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Motor Analysis

Techniques

2 November 2017
Multiple Motor Analysis Techniques

Rotor Bar Analysis


Stator Analysis
Voltage Imbalance
Shaft Voltage/Current Measurement
Temperature Measurement

2 November 2017
Rotor Bar Analysis

2 November 2017
Rotor Bar Analysis
Can be performed by two methods:
1) Current Measurement

2) Flux Measurement

2 November 2017
Vocabulary
Rotor bar slip frequency
= LF - (poles x slip)

Principal slot pass frequency or PSPs


= (RPS X #stator slots) - LF.

Rotor pass frequency or PSPr


= (RPS X #rotor bars) - LF.

Voltage imbalance frequency


= (# poles/2 * RPS) + LF
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Motor Current

Use 341 clamp on ammeter


Uses MCSA and the dB down method of
LF-(#poles x slip).
Detects
rotor bar condition

unbalanced current

Used as a baseline for FLUX

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Limitations of Motor Current

Must access electric panels


Ammeter connects to live power lead
Requires an electrician to take readings
Tells you about rotor
only 10% of motor failures are due to
rotor problems

2 November 2017
Diagnosing Rotor Bar Problems.
The life of a rotor is directly proportional to
the number of starts and stops of a motor.
To diagnose rotor problems with flux we
capture a baseline current reading to
normalize flux measurements.
Then we trend the flux measurement and
look for side bands of (slip frequency X
#poles) about Line Frequency.
2 November 2017
Lets Look at an example

450 HP forced draft fan motor

2 November 2017
35 dB down shows broken rotor bars
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MotorView II diagnosed data
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side bands

Repaired rotor bars on same machine

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Bad rotor bars current data on same machine

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Current good rotor bars
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FLUX
Use 343 Flux Coil
Position on the fan shroud of a motor
Measures magnetic flux signature of ac
induction motors
Detects
rotor bar faults

stator faults

unbalanced voltage

motor speed

2 November 2017
FLUX Notes

Do not need to know load


Do not need to know # of bars
Do not need to know # of stator slots
Need to position coil consistently
Need MCSA baseline

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FLUX Benefits

Detects same faults as motor current and


more
without accessing electric panels

without connecting to live power leads

without requiring an electrician

During vibration route collection

2 November 2017
Using Flux to Analyze Motor
Problems

2 November 2017
Flux Reading with Small Short

Increase in Sideband Values


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Flux Reading - Change from Baseline
Slot Pass
2xLF

increase decrease
in flux in flux -4xLF
-2xLF
4xLF 8xLF

6xLF 10xLF
-10xLF -6xLF
-8xLF

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We see 4.3 times increase in flux data
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Flux Reading with Medium Short

Sizeable Increase in Sideband Values


2 November 2017
Flux Reading - Change from Baseline

2xLF
Slot Pass

increase decrease
in flux in flux -2xLF
-4xLF 4xLF
8xLF
-6xLF 6xLF
-10xLF
-8xLF 10xLF

2 November 2017
Flux showed 8 times increase over baseline
2 November 2017
Test Measurement #3

Induce Severe Short in Stator

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Surge Test Results
Close Up

Small

Medium

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Severe Stator Short
Flux Reading with Severe Short

Significant Increase in Sideband Value


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Flux Reading - Change from Baseline
2xLF
Slot Pass

increase decrease -2xLF


in flux in flux -4xLF 4xLF
6xLF8xLF
-6xLF 10xLF
-10xLF
-8xLF

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23 X increase shown here
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Trend of 2xLF Sideband of Slot Pass
25
23.5
20
Ratio to Baseline

15

10
8.1
5 4.3
1.1
0
No Small Medium Severe
Short Short Short Short
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Voltage Imbalance

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Flux Analysis and Unbalanced
Voltage
Must take baseline flux reading. All
trending flux readings must be taken from
the same location.
Increase in LF+(#poles/2 x RPS) flux
peak with increase in voltage unbalance.
Data taken from low frequency flux
information.

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Motor Running with Unbalanced Voltage

LF+RPM

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6.3 % Voltage Imbalance
Shaft Current/Voltage
Measurement

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Shaft Current and Voltage
Faulty Rotor Isolation

Current travels through bearing to ground


causing bearing damage

Measure current
and voltage
present on shaft
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Bearing Damage
Excess voltage builds up on bearing inner race

Arcing occurs causing microweld, frosting or


fluting

Phenomenon knows as
Electric Discharge Machining

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Measure Directly on Shaft

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Example of Equipment for Shaft
Measurement

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Fluted Bearing from EDM

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Shaft Probe Applications
Electrical Test Engineer
Maintenance Crews
Predictive Maintenance Specialist
Machine Operators

2 November 2017
Temperature Measurement

2 November 2017
Normalized Thermal Parameter

Tpt - Tamb
Tn = X 100
% Load

Tn = Normalized Thermal Parameter


Tpt = Measured Motor Temperature Point
Tamb = Measured Ambient Temperature
% Load = % Full Load of Motor at Time of Measurement

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Temperature Measurement Locations

TBI TSI TS TSO TBO TTH TCP


C

TAF

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Common Causes of Overheating

Overloading
Bearing seizure
Misalignment
Restricted ventilation
Single phasing
High ambient temperature
Excessive duty cycles
Power supply variations
Winding faults
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MVII

Flux, Temperature, Current, and Shaft


Voltage/Current
Full Motor Diagnostic Capability On
Line
Unintrusive
Safe
Effective

2 November 2017
MVII

The only technology available today


that can monitor rotor and stator defects
on-line without accessing live power
leads.
Safety
Data Integrated to other CSI
technologies

2 November 2017
Summary
Flux data is a new technology, but it clearly
provides an early warning for stator faults in
electric motors
Flux provides a way trend voltage
imbalance, rotor bar analysis, and stator
problems on-line in a non-intrusive manor.
MotorView II provides a time saving way to
measure and trend this information.
2 November 2017
MotorView II

Software features
Automatic measurement point, analysis
parameter, alarm limit, and fault
frequency setup.
Automatic Electrical Diagnostics
Trend plots of rotor condition
Trend plots of stator condition
Trend plots of voltage balance
Normalized temperature trending
Shaft voltage/current trending and
recording
2 November 2017

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