Short Course: Motor Current Signature Analysis FOR Diagnosis of Faults in Induction Motor Drives

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 : [email protected] web site : www.mcsainterpreter.com
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© William T. Thomson EM Diagnostics Ltd 2001 - unauthorised copying, reproduction or amendment of all or part prohibited.
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 2
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
3
Power Pulp & Shipping
Utilities Paper Nuclear
MOD
Oil & Gas Uptime of

Wind
Induction Motor Power
Drive Systems
Chemical DuPont
Refineries Kodak
Mining Transport
Ford
4
8 CW Induction 8 PA Induction 8 ID Induction
Motor Drives Motor Drives Motor Drives
26 Mill Motors
2000 MW Coal Numerous
Induction Motor Fired other
Drives Induction
Motor Drives
Power Station
8 Coal Conveyor 8 Compressor

Induction Motor 8 FD Induction Induction Motor
Drives Motor Drives Drives
5
3 PHASE, SCIM, 6.6kV,
2800kW/3753H.P., 2-POLE,
3570r.p.m., 60Hz,
(Full-load slip = 0.00833 or
0.833%)
6
© 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
7
MCSA
MCSA : On-Line Monitoring and Analysis of Current to

Assess the Condition of an Induction Motor Drive System
8
APPLICATION OF CURRENT TRANSFORMER CT
9
MCSA Instrumentation
10
Time Domain signals and Current Spectra 11
CURRENT SIGNATURE DUE TO BROKEN BARS
f1 =SUPPLY FREQUENCY (60 Hz)

dB
LOWER UPPER
SIDEBAND
SIDEBAND
Hz
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SIGNATURE PATTERN DUE TO BROKEN BARS
TWICE SLIP FREQUENCY SIDEBANDS : 2sf1
dB
f1
-2sf1 +2sf1
fsb = f1±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
14
3-PH, HV, SCIM, 4155HP/3.1MW, 11kV, 2974r.p.m., 195A
BROKEN ROTOR BAR – LIFTED IN THE SLOT
SECONDARY DAMAGE TO HV STATOR
15
© 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
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• YOUR JOB IS ON THE LINE
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
20

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SHORT COURSE

MOTOR CURRENT SIGNATURE ANALYSIS

Prof Bill Thomson

EM Diagnostics Ltd 20 Greystone Road, Alford, Aberdeenshire, AB33 8TY, Scotland, UK

e-mail : [email protected] web site : www.mcsainterpreter.com

• BROKEN ROTOR BARS

© William T. Thomson EM Diagnostics Ltd 2001 - unauthorised copying, reproduction or

– USA 800,000 MW GENERATING CAPACITY

– 320,000MW PLANT SYSTEMS

Oil & Gas Uptime of

8 Coal Conveyor 8 Compressor

• CONDITION MONITORING TECHNIQUE

• REDUCE DOWNTIME AND REPAIR COSTS

• PREVENT LOST PRODUCTION

• INCREASE RELIABILITY - PRODUCT DELIVERY

MCSA : On-Line Monitoring and Analysis of Current to

f1 =SUPPLY FREQUENCY (60 Hz)

© William T. Thomson EM Diagnostics Ltd 2001 - unauthorised copying,

• TOTAL REPAIR COSTS : $270,000.00

• THE BOSS IS NOT HAPPY

• PREVENT THIS HAPPENING AGAIN

• 3-Phase SCIM, 6600V, 60Hz, 3.6MW/4285h.p.,376A,

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

• Sidebands = 2*0.0055*60 = 0.67 Hz (at full load)

• Pole Pass Sidebands = 2 *(60 - 59.667) = 0.67 Hz

DIE CAST ROTOR FAULTY END RING

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• Sidebands = 20.005560 = 0.67 Hz (at full load)