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Electrical Theory: Howard W Penrose, PH.D., CMRP Instructor
Electrical Theory: Howard W Penrose, PH.D., CMRP Instructor
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Classic Atom
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Electron Movement
Photon
Photon + N
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Conductors
Free Electrons (e) Easily Directed Usually metals Copper Aluminum Gold Platinum
- -
- - -
- -
- - - - - - - - - - - - -
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Semi-Conductors
+
Dielectrics 4 Valence Electrons Polarize with Some Electron Flow due to Electrical Fields
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Insulators
No Free Electrons No Current Flow with Field
+
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Current (Amperage - I)
Current is the flow of electricity, much like the flow of water in a pipe. It is measured in Amperage as opposed to gallons per minute of water.
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Current
Electron!
Electron!
1 Amp = 6.28 x 1018 electrons per second 1 Amp = 1 Coulomb per second Electron charge = 1.60219 x 10-19 Coulombs Flows Negative Charge to Positive Charge
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Voltage (Volts - V or E)
Voltage is the electrical pressure in the system, much like water pressure. Electrical pressure is measured in Volts as opposed to Pounds per Square Inch. (ie: 110V like water from a tap, 4160 like a fire hose)
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Resistance (Ohms - R or )
Resistance is simply the restriction of current flow in a circuit. Smaller wire (conductors) and poor conductors have higher resistance.
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Resistance
e e
e e e
e e
e e
e e
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Ohms Law
Current, Voltage, and Resistance relate as follow:
I=E/R
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Magnetics
Magnetic Flux
South
Magnet
North
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S Metal N
South
Magnet
North
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Electrical Properties
Frequency Inductance (L)
Mutual Inductive Reactance (XL)
Capacitance (C)
Capacitive Reactance (XC)
Frequency
90
180
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270
360
Inductance
Stores electromagnetic energy in its magnetic field mH di
I lags V
V L
dt
1 2 W Li 2
1 t i v( )d i(0) L 0
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Mutual Inductance
When 2 coils in close proximity, a changing current in one coil will induce a voltage in a second coil
N2 = 5 Turns 100 Volts
90
180
270
360
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Inductive Reactance XL
Inductive Reactance is the AC Resistance of a coil Presented as a resistance in Ohms Frequency and Inductance Dependant
X L 2fL
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Capacitance
Stores energy in an electric field Dielectric between 2 plates The charged condition is maintained until a discharge path is present Causes current to lead voltage
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Capacitive Reactance XC
1 XC 2fC
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V I
90
180
270
360
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Impedance Z
Z R (X L XC )
2
Complex AC Resistance
DC Resistance
X L 2fL X 1 C
2fC
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Summary
Atomic Structure and Electron Movement Conductors, Semi-Conductors, Insulators Basic Electricity: Current, Voltage and Resistance Electrical and Magnetic Fields Alternating Current Electricity: L, C, XL, XC, Z
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R ( X L X C )2
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Rotor Field
Rotating Fields
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Rotor Cage
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Output Torque
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Operating Motor
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STATOR LAMINATIONS
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Phase B Phase C
Circuit Capacitance Changes due to charge Effects of atoms in Insulation medium. Dipoles are created As electric field crosses Atoms. As they align Capacitance increases.
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The Dipole
Neg Potential
Pos Potential
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Ground Insulation
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GRND Pos
Low
Meg Ohms
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Low
Time
Conductor 1
Conductor 2
Overcomes Dipolar Spin and Circuit Capacitance Requires Higher Voltage as a Result In order to cross air gap (Paschen) Potentially Destructive!!! Voltage
Impulse
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Time
Arc during fault detection using surge test. The separated insulation is the result of the arc (burned). The grey area on the copper is carbonized insulation.
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wire
wire
wire
Capacitive Defect
wire
wire
wire
MCA Result on 20 hp with contamination and slight phase to phase defect. Still running.
MCA test results following surge test from previous example. Trips on start.
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Concept of TTFE
Setting test frequencies such that faults can be detected in advance Setting alarms at a point where fault detection is effective Knowing that failures are random Know that the resistance to failure decreases following detection of a CBM alarm
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Condition-Directed Example
100%
Resistance to failure
0%
Inspection Interval
DT
F (Winding fails)
(F-P)
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This Presentation
Stages of Winding Failure Causes and Effects Trending Time to Failure Discussion
< 600 Vac Standard, integral, three phase motors, operating an average of 4000 hours 50% load, balanced voltage, good power quality, constant load
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Insulation Breakdown
Contamination
Moisture and electric field expansion Gasses, vapors, dust, etc.
Arc Tracking
High Current Between Conductors
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Insulation Breakdown
VFD Applications
Partial Discharge
Mechanical Faults
Stress cracking Parts Faults
Stators awaiting assembly after rewind
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Contamination, Thermal, Moisture Incursion, Corona, Transients, Overloads, etc. may initiate fault.
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Stage 1
Insulation between conductors stressed Changes to R and C between conductors High temps and reactive faults Carbonization begins to occur MCA values of Fi and I/F begin to change
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Stage 2
Fault becomes more Resistive Mutual Inductance between good and bad I2R losses increase at point of fault Motor may start tripping although may run after short cooling period (ins res increases as insulation cools)
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Stage 3
Insulation breaks down Possible explosive rupture Vaporization of windings Inductance and sometimes resistance may change
Stage 3 winding failure
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Review
MCA Requirement:
Resistance Loose connections, Broken Wires (~5%) Impedance and Inductance Rotor position or contaminated windings. Also, used for rotor test in assembled equipment. (Parallel good, Unparallel bad) I/F and Fi Early winding shorts (I/F: +/-2; Fi: +/-1) Insulation Resistance Ground Faults (5 MOhm/100 MOhm)
Combination used for troubleshooting or trending Comparative tests: Assumes that phases do not fail at same rate
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How Trended
AC Motors
% unbalance: R, Z and L Phase Diff: I/F and Fi Reading: Insulation Resistance
MCA Being used to confirm the Winding voltage connection in a submersible Pump.
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R, Z, L
Fi, I/F
>5%
<1 pt
Red
Green
Fi, I/F
Fi, I/F
Yellow
Red
Trended Reading
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AC Motor 2
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12 Mo 6 Mo 3 Mo 6 Mo 12 Mo
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9 Mo 6 Mo 2 Mo 6 Mo 9 Mo
6 Mo 3 Mo 1 Mo 3 Mo 6 Mo
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Winding Contamination
7
Time to Action (Months)
6 5 4 3 2 1 0 Annual 9Months
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Quarterly
Monthly
10 8 1pt 6 4 2 0 Annual 9 Months Semi Quarterly Monthly Test Frequency 2pt 3pt >3
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Phase to Phase or Coil to Coil 7 6 5 4 3 2 1 0 -1 Annual 9 Months Semi Quarterly Monthly Test Penrose Frequency (c)2005 1pt 2pt 3pt >3
TTFE Software
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Final Comments
When is TTFE effective?
Technology can detect developing faults (Condition-Based) Optimized testing frequency or continuous monitoring A history exists or can be obtained Multiple-Technology approach to confirm condition and stage of failure Understanding that the functional failure is not instantaneous and some forcing function drives the failure Action is taken on findings: Risk-based decision
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SUCCESS by DESIGN
5 Dogwood Ln Old Saybrook, CT 06475 Ph: 860 575-3087 Fax: 860 577-8537 http://www.motordoc.net howard@motordoc.net
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