Online Condition Monitoring of Induction Motors through Signal Processing

S. H. Chetwani, M. K. Shah & M. Ramamoorty

Electrical Research and Development Association
ERDA Road, GIDC, Makarpura, Vadodara-10, India

the condition monitoring of the electrical equipment

Abstract- Induction motor is critical component in many assess the health of the machine.
power plants & industrial processes and is frequently Many operators now use online condition based
integrated in commercially available equipment. Safety, maintenance strategies in parallel with conventional
reliability, efficiency and performance are some of the major
concerns of induction motor applications. Due to high planned maintenance schemes. This has reduced
reliability requirements, and cost of breakdown, the issue of unexpected failures, increased the time between planned
condition monitoring of induction motors and diagnosis is of shutdowns and reduced operational cost. During past
increasing importance. For these reasons, there has been a fifteen years there has been substantial amount of research
continually increasing interest and investigations into the into the creation of new condition monitoring techniques.
fault detection and diagnosis of induction motors. New methods have been developed which are now being
used by the operators and research is continuing with the
This paper describes the utility of online monitoring development of new and alternative online diagnostic
technique for detection of various faults that can be applied techniques.
to existing motors without dismantling or shut down.
This basic objective of this work is to diagnose the
The technique presented here is based on the monitoring of different types of motors faults online through processing
the current when the machine is normally operated and and analysis of motor current. This technique is often
analyzing the same in frequency domain for detection of the called "current signature analysis"
faults. The technique can detect online the presence of
various faults such as broken bar in the rotor cage of 11. CURRENT SIGNATURE ANALYSIS
induction motor, Bearing faults, Eccentricity faults and
stator turn to turn short, by monitoring and analyzing the Signature analysis is the procedure of acquiring the motor
line current. current and voltage signals, performing signal
These different faults within induction motor are simulated conditioning and analyzing the derived signals to identify
in the laboratory and they are detected by online monitoring the various faults.
of current and analyzing same in frequency domain. This Motor current acts as an excellent transducer for detecting
technique was also applied for condition monitoring of fault in the motor. Spectrum analysis of the motor's
motors at a nuclear power station. The technique can be current and voltage signals can hence detect various faults
used as a diagnostic tool for condition monitoring of motors. without disturbing its operation.
Current signature analysis involves the measurement of
I. INTRODUCTION electric current around any one phase either through
clamp on meters or through CT's. This current is then
Motors are critical components for electrical utilities and transformed into its frequency spectra and analyzed for
process industries. A motor failure can result in the detection of fault.
shutdown of a generating unit or production line. The Information on the application of specific condition
operators of motors or electrical drive systems are under monitoring techniques in industry is not available and
continual pressure to reduce maintenance costs and evidence of diagnosing problem via reference to actual on
prevent unscheduled downtimes, which result in lost site case histories are also not considered. There is no
production and financial income clear distinction made between monitoring techniques,
Early detection of fault within a motor prior to complete which are at the R & D stage in comparison to those
failure provides an opportunity for maintenance to be which are being successfully applied in industry. It is a
performed on scheduled routine without loss of fact that the operator of induction motor requires evidence
production. of the successful application of monitoring systems to
This arises the need for condition based maintenance assist him in their selection of appropriate systems.
strategies i.e. monitoring the condition of motors and An operator must treat each induction motor drive as a
planning the maintenance based on an indication that a unique entity and the potential failure modes, fundamental
problem is about to occur. Condition monitoring implies causes, mechanical load characteristics and operational
monitoring various parameters of a machine in order to conditions have all to be taken into consideration when a
assess the health of the machine. Condition monitoring is condition monitoring system is being selected. The focus
akin to cardiogram analysis of the human heart. A has been on the use of online condition monitoring to
cardiogram assesses the state and health of the human detect degradation processes and failure mechanism. Fig. 1
heart. Similarly the various parameters measured during

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presents an overview of problems and possible online V. ROTOR FAULTS
monitoring techniques.
Each individual rotor bar can be considered to form a
short pitched single turn, single-phase winding. The air
gap field produced by a slip frequency current flowing in
a rotor bar will have a fundamental component rotating at
a slip speed in the forward direction with respect to rotor
and one of equal magnitude that rotates at the same speed
in the backward direction. With symmetrical rotor, the
backward component sums to zero. For a broken bar
rotor, however the resultant is non-zero. The field, which
rotates at slip frequency backward with respect to the
rotor, will induce EMF on stator side that modulates the
main frequency component at twice slip frequency
...IRGAP MONOR MECHANICAL [1],[2],[3]. The side band components around the
CU
?r CCENMRCtTY
ECC~ThICJTY VIBRATION PROBLEMS
VIBJATION P YES ARWING #W fundamental of the line current spectrum are usually
FL UX .L M IGNMEN measured, detecting broken bar faults given by
Fig. 1 Problems, failures and possible online monitoring Technique for
Induction motors
fb 1 ± 2s)f Hz
At this stage it is suffice to state that a user of critical
induction motor drives should select a condition The measurements on totally enclosed IHP motor with
monitoring system based on evidence of its reliability to cast rotor was undertaken to verify the presence of broken
diagnose problem in industrial drive and on its bar signals predicted by the above analysis. The motor
applicability to the particular industrial installations. was fed with 3ph-balanced supply through measurement
panel. The line current was recorded through the non-
III. METHOD OF MEASUREMENT inductive shunt. The signal was then given to
Oscilloscope for the processing. Initially the no load
The method of measurement involves measurement of current and no load losses were also calculated and then
electric current around any one phase or all the three the motor was operated at rated output. The slip and
phases, if the line current is too high then measurements efficiency of the motor were calculated. The same
may be made on the secondary of current transformer. experiments were repeated first for motor with one broken
The current signal is conditioned. A/D board digitizes the bar, two broken bar and three broken bars. The results are
signal to permit the time and frequency spectra for tabulated in Table I. Fig. 3, 4, gives the spectral plot of
analysis. The time varying current signal is then current for the no broken bar, one broken bar respectively.
transformed into frequency domain through FFT
algorithm. From Table I it can be seen that with no broken bars there
is appearance of lower side band LSB 1 but the magnitude
IV. FAULTS IN INDUCTION MOTOR is very less and the ratio of slip frequency amplitude to
line frequency amplitude is around 48 Db i.e. greater than
The most prevalent faults in Induction Motor are briefly 45 Db and hence no fault exists within the rotor. With one
categorized as broken bar, there is increase in the magnitude of LSB 1.
Rotor faults The ratio also drops down to 31 indicating the fault within
Bearing faults rotor. The constant losses and no load current of the
Eccentricity faults motor also increases. There is also decrease in the
Stator faults efficiency of the motor. With increase in the bar failure
The surveys indicate that in general, failures in electrical there is increase in magnitude of LSB 1 and ratio and
machines are dominated by bearing and stator faults with efficiency goes on decreasing. The slip, constant losses
rotor winding problems being less frequent. Fig. 2 shows and no load current go on increasing.
the statistical spread in the various dominant mechanisms.
Dominant failure mechanism
VI. BEARING FAULTS

The relationship of the bearing vibration to the stator

*Bearing
EStator
current spectrum can be determined by remembering that
DRotor any air gap eccentricity produces anomalies in the air gap
MEccentricity and others flux density. As with the air gap eccentricities, these
variations generate stator current at predictable
frequencies [6]. Fbng, is related to the vibration and
Fig 2 Different faults within Induction motors electrical supply frequencies by

2176
fbng [fe ± mf v ] ,
3. Phase to phase short - motor fails and protection
equipment disconnects the supply
where m = 1,2,3 ... and f, is one of the characteristics 4. Phase to earth short - Motor fails and protection
vibration frequencies calculated based on bearing equipment disconnects the supply
dimensions. The characteristic frequencies for ball 5. Open circuit in on phase (Single Phasing) -
bearings are based upon dimensions and given by motor may continue to operate depending on the
fbrg =f± nbf i,, ,with load condition and protection equipment.
Pre warning of serious problem (3 and 4 above) can only
fi,o 2 frF1± RD cosf];Where
=

2L PD j
be achieved if shorted turns within coil ( one or two
shorted turns) can be initially diagnosed via online
nb is the number of balls, fr the mechanical rotor speed in diagnostic techniques. This requires continuous online
Hz, PD the bearing pitch diameter, BD the ball diameter, monitoring to diagnose the faults state in 1 and 2 above.
) dat ccntcmn There is also the question of how long does it take for
The Bearing fault was simulated by replacing the driving shorted turns within coil to develop into phase to phase or
end bearing with the degraded bearing of same size and phase to earth fault and motor failure? This question has
number. The fault frequencies were predicted as given in not been resolved and will be function of many variables
Table II and These frequencies were visible in the and will be unique to each motor. Some operators and
frequency spectrum. manufacturers have previously considered that it is not
worth diagnosing shorted turns or coils in stator windings
since the lead time to failure is too short to merit a
VII. ECCENTRICITY FAULTS continuous online diagnostic system. The concept that the
motor has already developed a fault and will need to be
repaired has prevailed. This philosophy is generally now
The use of current monitoring for detection of air gap considered to be somewhat out dated and defeatist. In
eccentricity to identify the frequency component in the modern production process any lead time can be
current spectrum [4], [5] is given by extremely advantageous since unexpected failure of a
drive can be very costly and in some industries it can also
= fl (R ± nd
f[ec n] where be a serious safety hazard. If shorted turns in a stator coil
can be diagnosed a preplanned shut down can be arranged
R = no. of rotor bars. P= pole pairs, s= slip fo rthe motor to be replaced by healthy one and the faulty
nw = 1,3,5..... , f, = supply frequency, nd = dynamic one sent for repair
eccentricity =1 With respect to the problem of single phasing it is
relatively easy to diagnose the problem provided the
The eccentricity fault was simulated by inserting the 0.1 correct protection equipment is used to cater for all load
mm copper strip in the end shield of driving end. This will conditions. It is also possible to monitor and analyze
create the static eccentricity in the motor. The motor will
signals such as current to diagnose single phasing under
be allowed to run at rated speed to create the dynamic any load operating condition.
eccentricity. The fault frequency related to this fault were The stator winding itself is used as the sensor for the
predicted as given in Table III. These frequencies were detection of abnormalities in the windings. The harmonics
visible in the frequency spectrum. Fig. 5 & 6 shows the which are expected to vary and which have their origin in
current spectrum without and with eccentricity fault the stator currents [8], [9] are given
s
VIII. STATOR FAULTS as fsc = fl (jrtR j± 2 jsa ± ist

Stator winding failures are also a major problem in low

and medium voltage induction motors. It should be noted The stator fault i.e interturn short circuit in the windings
that volume of low voltage motors is much greater than was simulated by the rewinding the 1 hp, 4 pole motor.
high voltage machines. In motors it is normally the case The winding of the motor was rewinded and the tapings at
that insulation degradation cannot be initially diagnosed the end of the coils and the tappings at 1,3,5, 20 and 25
via on line measurements and the first indication of a turns were taken out on the terminal box. The interturn
problem will be that a fault actual develops. It is short circuit was created by shorting the turns through
important to appreciate that there is clear distinction rheostat to limit the short circuit current to rated current of
between insulation degradation prior to a fault and an the winding. Fig. 7 shows the arrangement for simulating
actual fault. Stator winding faults can be classified as the stator fault. The fault frequencies related to stator fault
follows were predicted and obtained in the spectrum
1. Turn to turn short within coil - motor will It was found that for the 2 turn interturn short circuit,
continue to operate but for how long? frequency component 398 was most sensitive to fault.
2. Short between coils of the same phase - motor From no fault to maximum fault current variations in the
can continue to operate but for how long? range of 49% was recorded. Components 498 Hz were
found to be less sensitive. The component 198 and 298

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Hz was decreasing in all the phases. But decreasing being TABLE I
SUMMARY OF RESULTS FOR ROTOR FAULTS
more pronounced in the faulty phase. Sr. Particulars W/o One Two Three
For 4 turn interturn short circuit, frequency component no. fault bar bar bar
398 Hz also increased from no fault conditions. The failure failure failure
variations of more than 100% was observed from no fault 1 No load current, A 0.813 0.916 0.916 0.94
2 Constant losses, w~ 129.5 160.5 170.3 178.5
to maximum fault current. 3 Load current, A 1.71 1.7 1.91 2.06
For 20 turn interturn short circuit, frequency component 4 Speed, rpm 2825 2825 2797 2758
398Hz also increased. The variation of more than 400% 5 LSB1, % 0.36 2.7 3.3 4.36
was observed from no fault to maximum fault current. 6 Motor current slip 48.8 31.2 29.5 27.2
From the experiments it was apparent that some of the ratio amplitude, db

specified frequency components were redundant, but 7 Starting current, A 10.4 10.3 12.4 17
8. Efficiency, %o 73.4 71.24 68.6 66.4
whether or not this would be the case for other machines.
Fig. 8, 9 shows the variations of different frequency
components for 2 turn, 4 turn and 20 turn interturn
shortciruit.
CO)NCLU SION
Online current monitoring and diagnostic can be applied
for the detection of various internal faults within the
machine. Laboratory trails have verified that these
problems can be reliably detected in industrial motor 0 8 30 0

drives.

ACKNOWLEDGMENT

The investigators are thankful to ERDA management for

allowing to undertake the study on the Online Condition
Monitoring of Induction motor and permitting to carry out Fig. 3 Current Signature with no bar failure
the experiment based on the study

REFERENCES
[1] G.B. Kliman and R.A. Koegl, "Non invasive Detection of
Brokeni bars in operating Iniductioni motors," IEEE Trans. on
EC vol.3 No.4 Dec'98, pp. 873
[2] 5. Williamsom and A.C. Smith, "Steady State Analysis of 3
phase cage motors with rotor bar and end ring fault," IEEE
Proc. Vol. 129, Pt. B, no. 3 May 82, pp. 93
[3] Nagwa M. Elkasabgy, Anthony R. Easthama, "Detection of
Broken bars in the cage Rotors on an Induction machine"
IEEE Trans. onlIA vol. 28 no. 1 Jan' 92, pp. 165 Fi.40Curn intr t n a alr
[4] W.T.Thomson, D Rankin, D.G. Dorrell, "Online Current
Monitoring to Diagnose air gap eccentricity in large 3ph
induction motors," IEEE Trans. on EC vol. 14 no.4 Dec'99. -50~~~~ALEI
[5] Alberto Bellini, Fiorenzo Filippetti, Giovanni Franceschini,
Carla Tassoni, "On field experience with online Diganosis of
Large Induction motors cage failures using MCSA," IEEE
Trans. on IA vol. 38, no.4 July! August 2002.
[6] Randy R Schoen, Thomas G., Farrukh K., Robert G, "Motor
Bearing Damage Detection using Stator current Monitoring,"
IEEE Trans. on IA vol. 31 no. 6 Dec 1995. 2 Fo ~~~~~~3 4 8 54 6 6 7
[7] Randy R Schoen, Brian K, Thomas G., Jay H., Samir F, "An
Unsupervised On Line System for Induction motor fault Fi.4 f+foen 134trewt oebralr
detection using stator current monitoring," IEEE Trans. on IA
vol. 31 no.6 Dec 1995.
[8] Mohamed El Hachemi, Michelle Vieira, "Induction Motors'
Faults Detection and Localization using stator current
Advanced Signal processing Techniques," IEEE Trans. on
PE vol. 14 no. 1 January 1999. 6 F+i 180
[9] Andreas Stavrou, Howard G. Sedding, "Current Monitoring
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IEEE Trans. On EC vol. 16 no. 1 March 2001.

2178
 TABLE III
CHARACTERISTIC FREQUENCY FOR ECCENTRICITY FAULT FOR TYPICAL
LABORATORY MOTOR

Rotor 14
0.00533
Speed 1492 rpm Slip 3
Nw 1 -1 3 -3 5 -5
+
Se 398 298 498 198 598 98
Nd 1 __ ___
de 423 323 523 223 623 123
Nd l1 = = I= =
de 373 273 473 173 573 73

2.OOE+01
+

Fig. 7 Schematic Diagram of Laboratory Machine

0.1
*) 0.09 A
U
008
0.07-
.,0.06- 2 turn fault
Oa 0.05- * 4 turn fault
aL 0.04- 20 turn fault
Eo
0.03-
002
Fig. 5 Current Signature with inherent level of eccentricity co 0.01

0 0.5 1.5 2
Fault current in Amps
2.OOE+01 l

O.OOE+00 Fig. 8 Variation of 398 Hz frequency component with fault current

-2.0+1
|100 200 300 400 500 6 00
-2.OOE+01-
-4.OOE+01-

-6.OOE+01 L) I I -1
-8 .OOE+01

-1.OOE+02 -I I I 9

-1.20E+02-I
-1.40E+02-

Fig. 6 Current Signature with eccentricity fault

0.16
'a
0)0.14
a
0.12
0.1 2 turn fault
"
0.08 4 turn fault
0
A
0.06 20 turn fault

*~~~-=
E
() 0.04
N
-I
co 0.02
a0
'I

0 0.5 1 1.5 2
fault current in amps

Fig. 9 Variation of 498 Hz frequency component with fault current

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