A

Project Report on

INDUCTION MOTOR MAJOR CAUSES OF FAILURE AND

PREVENTIVE MEASURES
Submitted in the partial fulfillment of the requirement
for the award of the degree of

BACHELOR OF TECHNOLOGY
IN
ELECTRICAL AND ELECTRONICS ENGINEERING

By

A.N.V.L.LAVANYA 09A31A0202
Y.J.S.SRINIVAS 09A31A0260
R.JAYA CHANDRA 10A35A0203
G.RAMAKRISHNA 09A31A0226
M.S.N.P.B.SURYA TEJA 09A31A0238

Under the esteemed guidance of

Sri.B.RAMESH
M.Tech,
Asst. Professor.

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

PRAGATI ENGINEERING COLLEGE
(Approved By AICTE & Affiliated to JNTU, Kakinada)
1-378, A.D.B.Road, Surampalem, Near Peddapuram - 533437.
2009-2013

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 PRAGATI ENGINEERING COLLEGE
(Approved By AICTE & Affiliated to JNTU, Kakinada)
1-378, A.D.B.Road, Surampalem, Near Peddapuram - 533 437.

CERTIFICATE

DEPARTMENT OF ELECTRICALAND ELECTRONICS

ENGINEERING

This is to certify that the project report entitled as, ‘INDUCTION MOTOR
MAJOR CAUSES OF FAILURE AND PREVENTIVE MEASURES’ that is being
submitted by A.N.V.L.LAVANYA (09A31A0202), Y.J.S.SRINIVAS (09A31A0260),
R.JAYACHANDRA (10A35A0203),G.RAMAKRISHNA (09A31A0226),
M.S.N.P.B.SURYA TEJA (09A31A0238) in partial fulfillment for the award of the degree
of Bachelor of Technology in Electrical and Electronics Engineering to PRAGATI
ENGINEERING COLLEGE, is a record of bonafide work carried out by them.

Sri.B.RAMESH
M.Tech,
Asst. Professor,
Internal guide.

Prof.K.SATYANARAYANA
M.Tech., (Ph.D), MIE MIEEE, MISTE
Professor & H.O.D of EEE Department

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 ACKNOWLEDGEMENT

We express our thanks to our guide Sri. B.RAMESH, Associate professor in Electrical
and Electronics Engineering, who deserves a special note of thanks and gratitude, for
having extended their fullest co-operation and guidance, without this project would never
have materialized.

We express our deep sense of gratitude to Prof.K.SATYANARAYANA, Professor

and H.O.D. of Electrical and Electronics Engineering, for having shown keen interest at
every stage of development of our project work and guiding us in every aspect.

We express our thanks to the Director Dr.A.KAILASA RAO for providing the
necessary facilities during the execution of this project and supporting completing our
project successfully.

We wish to express our special thanks to our beloved Principal DR. S. SAMBHU
PRASAD and Directors Prof.K.ANAND MOHAN and Dr.G.RAGHU RAM for giving
us guidelines and encouragement.

We wish to express our sincere gratitude to our beloved and respected Chairman
Dr.P.KRISHNA RAO, and Director M.V. HARNATHA BABU, for their encouragement
and blessings.

We are also thankful to all other faculty members of our department, for their valuable
suggestions. Our sincere thanks also extended to all the teaching and non-teaching staff of
Pragati Engineering College.

A.N.V.L.LAVANYA
Y.J.S.SRINIVAS
R.JAYA CHANDRA
G.RAMAKRISHNA
M.S.N.P.B.SURYA TETA

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 ABSTRACT

Electric motors play a very important role in the safe and efficient running of industrial
plants and processes. The induction machine is the single most common electromechanical
energy conversion device available. It is used to drive numerous important propulsion and
mechanical loads. The induction machine is considered inherently reliable due to its robust
and relatively simple design. But, the induction machine does fail most usually as a result of
aging or poor construction and lack of proper maintenance. If the failure is severe it may
become necessary to replace the machine completely which is very expensive. Early
detection of abnormalities in the motors will help to avoid expensive failures. So by proper
maintenance and protection the motor life span can be improved thus providing economy.

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 CONTENTS

1. INTRODUCTION

2. CONSTRUCTION AND WORKING

3. MAJOR FAULTS

4. PROTECTION AND MAINTENANCE

5. CONCLUSION.

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 CHAPTER 1

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. This means that the electric motor
should receive proper attention. Its installation and routine maintenance require specific care
to ensure perfect operation and longer life of the unit. Of all 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. As 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. Also 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.so 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 resistance,
smoke or fire, sparking or unusual slip ring or brush wear, sudden changes of bearing
temperatures. 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, which is normally done by turning off the respective switches. In the event of fire
within the motor itself, steps should be taken to restrain and suffocate it by covering the
ventilation vents. To extinguish a fire, dry chemical or C02 extinguishers should be used –
never use water.

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 CHAPTER 2
CONSTRUCTION AND WORKING OF INDUCTION MOTOR

2.1 Choice of materials:

The magnetic and electric circuits essential to machines require materials of high
permeability and low resistivity, respectively, and these are generally metals. Metals with
good magnetic and electrical properties do not necessarily have high mechanical strength.
Indeed the atomic structure of a good conductor is such that it will naturally have a low
yield strength and high ductility. Yet the magnetic and electric circuits of the machine must
bear the mechanical loads imposed upon them by the transfer of energy across the air gap.
Furthermore, the magnetic and electrical circuits must be separated by insulating materials,
such as films, fibers and resins, which have even weaker mechanical properties. Right from
the outset, there is a conflict between the electrical and mechanical requirements of the
various parts of an electrical machine, which the designer must attempt to resolve.
However, there is a further complication. The transfer of energy inevitably involves the
dissipation of heat, by ohmic losses in the electric circuit and by eddy current and hysteresis
losses in the magnetic circuit. The performance of the insulating materials that keep these
circuits apart is highly dependent upon temperature, and deteriorates rapidly at higher
temperatures. Materials that can sustain these higher temperatures become progressively
more expensive and their mechanical and dielectric properties are often worse than lower
temperature materials. The common insulating materials used in electrical machines and
shows the relatively low temperatures at which they are permitted to operate.
The health of an electrical machine, its failure modes and root causes, are ultimately related
to the materials of which it is made, the mechanical and electrical stresses those materials
are subjected to and the temperatures they attain in service.
However, when fault currents are flowing the machine has already failed as an electrical
device. Electrical or mechanical failure modes are always preceded by deterioration of one
of the mechanical, electrical, magnetic, insulation or cooling components of the machine.
This is the case regardless of the type of electrical machine. If this deterioration takes a
significant period of time and can be detected by measurement, then that root cause
detection will be a means of monitoring the machine before a failure mode develops.

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2.2 Construction:

Fig 2.1 Construction of Induction Motor

a) The 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
1. Reduce the leakage flux between stator and rotor
2. Lead to better operating power factor of the induction motor.

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 Fig 2.2 construction of the stator

b) 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. These solid bars are short
circuit at both ends by end rings of the same material. For good electrical connection, the
bars are riveted, brazed or welded with the two end rings. In smaller sizes, say below 40
kW, the assembled rotor core is placed in a mould and the molten conducting material,
usually aluminum, is forced into the slots. Thus the rotor bars, end rings and the cooling fan,
are cast in one operation. Without the rotor core, the rotor bars and end-rings look like the
cage of a squirrel, hence the name squirrel cage induction motor. Note that the 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.

c) Windings:
The stator windings of all high-voltage AC machines comprise conductor bars made series
or parallel. Individual sub-conductors are covered with a paper or glass-based tape and the
assembled bar is over taped with a similar material impregnated on older designs with
bitumen but nowadays with epoxy resins .In the portion of the conductor bar embedded in

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the stator slot the insulation system is compacted by being heated and pressed or it may be
impregnated under vacuum and pressure. In the end-winding portion, where one coil is
connected to another, the insulation system is not compacted and may be slightly altered,
containing less impregnate, so that it is more flexible and therefore better able to withstand
the large electromagnetic forces that part of the winding experiences. An important part of
the construction is the manner of the bracing of these end windings. They are usually pulled
back onto rigid insulated brackets made of impregnated laminate or steel using nylon or
Terylene lacing cord. On the largest machines bracing rings of glass- reinforced plastic are
used with insulating bolts. The exact nature of the bracing depends upon the machine rating
and the relative length of the end winding, as determined by the number of pole pairs. The
yoke (or stator core) is fitted into a frame and enclosure. On smaller machines and those of
standard design, the stator core is secured directly into a simplified design of a machine
main frame but on larger machines the core has its own inner frame, which is separate from
the outer frame so that the clamped core can be removed from the enclosure for repair up of
hard-drawn, higher strength copper sub0-conductors that may be connected in figures.

d) Enclosures
The machine enclosure can take a wide variety of forms, depending on the manner in which
the machine is cooled, and the protection it needs from the environment in which it will
work. Where a pressurized gas system of cooling is used the enclosure will be a thick-
walled pressure vessel but for simple air-cooling with an open-air circuit the enclosure will
consist of thin-walled ducting.

e) Connections
Electrical connections are made to the windings via copper bus-bars or cables that leave the
machine enclosure through bushings into a terminal box. The bustards may be lightly
insulated to protect them against the environment. The bushings usually consist of the
busbar embedded into an epoxy resin casting, although wound paper bushings may be used
on older machines. The electrical connections are well braced to withstand the large
electromagnetic forces that are developed when fault currents flow. The terminal enclosure
allows the proper termination of the supply cables or bus-bars, and must be specially
designed to suit the environment in which the machine works. For example, special
enclosures are required for motors that operate in inflammable areas and these incorporate

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baffles and seals to ensure that any flashover in the enclosure does not ignite gas or vapour
outside the terminal box.
Many machines incorporate brush gear for connection to the rotor windings either
through steel or copper slip rings or through a copper commutator. The commutator is a
very carefully designed component in which copper segments interlock with the rotor so
that they can withstand the bursting forces acting upon them. Also, each segment must be
well insulated from its neighbors, and mica is normally used for this purpose. Slip rings are
usually shrunk onto an insulating sleeve mounted on a boss on the rotor shaft, and electrical
connections to the slip rings are insulated and carefully braced to withstand the centrifugal
forces upon them. Brushes are spring-loaded and mounted in brass brush boxes around the
periphery of the rings or commutator.
Heat exchangers for the cooling system of the machine are mounted
on the enclosure or may be a part of it, as shown in Figure .They may be as simple as a
finned casing to the machine to promote convective heat transfer to the surrounding air or
they may be a more complex water-cooled system through which the cooling gas or air is
ducted.

2.3. 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.
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.

Fig 2.3 principle of operation

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The following sequence of events takes place:
1. A voltage E = BLv is induced in each conductor while it is being cut by the flux
(Faraday’s Law)
2. The induced voltage produces currents which circulate in a loop around the conductors
(through the bars).
3. Since the current-carrying conductors lie in a magnetic field, they experience a
mechanical force (Lorentz force).
4. 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.

Fig 2.4 squirrel cage rotor winding

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 and Ic will flow in the windings, but will be displaced in time by
120°. Each winding produces its own MMF, which creates a flux across the hollow interior
of the stator. The 3 fluxes combine to produce a magnetic field that rotates at the same
frequency as the supply.

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 Fig 2.5 rotating magnetic field
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.
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.

2.4 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.

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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.
Slip:
The difference between the synchronous speed and rotor speed can be expressed as a
percentage of synchronous speed, known as the slip.
s = slip, Ns = synchronous speed (rpm), N = rotor speed (rpm)
• At no-load, the slip is nearly zero (<0.1%).
• At full load, the slip for large motors rarely exceeds 0.5%. For small motors at full load, it
rarely exceeds 5%.
• The slip is 100% for locked rotor.
Frequency induced in the rotor:

f R =s f
The frequency induced in the rotor depends on the slip:
fR = frequency of voltage and current in the rotor
f = frequency of the supply and stator field
s = slip

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 CHAPTER 3
MAJOR FAULTS

Many faults occur because machines are incorrectly specified for the application to which
they are being applied. For example, a machine may be underpowered or have an inadequate
enclosure. The specification of a machine must ensure that it is of an appropriate design for
the use to which it is being put. It is a waste of time applying sophisticated monitoring
techniques to a machine that is unfit for its purpose. It is far better to remove the monitoring
and change the machine for one that is more suited to the application. By the same token
many operational problems could be avoided by using an over-designed machine. For
example, in a hot environment it may be better to use an over-rated machine, which has a
substantial design margin, than push an adequately designed machine to its limit. On the
other hand, it is sometimes an operational fact of life, especially with an expensive machine,
that it must continue to operate even though it suffers from shortcomings in the original
specification. In such cases effective monitoring can help to ease the burden placed upon the
maintenance engineer. The specification of a machine must reflect the mechanical,
electrical and environmental conditions in which the machine will work. These matters will
have a bearing on the mechanisms by which the machine may fail in service. The need for
monitoring and the selection of the parameters to be monitored must be affected by these
operational conditions.
Mechanically, machines can be exposed to periods of intermittent running, frequent
starting and to arduous duty cycles, where the load varies frequently between no-load and
full-load with occasional overloads. These can lead to insulation degradation, bearing wear,
vibration and slackening of windings, commutator or brush gear. Similarly a machine
driving a pulsating load, such as a compressor, is going to experience heavy bearing wear,
vibration and slackening of windings, commutator or brush gear.
From an electrical supply point of view a machine, by virtue of its location in a supply
system or its task in a manufacturing process may be subjected to a variety of transients at
its supply terminals. These may be slow fluctuations in the supply voltage or even
unbalance between the three phases that can cause operational problems; for example, if the
machine does not have the thermal capacity to deal with the overheating that unbalance can
lead to. More rapid transients in the supply voltage, however, can overstress the winding
insulation because the electric stress is not uniformly distributed throughout the winding

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length. Modern interrupters produce very rapid voltage surges that were known to break
down class B inter- turn insulation on the line end coils of motors but with modern class F
systems this is now rare.
3.1 Standard Three-Phase Motor Failures
Owing to the widespread usage of asynchronous three-phase motors in industry which are
more often repaired in the plant workshops, there follows a summary of possible failures
and their probable causes, detection and repairs. Motors are generally designed to Class B or
F insulation and for ambient temperatures up to 40°C. Most winding defects arise when
temperature limits, due to current overload, are surpassed throughout the winding or even
in only portions thereof. These defects are identified by the darkening or carbonizing of wire
insulation.
3.1.1 Short Circuits Between Turns
A short circuit between turns can be a consequent of two coinciding insulation defects, or
the result of defects arising simultaneously on two adjacent wires. As wires are randomly
tested, even the best quality wires can have weak spots. Weak spots can, on occasion,
tolerate a voltage surge of 30% at the time of testing for shorting between turns, and later
fail due to humidity, dust or vibration. Depending on the intensity of the short, a magnetic
hum becomes audible. In some cases, the three-phase current imbalance can be so
insignificant that the motor protective device fails to react. A short circuit between turns,
and phases to ground due to insulation failure is rare, and even so, it nearly always occurs
during the early stages of operation.
3.1.2 Winding Failures
a) 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.
b) 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 currentless while the others absorb the full
voltage and carry an excessive current. The slip almost doubles.

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c) Three burnt winding phases
Probable cause 1
Motor only protected by fuses; an overload on the motor will be the cause of the trouble.
Consequently, progressive carbonizing of the wires and insulation culminate in a short
circuit between turns, or a short against the frame occurs. A protective switch placed before
the motor would easily solve this problem.
Probable cause 2
Motor incorrectly connected. For example: A motor with windings designed for 230/400V
is connected through a star-delta switch to 400V connection. The absorted current will be so
high that the winding will burn out in a few seconds if the fuses or a wrongly set protective
switch fail to react promptly.
Probable cause 3
The star-delta switch is not commutated and the motor continues to run for a time connected
to the star under overload conditions. As it only develops 1/3 of its torque, the motor cannot
reach rated speed. The increased slip results in higher ohmic losses arising from the Joule
effect. As the stator current, consistent with the load, may not exceed the rated value for the
delta connection, the protective switch will not react. Consequent to increased winding and
rotor losses the motor will overheat and the winding burn out.
Probable cause 4
Failures from this cause arise from thermal overload, due to too many starts under
intermittent operation or to an overly long starting cycle. The perfect functioning of motor
operating under these conditions is only assured when the following values are heeded:
a) number of starts per hour;
b) starting with or without load;
c) mechanical brake or current inversion;
d) acceleration of rotating masses connected to motor shaft
e) load torque vs. speed during acceleration and braking.
The continuous effort exerted by the rotor during intermittent starting brings about heavier
losses which provoke overheating. Under certain circumstances with the motor idle there is
a possibility that the stator winding is subjected to damage as a result of the heating of the
motor. In such a case, a slip ring motor is recommended as a large portion of the heat (due
to rotor losses) is dissipated in the rheostat.

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3.2 Insulation Ageing Mechanisms
3.2.1 General:
Electrical insulation faults are a significant contributor to the failure of rotating machines.
Industry studies indicate that up to one- third of rotating machine failures can be attributed
to loss of function of the stator winding electrical insulation. Therefore they deserve special
consideration before we consider failure modes in general. However, it should be borne in
mind that although the final failure mode may be electrical breakdown of a dielectric
component, the underlying mechanism driving the breakdown may be thermal, mechanical
or environmental stress as well as electrical factors. This section will cover the basic stresses
that affect the performance of stator winding, stator core and rotor winding insulation
systems on operating machines as well as discussing the roles that design, operation and
maintenance have on the life of the equipment.
Insulation in service is exposed to high temperature, high voltage, vibration and
other mechanical forces, as well as some adverse environmental conditions. These stresses
can act together or individually to degrade insulation materials or systems. Thermal ageing
of insulating material due to high temperatures has been studied the most and is perhaps best
understood. The mechanism may be treated as a chemical rate phenomenon, described by
the Arrhenius relationship, and includes loss of volatiles, oxidation, de-polymerization,
shrinkage and embrittlement. In actual service, loss of insulation system integrity is
aggravated by cyclic and transient mechanical forces, which cause relative movement and
abrasion of insulation. Furthermore, insulation subjected to high voltage can degrade due to
partial discharge activity. Eventually, the stresses will so weaken the insulation that
punctures results and the conductor is connected to earth. Thus, although the final result is
electrical failure, the root cause may be the result of non-electrical stress. In general, the
higher the electrical stress, the more rapidly the insulation will age. In the discussion to
follow, each of these stresses, thermal, electrical, mechanical and ambient conditions will be
described in generic terms. The exact details of which mechanisms are the most critical are
very much dependent on the type of equipment and service conditions.

3.2.2 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. Cycling of the temperature

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can also induce mechanical stresses causing deterioration, even if the temperature alone is
insufficient to cause damage; for example, the loss of the copper/insulation bond in the
stator windings of rotating machines as a result of successive heating and cooling of a
conductor.
The operating temperatures of inorganic insulating materials for example, porcelains and
glasses – are limited by softening, by reversible changes of conduction, dielectric loss or
strength, or by the danger of fracture due to differential thermal stresses. Organic materials
suffer irreversible changes at high temperatures.
Generally, the temperature limit that will restrict deterioration to what is acceptable over the
design life of the equipment is lower than that imposed by immediate changes such as
softening, except when the temperature rise in service is of short duration. Typical obvious
symptoms are shrinkage, hardening, spontaneous cracking or crazing, loss of strength,
embrittlement, discolouration, distortion and, in extreme cases, charring. These effects are
generally due to, or accompanied by
 loss of weight resulting from evaporation of volatile components,
 oxidation or pyrolysis to form volatile substances or gases such as CO, CO2 , water
and low-molecular-weight hydrocarbons,
 Excessive cross-linking.

3.2.3 Electrical ageing:

a) General:
Electrical ageing occurs when the electric stress applied to insulation causes deterioration.
Although electric stress due to DC and transient voltages can cause ageing, AC voltage is
normally the most severe. It should be noted that the insulating materials used in practical
equipment operate well below their inherent breakdown strength. Consequently, electrical
ageing of insulation usually occurs as the result of the presence of faults in the material; for
example, gas voids arising from imperfect impregnation, resulting in partial discharge. The
following are electrical ageing mechanisms that can be induced by the principal power
frequency voltage or by the transient surge voltage from power system disturbances.
b) Partial discharges:
In general, deterioration from partial discharges will occur in insulation that has voids
created during manufacture or by thermal or mechanical ageing in service. The direct
impingement of discharges on insulation surfaces will cause decomposition of the solid
insulation.

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3.3 Rotor Vibrations:
Vibration problems in induction motors can be extremely annoying and may lead to greatly
reduced reliability. It is crucial; in all operations and manufacturing processes such that
down time is avoided and/or minimized. If a problem does occur the source of the problem
is quickly identified and corrected. By using the proper data collection and analysis
techniques, the true source of the vibration can be discovered. This includes Electrical
imbalance, Mechanical unbalance – motor, coupling, or driven equipment Mechanical
effects – looseness, rubbing, bearings, etc. External effects - base, driven equipment,
misalignment etc.

Fig 3.1 effects of vibration

Vibration problems can occur in the installation or operation of a motor. When they occur it
is normally critical that one reacts quickly to solve the problem. If not solved quickly, there
can be long term damage to the motor or immediate failure, which would result in
immediate loss of production. The loss of production is oftentimes the most decisive
concern. To solve a vibration problem cause and effect should be differentiated. For this to
happen, the root cause of the vibration must be understood.
A proper routine vibration program using a portable data collector, or permanent on-line
vibration monitoring, will become the foundation of any predictive maintenance proposal.
Measuring, trending, alarming and analyzing fan and motor vibration will provide earlier
warning of developing problems and allow replacement parts to be ordered. Bearings can be
replaced during scheduled down times prior to non-repairable damage occurring.
Causes of Vibrations
There are many electrical and mechanical forces present in induction motors that can cause
vibrations. Additionally, interaction of these various forces makes identification of the root
cause elusive.

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a. Eccentric Rotor
An eccentric rotor, This means the rotor core OD (outer diameter) is not concentric with the
bearing journals, creates a point of minimum air gap which rotates with the rotor at one
times rotational frequency. There will be net balanced magnetic force acting at the point of
minimum air gap associated with this, since the force acting at the minimum gap is greater
than the force at the maximum gap. This net unbalance force will rotate at rotational
frequency, with the minimum air gap, causing vibration at one time rotational frequency.
b. Broken Rotor Bar
If a broken rotor bar or open braze joint exists, no current will flow in the rotor bar .Hence
this the field in the rotor around that particular bar will not exist. Therefore the force applied
to that side of the rotor would be different from that on the other side of the rotor again
creating an unbalanced magnetic force that rotates at one times rotational speed and
modulates at a frequency equal to slip frequency times the number of poles.
If one of the rotor bars has a different resistivity a similar phenomenon (as in the case of a
broken rotor bar) can exist.
c. Thermal Unbalance
Thermal unbalance is a special form of unbalance. It is caused by uneven rotor heating, or
uneven bending due to rotor heating. The proper solution is to find out the reason for uneven
heating affecting shaft straightness, and fix the rotor.
d. Decoupling Unbalance
The coupling unbalance limit given in API 671 of 40W/N, when applied to a classic 1000
HP 3600 rpm 2 pole motor for example, results in a value equal to about one-third of the
motor unbalance limit for one end.
e. Weak Motor Base
If the motor is sitting on a fabricated steel base, such as weak base, then the possibility
exists that the vibration which is measured at the motor is greatly influenced by a base
which itself is vibrating. Ideally the base should be stiff enough to meet the ‘Massive
Foundation’ criteria defined by API 541. It is essential that, this requires that support
vibration near the motor feet to be less than 30% of the vibration measured at the motor
bearing. To test for a weak base, measure and plot horizontal vibration at ground level, at
bottom, middle, and top of the base, and at the motor bearing.
f. Effect of resonance on Vibrations
Resonant frequency is the natural frequency of a component or an assembly or a structure.
All structures have a resonant frequency. If impact is made on the structure with enough

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force to make it move, it will vibrate briefly at its natural frequency. A structure will have a
resonant frequency in each of its 3 directional planes (x, y and z, or as we call them,
horizontal, vertical and axial). Resonance serves to amplify the vibration due to whatever
vibration force is present at (or near) that resonant frequency. It is important to note that
resonance does not cause vibration - it amplifies it.

3.4 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.
Table gives a summary of the conditions involved in the choice. These can be helpful when
considering fault conditions
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, which are detectable by temperature sensors. An
important consequence of bearing deterioration for electrical machines is the rotor becomes
eccentric in the stator bore causing a degree of static and/or dynamic eccentricity, disrupting
the fine balance between the magnetic forces of adjacent poles, causing UMP and placing
more load on the bearing. This also causes an increase in vibration as the shaft dynamics are
affected by the altered air gap and bearing stiffness.

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Following tabular form shows most probable faults their causes and corrective measures:

FAILURE PROBABLE CAUSE CORRECTIVE MEASURE

Motor fails to start 1.No voltage supply • Check feed connections to control
system and from this to motor.
2. Low voltage supply • Check voltage supply and ascertain
that voltage remains within 10% of the
rated voltage shown on the motor
nameplate.
3. Wrong control • Compare connections with the wiring
connections diagram on the motor nameplate
4. Loose connection at • Tighten all connections.
some terminal lug
5. Overload • Try to start motor under no-load
conditions. If it starts, there may be an
overload condition or a blocking of the
starting mechanism. Reduce load to
rated load level and increase torque.
High noise level 1. Unbalance • Vibrations can be eliminated by
balancing rotor. If load is coupled
directly to motor shaft, the load can be
unbalanced.
2. Distorted shaft • Shaft key bent; check rotor balance
and eccentricity.
3. Incorrect alignment • Check motor aligment with machine
running.
4. Uneven air gap • Check shaft for warping or bearing
wear.
5. Dirt in the air • Dismantle motor and remove dirt or
dust with jet of dry air.
6. Extraneous matter • Dismantle motor and clean. Remove
stuck between fan and trash or debris from motor vicinity.
motor casing

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 7. Loose motor • Tighten all foundation studs. If
foundation necessary, realign motor.
8. Worn bearings • Check lubrication. Replace bearing if
noise is excessive
and continuous.

Overheating of 1. Excessive grease • Remove grease bleeder plug and run

bearings motor until excess grease is expelled.
2. Excessive axial or • Reduce belt tension.
radial strain on belt
3. Deformed shaft • Have shaft straightened and check
rotor balance.
4. Rough bearing surface • Replace bearings before they damage
shaft.
5. Loose or poorly fitted • Check end shields for close fit and
motor end shields tightness around circumference.
6. Lack of grease • Add grease to bearing.
7. Hardened grease cause • Replace bearings.
locking of balls • Flush out housings and relubricate.
8. Foreign material in
grease
Intense bearing 1. Unbalanced rotor • Balance rotor statically and
vibration dynamically.
2. Dirty or worn bearing • If bearing rings are in perfect
condition, clean and relubricate the
bearing, otherwise, replace bearing.
3. Bearing rings too tight • Before altering shaft or housing
on shaft and/or bearing dimensions, it is advisable to ascertain
housing that bearing dimensions correspond to
manufacturer’s specifications.
4. Extraneous solid • Take bearing apart and clean.
particles in bearing Reassemble only if rotating and support
surfaces are unharmed

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Overheating of 1. Obstructed cooling • Clean and dry motor; inspect air vents
motor system and windings periodically.
2. Overload • Check application, measuring voltage
and current under normal running
conditions.
3. Incorrect voltages and • Compare values on motor nameplate
frequecies with those of mains supply. Also check
voltage at motor terminals under full
load.
4. Frequent inversions. • Exchange motor for another that
meets needs
5. Rotor dragging on • Check bearing wear and shaft
stator curvature.
6. Unbalanced electrical • Check for unbalanced voltages or
load (burnt fuse, operation under single-phase condition
incorrect control)

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 CHAPTER 4

PROTECTION AND MAINTENANCE

4.1 Protection

In today's economy, plants must able to produce quality products at desired

costs. Costs can be broken down into the following categories:
• Investment costs
• Maintenance and repair costs
• Operational costs
• Lost production costs due to down time
It is possible to minimize these costs by proper selection and application of motor protective
equipment. Close coordination of the motor, the load and protection avoids the need for
oversized motors. This reduces the investment costs and energy consumption since the
motors run at a higher efficiency level. The early detection of faults can reduce repair costs.
Pre-warning and start prevention can reduce plant downtime. If pre-warning alarms are
available to alert personnel of impending motor failure, the system can be shut down in a
planned, orderly fashion. Once shut down, preventive maintenance can occur, possibly
eliminating the need for costly repair or replacement.
4.1.1 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. Hence fault can be detected by detecting
the temperature rise.
4.1.2 Ground/Earth Fault Protection

A large percentage of motor insulation failures result in ground/earth fault currents. Early
detection keeps damage to a minimum, thereby shortening repair times and minimizing repair
costs. In isolated supply systems, a first ground/earth fault could even be reason for only an

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alarm. The plant could continue to operate until a convenient time to shut down such as the
end of the shift, day, or week. During the scheduled shutdown, maintenance personnel could
then correct the fault without affecting production time. Ground/earth fault trips normally
work with a short delay in order to overcome the problem of current transformer saturation at the
start of the fault. This delay is also important for discrimination against short circuits. This allows the
fuses or circuit breaker to clear the fault instead of attempting to have the relay interrupt the fault.
Ground/earth fault protection can be applied as individual protective devices. But this protection is
also standard with high level digital protection.

4.1.3 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.

4.2 Maintenance:
A well-designed maintenance program for electric motors can be summed up as:
periodical inspection of insulation levels, temperature rise, wear, bearing lubrication and the
occasional checking of fan air flow. Inspection cycles depend upon the type of motor and the
conditions under which it operates.
4.2.1 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.
4.2.2 Lubrication
Proper lubrication extends bearing life.
Lubrication Maintenance Includes:
a) Attention to the overall state of the bearings;
b) Cleaning and lubrication;
c) Critical inspection of the bearings.
Motor noise should be measured at regular intervals of one to four months. A well-tuned ear
is perfectly capable of distinguishing unusual noises, even with rudimentary tools such as a

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screw driver, etc., without recourse to sophisticated listening aids or stethoscopes that are
available on the market. A uniform hum is a sign that a bearing is running perfectly. Bearing
temperature control is also part of routine maintenance. The temperature of bearings
lubricated as recommended under item 4.2.2 should not exceed 70°C. Constant temperature
control is possible with the aid of external thermometers or by embedded thermal elements.
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.

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 CHAPTER 5
CONCLUSION

While running an industrial plant an Electric Motor exposes itself to many risks calling for
safety of the plant and people operating around it. Factors such as productivity and reliability
of the plant mainly depend on the operation of its drives. If the performance of machine is
effected overall performance of the plant will be effected which is not desired. To improve
performance of the machines regular maintenance is mandatory. Along with this proper
protection and preventive measures against frequently occurring faults ensures safe and
secure operation of plant. So analysis of faults in motors and corresponding measures to be
taken is of greater importance.

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