conductor and field an emf is induced in the
conductor.
 lorentz force equation:-
when ever the current carrying conductor are placed
under the magnetic field the conductors experiences a
force called lorentz force given by equation:
F=BILSIN
Consider a series of conductors (length L) whose
extremities are shorted by bars A and B. A permanent
magnet moves at a speed v, so that its magnetic field
sweeps across the conductors.
The following sequence of events takes place:
• A voltage E = BLV is induced in each conductor while
it is being cut by the flux (Faraday’s Law)
• The induced voltage produces currents which circulate
in a loop around the conductors (through the bars).
• Since the current-carrying conductors lie in a magnetic
field, they experience a mechanical force (Lorentz
force).
• The force always acts in a direction to drag the
conductor along with the magnetic field.
• Now close the ladder upon itself to form a squirrel
cage, and place it in a rotating magnetic field you have
an induction motor.
ROTATING MAGNETIC FIELD:
• Consider a simple stator with 6 salient poles - windings
AN, BN, CN. The windings are mechanically spaced at
120° from each other.
• The windings are connected to a 3-phase source.AC
currents Ia ,Ib , Ic will flow in the windings,but will be
displaced in time by120°.
• The phase current waveforms follow each other in the
sequence A-B-C. This produces a clockwise rotating
magnetic field. If we interchange any two of the lines
connected to the stator, the new phase sequence will be
A-C-B. This will produce a counter clockwise rotating
field.
Fig shows rotating magnetic field
NUMBER OF POLES – SYNCHRONOUS SPEED:-

The rotating speed of the revolving flux can be reduced

by increasing the number of poles (in multiples of two).
In a four-pole stator, the phase groups span an angle of
90°. In a six-pole stator, the phase groups span an angle of
60°. This leads to the definition of synchronous speed:
Ns = 120 f / p
Ns = synchronous speed (rpm)
f = frequency of the supply (Hz)
p = number of poles of the motor.
 a
b’ 1.5
c’ Fc F
a F 1 F t = t 0= t4
c Fa Fc
b 0.5

a’ Fb 0
Fb
-0.5
t = t 0= t4
-1

-1.5
-93 10 113 216
F Space angle () in degrees

Fb Fc Fb
a
b’ a a
c’ b’ b’
c’ c’
b c
F b c b c

a’ Fc Fc
a’ a’ Fb
t = t2 t = t3
t = t1
F
WORKING:

Locked rotor: When the rotor is stationary, the field

rotates at a frequency (relative to the rotor) equal to the
supply frequency. This induces a large voltage – hence
large currents flow within the rotor, producing a strong
torque.

Acceleration: When released, the rotor accelerates rapidly.

As speed increases, the relative frequency of the magnetic
field decreases. Therefore, the induced voltages and
currents fall rapidly as the motor accelerates.
 Synchronous speed: The relative frequency of the
rotating field is zero, so the induced currents and
voltages are also zero. Therefore, the torque is zero too.
It follows, that induction motors are unable to reach
synchronous speed due to losses such as friction.

 Motor under load: The motor speed decreases until the

relative frequency is large enough to generate sufficient
torque to balance the load torque.
 FAULTS
we say motor is not working properly when we
observe any one or more of the following things

 Burning smell
 Rotor does not rotate
 Fuse blows as soon as supply is given
 Motor starts but rotates at lower than expected speed
 Motor starts and makes unusual sound .
 Rotor rotates in the reverse direction
 Motor starts but trips quickly
The faults in a motor can be classified as :
 Winding faults
 One burnt winding phase
 Two burnt winding phases
 Three burnt winding phases

 Insulation ageing mechanisms

 General
 Thermal
 electrical

 Mechanical faults
 Rotor vibrations
 Bearing faults
Winding faults:

 One burnt winding phase: This failure arises when a

motor runs wired in delta and current rises from 2 to 2.5
times in the remaining winding with a simultaneous
marked fall in speed. If the motor stops, the current will
increase from 3.5 to 4 times its rated value. In most
instances, this defect is due to the absence of a
protective switch, or else the switch has been set too
high.
 Two burnt winding phases: This failure arises when
current fails in one main conductor and the motor
winding is star-connected. 0ne of the winding phases
remains current less while the others absorb the full
voltage and carry an excessive current. The slip almost
doubles.
 Three burnt winding phases: This failure may arise
due to the following reasons
 Motor overloading
 Incorrectly connected supply to motor
 Motor running under loaded conditions connected in star
due to malfunctioning of star-delta starter.
 Many starts during intermittent operation.
Insulation Failures:
 Up to one third of rotating machine failures can be
attributed to insulation failure.
 Although the final failure mode may be electrical
breakdown of a dielectric component, the underlying
mechanism driving the breakdown may be thermal,
mechanical, environmental as well as electrical factors.
 Insulation in service is exposed to high temperature,
high voltage, vibration and other mechanical forces, as
well as some adverse environmental conditions
Stator winding insulation
AGEING
 Thermal ageing:
 Thermal ageing occurs when the temperature of the
insulation is high enough to cause the electrical and
mechanical properties of the insulation to degrade.
 Electrical ageing:
 Electrical ageing occurs when the electric stress applied
to insulation causes deterioration.
 Electrical ageing of insulation usually occurs as the result
of the presence of faults in the material.
 Deterioration from partial discharges will occur
in insulation that has voids created during
manufacture or by thermal or mechanical ageing
in service.
Mechanical Faults
 Rotor vibrations:
Vibration problems in induction motors can be
extremely annoying and may lead to greatly reduced
reliability.
CAUSES OF VIBRATION:

 Eccentric rotor
 Broken rotor bar
 Thermal unbalance
 Decoupling unbalance
 Weak motor base
 Resonance effect
BEARING FAULTS:
 Rolling element, sleeve and pad bearings are used in
rotating machines as guide and thrust bearings and fail
when the load upon the bearing is excessive or its
lubrication fails.
 The choice of bearing and the lubrication used depends
upon the load borne and the shaft speed.
 Bearing failure is usually progressive but ultimately its
effect upon the machine is catastrophic.
 Failure is accompanied by a rising temperature at the
bearing surface, in the lubricant and in the bearing
housing.
 PROTECTION
Induction motor constitutes major portion of electrical
load. And it is in operation for long durations. For safe
operation of motor and also the industry, protection is
must.
The following protection schemes can be employed in an
induction motor:
 Thermal protection
 Ground or earth fault protection
 Under load protection
 THERMAL PROTECTION:
During normal running conditions, the current
flowing through the stator windings produces stator
copper losses proportional to the square of the current.
However, the losses in the stator iron are due to
magnetization and eddy currents, which are a function of
voltage. The main losses in the rotor are the rotor copper
losses caused by the current induced in the cage. These
losses are dependent on the loading on the motor.
Frictional losses (air and bearings) and additional losses
are relatively small and are of less importance. The heat
generated in the rotor and stator lead to respective
temperature rise. During fault conditions high currents
flow causing high temperature rise. Hence fault can be
detected by detecting the temperature rise.
STATOR RTD PROTECTION:
 A simple method to determine the heating within the
motor is to monitor the stator with RTDs.
 Stator RTD trip level should be set at or below the
maximum temperature rating of the insulation.
 For example, a motor with class F insulation that has a
temperature rating of 155°C could have the Stator RTD
Trip level be set between 140°C to 145°C, with 145° C
being the maximum (155°C - 10°C hot spot)
 The stator RTD alarm level could be set to a level to
provide a warning that the motor temperature is rising
PTC-SENSORS:
 The sensor most commonly used in low voltage
motors is the thermistor with positive
temperature coefficient (PTC). These PTC-
resistors are also referred to as thermistors. The
miniaturised sensors have a low resistance below
the rated response temperature, and increase
their resistance in the rated response
temperatures range, by several ranges. This
resistance change is evaluated by means of a
tripping device. The rated response temperature
is defined by the PTC - sensor and thus is
independent of the tripping device.
 The sensors are installed into the motor’s winding
shoulder from the discharge airside, and the rated
response temperature TNF is allocated to the
corresponding insulation class. The sensor’s response
can be used to switch off the motor switch or for
detection. If a warning is to occur before the critical
temperature has been reached, further sensors with a
lower rated response temperature have to be installed.
EARTH FAULT PROTECTION:
 A ground fault is a fault that creates a path for current
to flow from one of the phases directly to the neutral
through the earth bypassing the load.
Ground faults in a motor occur:
 When its phase conductor’s insulation is damaged for
example due to voltage stress, moisture or internal fault
occurs between the conductor and ground
 To limit the level of the ground fault current connect an
impedance between the supplies neutral and ground.
This impedance can be in the form of a resistor or
grounding transformer sized to ensure maximum
ground fault current is limited.
 PHASE TO GROUND
FAULT:
 Due to a short between
supply winding and
motor casing.
GROUND FAULT PROTECTION (cont..):
 All phase conductors are passed through the window of
the same CT referred to as the zero sequence CT
 Under normal circumstances, the three phase currents
will sum to zero resulting in an output of zero from the
Zero Sequence CT’s secondary.
 If one of the motors phases were to shorted to ground,
the sum of the phase currents would no longer equal
zero causing a current to flow in the secondary of the
zero sequence. This current would be detected by the
motor relay as a ground fault.
GROUND FAULT PROTECTION (cont..)

 Zero Sequence CT
Connection
 Best method
 Most sensitive &
inherent noise immunity
 UNDER LOAD PROTECTION:
It may seem surprising to talk about under load
protection when motor protection is normally required
when overloads occur. In cases where the motor is cooled
by the medium it drives, such as fans and submersible
pump motors, a lack of this medium (due to an
obstruction of air or liquid flow) would result
simultaneously in a reduced motor load and excessive
motor heating. For this reason a warning signal or a trip
before damage is useful.
 MAINTENANCE
A well-designed maintenance program for electric motors
can be summed up as:
 periodical inspection of insulation levels
 temperature rise
 bearing lubrication
 occasional checking of fan air flow.
Inspection cycles depend upon the type of motor and the
conditions under which it operates.
 CLEANLINESS:
Motors should be kept clean, free of dust, debris and oil.
Soft brushes or clean cotton rags should be used for
cleaning.
A jet of compressed air should be used to remove non-
abrasive dust from the fan cover and any accumulated
grime from the fan and cooling fins.
Oil or damp impregnated impurities can be removed
with rags soaked in a suitable solvent.
 LUBRICATION:
Motors are normally equipped with grease lubricated ball
or roller bearings. Bearings should be lubricated to avoid
metallic contact of the moving parts, and also for
protection against corrosion and wear. Lubricant
properties deteriorate in the course of time and
mechanical operation. furthermore, all lubricants are
subject to contamination under working conditions. For
this reason lubricants must be renewed and any lubricant
consumed needs replacing from time to time. Proper
lubrication extends bearing life.
Lubrication Maintenance Includes:
 Attention to the overall state of the bearings;
 Cleaning and lubrication.
 Critical inspection of the bearings.
 CONCLUSION

 Induction motors are valuable assets to today’s

industrial facilities.
 The temperature rise of motor dictates its life
 When applied, thermal protection can prevent loss of
motor life
 Additional protection elements such as overvoltage,
under voltage, ground fault, differential, short circuit
and stator RTD supplement the thermal model
protection and provide complete motor protection.