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1 Introduction................................................................. 2
2 Definitions................................................................... 2
3 Overview............................................... 3
3.1 What is a Partial Discharge Monitor (PDM)
3.2 Applying PDMs
3.3 Role of Standards
4 Deciding whether to use a PDM............................. 5
4.1 Benefits
4.2 Economic Evaluation
4.3 Typical Applications
4.4 New systems
4.5 Retrofitting to existing systems
5 Installing the PDM... 8
5.1 Location of the Monitoring Unit/Sensor Termination Box
5.2 Grounding
5.3 Stator RTD
5.4 Location of Additional Sensors
5.5 Communication Hardware
6 Communication.. 10
6.1 Direct Keyboard (local)
6.2 Direct RS-232 (local)
6.3 RS-485 (remote)
6.4 Fiber Optic (remote)
6.5 Wireless (remote)
7 Software & Data Analysis. 12
7.1 PDM unit
7.2 Laptop/Desktop
7.3 Analyzing PD
Appendices
A Insulation Failure Mechanisms. 16
B PD Interpretation. 23
1 Introduction
1.1 Purpose
1.2 Disclaimer
1.3 References
2 Definitions
Page 2 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
PD: Partial Discharge. Internal sparking that occurs within voids found in stator
winding insulation.
PDM: Partial Discharge Monitor. An electronic device that monitors the PD occurring
within the windings of a motor and outputs a measurement of the level of measured PD.
RTD: Resistance Temperature Detector. Typically, 100 ohm platinum in large motors.
3 Overview
Practically all large motors that are used in Saudi Aramco for process applications
operate on 13.2 kV alternating current (AC). These motors have stators mounted within
their frames that have been wound with insulated, high voltage windings that are subject
to the typical stresses expected in the operating environment.
The internal voids give rise to sparking during normal operation. This sparking is also
called partial discharge, and is an incomplete or partial electrical discharge that occurs
Page 3 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
between insulation or a conductor. It is damaging to the resins used with the insulation
materials but degradation of the winding is usually slow due to the addition of
discharge-resistant material called mica. It is because of this relatively slow aging
process that periodic monitoring of PD activity makes sense.
This BP outlines the selection of motors upon which to apply the technology and the
application of the technology to the chosen motors. Present experience is limited to one
vendor with two types of systems but many of the features are common to all vendors.
More overview on failure mechanisms can be found in Appendix A, and more detail on
PD theory can be found in the Journal of Technology and Technology Item Final Report
references.
The PDM, in its simplest form, is a box that is mounted onto the motor main
terminal box. PD signals go in via the sensors and characterized PD data comes
out. Depending upon the manufacturer of the PDM, different components may
be involved. For example, some large types of PDMs are carried into the field
and manually attached to the sensors via a small terminal box. Large PDMs
typically take more accurate data but require a laptop computer to download the
measurements directly while in the field.
Use of PDMs have no impact on the operation of a motor. The PDM simply
takes periodic measurements from the sensors and records them into its memory
for later download. If the high voltage sensors are already installed within the
main terminal box (which is the case for all newly ordered 13.2 kV motors per
its applicable SAMSS) then the motor should not need to be shut down for
installation of the PDM. As a minimum, in order to operate, a PDM requires
120 V power and connection to the high voltage sensors. Connection to a single
motor RTD is also strongly recommended, and if the unit is supplied with an
ambient thermocouple and humidity sensor these should be connected as well.
Successful operation of the PDM requires that its 120 V power supply always
Page 4 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
be turned on. If the power is not turned on the PDM will not collect data even if
the motor is running. Lastly, it is recommended that each PDM be connected to
a central terminal server so that remote communication and data downloading
can be accomplished without visiting the unit in the field.
There are three MSAERs that govern the selection and application of motors
that will use PDM systems:
17-SAMSS-502
This is the material specification for induction motors, which includes large,
high voltage types. At the time of this revision there is a requirement for a
PD sensor installation only, but a recommendation for a full PDM system
installation is detailed in SAER-5999, the final report for the remote motor
monitoring technology item. In this report, it is recommended that PDMs
are installed at the factory to ensure proper installation and to gather PD
baseline data before the motor leaves the factory.
17-SAMSS-520
SAES-P-113
This is the standard for motors and generators. At the time of this revision
there is a requirement for a PD sensor installation only, but a recommendation
for a full PDM system installation is detailed in SAER-5999, the final report
for the remote motor monitoring technology item. In this report it is
recommended that PDMs are installed at the factory to ensure proper
installation and to gather PD baseline data before the motor leaves the factory.
4.1 Benefits
As discussed previously, all large, high voltage motors are built with insulated
Page 5 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
windings that contain voids. The internal voids give rise to sparking during
normal operation. This sparking is also called partial discharge, and is an
incomplete or partial electrical discharge that occurs between insulation or a
conductor. It is damaging to the resins used with the insulation materials but
degradation of the winding is usually slow due to the addition of discharge-
resistant material called mica. It is because of this relatively slow aging
process that periodic monitoring of PD activity makes sense.
Monitoring the PD levels in a machine allows the user to, in effect, take a
snapshot of the condition of that winding relative to other similar
machines. If the levels are relatively high the plant can take appropriate
remedial action to reduce the PD. If it is not possible to reduce the PD the
plant can schedule the machine for a rewind or continue to use the machine
with the knowledge that it has a higher risk of failure. In response to the
higher risk of failure, the plant should ensure that a spare is readily available
when the machine fails.
For machines with high PD levels, or for machines with rapidly increasing PD
levels, an inspection is a must. If these machines are not inspected it is more
likely that the plant will suffer a stator winding failure. The most significant
impact in this case would be a loss of production, the amount of which would
depend on the availability of spare capacity in the system. For machines that are
operating in a plant with excess spare capacity the cost of loss of production will
be minimal.
A machine that is identified as high risk by its PDM is more likely to fail
catastrophically. If this machine, after inspection, is identified as a candidate for
rewind, significant core damage would have been avoided because it is possible
that a catastrophic stator failure can create so much damage that the core may
need to be replaced. Rewind of a high risk machine before this occurs will
allow the reuse of the existing core and will thus greatly reduce the overall cost
of the refurbishment.
Page 6 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
Pump motors
Compressor motors
Boiler forced draft fan motors
Synchronous motors
Induction motors
LV PDMs
At this time only HV PDMs are recommended for application within Saudi
Aramco. It is possible to use PDMs to monitor 6 kV and 4 kV motors but
the applications are limited. The nature of PD monitoring at these voltages
is such that PD changes that indicate an increasing risk of failure occur on a
much shorter timeline and thus need more stringent monitoring.
If there are specific applications where 6 kV and 4 kV motors are critical and
are not spared then the use of an LV PDM should be considered. However,
this is unlikely to occur with any new installation.
HV PDMs
These sensors are rated at 80 pf and are also called capacitor couplers. They
are terminated in a conduit box outside the main terminal box and thus are
easily accessible. It is recommended that PDMs are installed at the factory to
ensure proper installation and to gather PD baseline data before the motor
leaves the factory. This baseline data should be forwarded to CSD for
archiving, as it will be referenced once PD data is being measured in the field.
Retrofitting PDMs to existing systems requires special attention. The need for
an engineered system still exists, but since the motor is already in place and the
plant construction has already been completed it is more challenging to engineer
Page 7 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
In the case of machines that do not already have sensors installed there would
definitely need to be a shutdown, typically lasting for two days, during which
the HV sensors would be installed. But since these machines are old there is
typically even greater justification to install PDMs since they are running with a
higher risk of failure.
The PDM unit must be mounted in a location that will minimize exposure to the
sun. If the unit must be installed in the sun it should have a sun shade installed
over it to protect it from excessive heat buildup. The unit must also be kept
away from sources of heat, such as motor cooler exhaust vents. This is normally
not an issue with newer machines as they typically exhaust upwards and away
from the motor, but it may be an issue on older machines, such as the large BBC
WPII motors that exhaust from the side.
The monitoring unit must also be mounted such that its display can easily be
seen and its front door opened for maintenance and/or local RS-232 data
download.
If the PD sensors have already been installed location possibilities for the PDM
will be constrained because the monitoring unit must be located no further than
approximately 55 cm from the sensor termination box. If the PD sensors have not
already been installed the sensor termination box may be placed as far away as 30
meters from the sensors. However, it is strongly recommended that the sensor
termination box be mounted on the main terminal box of the motor, in a location
that will also allow a suitable location for the monitoring unit as described above.
Page 8 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
5.2 Grounding
Proper grounding is critical for the reliable operation of the unit. In all cases,
coupler coaxial cables must be run in grounded metallic conduit when running
external to metal cubicles, such as the main terminal box, and secured to a
metallic ground plane within enclosures.
The PDM will likely be supplied with an external temperature sensor and an
external humidity sensor. It is possible that a single device containing both may
be supplied. The wiring for these sensors should also be run in grounded
metallic conduit.
In the case of older WPII enclosure machines, where external air is input and
circulated around the stator for cooling and then exhausted, the sensors may be
placed outside the main terminal box. These sensors must be located out of
direct sun and away from the motor cooler exhaust vent.
In the case of newer TEAAC machines, where internal air is circulated within
the enclosure with no contact with outside air, the sensors should be placed
inside the machine. There will be limits as to how far the sensors can be located
away from the monitoring unit, thus these sensors are typically installed inside
the main terminal box, close to the monitoring unit.
There are several ways in which communication may be built into the PDM
system:
1. Direct keyboard access in the field.
2. Direct RS-232 connection in the field to a laptop.
3. RS-485 cabling from the unit to the CCR into a computer.
4. Fiber optic cabling from the unit to the CCR into a computer.
5. Wireless to a base unit located in the CCR, into a computer.
In the final three methods the computer may actually be a server, but whether it
is a computer or a server a link can then be made to the company LAN such that
Page 9 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
In the final four methods above PDM vendor software will be required
download data and upload changes to the measuring configuration in the
monitoring unit.
6 Communication
There are several ways in which communication can be established with the PDM,
depending on what has been installed:
Direct keyboard access in the field.
Direct RS-232 connection in the field to a laptop.
RS-485 cabling from the unit to the CCR into a computer.
Fiber optic cabling from the unit to the CCR into a computer.
Wireless to a base unit located in the CCR, into a computer.
Local communication may be accomplished by direct keyboard access, but may limit
the range of changes that can be made to the resident software and requires a visit to the
field. Local communication with direct RS-232 to a laptop can typically host any of the
changes that are possible to the system.
Remote communication does not require a visit to the field but may limit the range of
changes that may be made to the resident software. Every PDM unit will be terminated
into a dedicated computer or server, likely located in the CCR. If the PD software is
installed on the dedicated computer or on a desktop that is linked to the server by the
plant LAN, a connection can be made to each PDM in turn. Accumulated PD data can
then be downloaded within a plant building and any changes to the measuring
parameters and alarm settings of the PDM can be uploaded. Analysis can be done on
the dedicated computer or a desktop.
This method is the most reliable but is also the most time consuming since the
local keyboard and screen size is limited. Thus the number of changes that can
be made to the system is also limited to simple data readout from the small local
screen and changes such as PD measurement alarm limits. This method is used
to set up the unit during commissioning and for debugging.
Page 10 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
This method is reliable and most comprehensive, but is also time consuming.
A laptop loaded with the PDM vendors software is carried to the field. This
method is not remote as each PDM must be visited. The door of each unit is
opened and an RS-232 cable is plugged into the laptop and the PDM.
Accumulated PD data can then be downloaded and any changes to the
measuring parameters and alarm settings of the PDM can be uploaded.
Analysis can be done on the laptop or the data can be transferred to a desktop.
This IEEE standard utilizes STP cabling. In older plants this cabling is likely
already in place and if there is any extra spare capacity it can be used. It is also
possible to initiate a project to install additional STP cabling but this would be
very expensive and disruptive in an existing plant.
One advantage of this system is that central engineering, such as CSD, may
download data directly such that they can help in the analysis. A disadvantage
is that there can be length limitations. The engineer must check to make sure the
PDM equipment has RS-485 capability built in.
Fiber optic cabling is becoming more popular and is being installed in many
modern plants. Cable lengths can be very long, especially compared with
RS-485. Although fiber optic cables are capable of very high data throughput
there is no need for large amounts of data to be transferred in this application.
One advantage of this system is that central engineering, such as CSD, may
download data directly such that they can help in the analysis. A disadvantage
is that trenching will be required. It is unlikely that fiber optic cabling will be
available in the older plants. The engineer must check to make sure the PDM
equipment has fiber optic capability built in.
Page 11 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
Every PDM vendor will provide proprietary software that can analyze to some degree
the data downloaded from the PDM. However, there are some PDM vendors that insist
the data be returned to them for detailed analysis and allow only detailed analysis by
their own experts these vendors are not recommended. A self-analysis PDM will
allow Saudi Aramco personnel to analyze the data with minimal training. It is
recommended that only self-analysis type PDM vendors be approved for use within
Saudi Aramco. Any PDM vendors that require the data be sent back to them for
detailed analysis should not be utilized.
Most, if not all PDM vendors also maintain databases of customer data in order to
statistically analyze the PD levels of machines over a large database. It is
recommended that only PDM vendors with customer available statistical database
analysis be approved for use within Saudi Aramco. This statistical analysis is useful
and can be utilized by Saudi Aramco in order to better evaluate the condition of our
machines.
Software will be loaded within the PDM itself. This software provides such
internal functions as local display of PD readings and machine parameters,
internal measurement and manipulation of the PD data, data storage,
communication, and alarm and measurement threshold settings. The PDM unit
may have a local keypad wherein these settings can be changed.
7.2 Laptop/Desktop
The PDM vendor will also provide sophisticated software that can communicate
and manipulate the PDM software. This higher order software may be utilized
in a laptop connected to the PDM locally via RS-232, or remotely via RS-485,
fiber optic or wireless.
The main purpose of this software is to analyze the PD data downloaded from
the PDMs in order to evaluate the condition of the motors to which they are
connected to.
Page 12 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
7.3 Analyzing PD
These two values are recorded periodically and then trended over time to look
for sudden increases or a significant ramping increase. NQN is more sensitive
to changes in the insulation system but both NQN and QM can be plotted. The
magnitude of QM can be compared to statistical values provided by the vendor
to give an indication of how the machine compares to others in the world. Table
1 below indicates the typical values of a large number of machines the higher
the Qmax, the worse the machine.
There are generally two types of plots that are analyzed. The first plot, shown in
Figure 1 below, shows the PD distribution for a sample motor. This curve is
normal except that the highest value of PD, at the bottom right hand corner, is
Page 13 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
high compared to the QM data range in Table 1 above. The red (negative) and
blue (positive) lines are close together which indicates the PD is distributed
evenly throughout the winding. This machines high PD is probably due to aging.
Figure 1 BBC 21,000 HP SN# HM1002170 2-D Plot, Aug. 25, 2006
The second type of plot to be analyzed is the trending plot as shown in Figure 2.
In this example, the motors PD values have jumped significantly, which can be
indicative of a pending failure. This machine should be watched closely.
350
300
250
200 QM+
PD
150 QM-
100
50
0
2 0 .1 2 0
2 0 6 .0 8
2 0 .0 1 5
2 0 6 .0 3
2 0 .0 2 0
2 0 .0 3 8
2 0 6 .0 8
2 0 .0 5 5
2 0 6 .0 2
2 0 .0 6 0
2 0 6 .0 7
2 0 .0 7 5
2 0 .0 7 3
2 0 6 .0 1
.0 8
14
05 1.3
0 .1
06 1.0
0 .2
06 2.1
06 .2
0 .1
06 4.0
0 .0
06 5.2
0 .0
06 6.2
06 .1
0 .3
06 8.1
9.
2 0 5 .1
0
20
Date
Figure 2 BBC 21,000 HP SN#HM1002177 Qmax, Nov. 30, 2005 to Sept. 14, 2006
Page 14 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
A complete PD report for a plants motors would analyze the trending to make
sure there were no sudden jumps in PD. Those machines with sudden jumps in
PD would need to be closely monitored. If their PD levels did not subside then
they should be prioritized for inspection and maintenance. The report would
also include a ranking of the machines from highest to lowest PD values. The
machines with the highest PD values that are also high in relation to Table 1
above should be prioritized for inspection and maintenance.
Revision Summary
3 January 2009 New Saudi Aramco Best Practice.
Page 15 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
There are a number of stresses that can contribute to and hasten the failure of an HV stator
winding, and all of these are detectable by measuring PD. They are:
1) Thermal Deterioration
2) Load Cycling
3) Looseness
4) Electrical Slot Discharge
5) Improper Impregnation
6) Endwinding Contamination
7) Inadequate Coil Spacing
8) Semicon Degradation
9) Endwinding Vibration
The following, authored by Iris Power and approved for inclusion in this best practice,
provides a more detailed explanation:
Page 16 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
Page 17 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
Page 18 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
Page 19 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
Page 20 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
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Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
Page 22 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
Appendix B PD Interpretation
The stresses that are described in Appendix A are detectable by measuring PD and exhibit
specific PD characteristics that can be recognized.
The following, authored by Iris Power and approved for inclusion in this best practice,
provides a more detailed explanation:
Page 23 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
Page 24 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
Page 25 of 26
Document Responsibility: Motors and Generators Standards Committee SABP-P-010
Issue Date: 3 January 2009 Motor Partial Discharge Monitors
Next Planned Update: TBD - Selection and Application
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