A SURVEY OF FAULTS ON INDUCTION MOTORS IN OFFSHORE OIL
INDUSTRY, PETROCHEMICAL INDUSTRY, GAS TERMINALS
AND OIL REFINERIES
Copyright Material IEEE
Paper No. PCIC-94-01
Olav Vaag Thorsen, Senior Member IEEE
Bergen College of Engineering
Lars Hillesgt.34, 5008 Bergen
Norway
Abstract - The report presents a survey of the reliability of
squirrel cage motors on board drilling-, production- and other
platforms offshore, together with cage motors in petrochemical
industry, gas terminals and refineries onshore. Most of the
activity in this connection is related to The North Sea that
offers a tough environment for motors. The collected data have
been treated statistically, and the faults sorted according to
supply- and motor data, driving conditions, maintenance and
so on. Comparisons between this survey and a survey from
IEEE have been done. The report also pays some attention to
methods for monitoring of machinery and detecting of faults.
INTRODUCTION
The oil industry *in The North Sea and on the coast of Norway are
among the most demanding markets for electrical equipment. One
has to cope with a chemical- and explosive atmosphere, vibrations,
very limited space, rough treatment and so on. Investigations are
going on to find out if converter fed squirrel cage motors may
replace the less robust DC motors in large drilling- and injection
drives. There is also a substantial amount of smaller and medium
sizes squirrel cage motors for many other services in the area.
The bulk of the motors in this survey are offshore. All together
there are at present installed 59 stationary platforms for drilling,
production, storing, pumping and quartering. Water injection has
been more and more important, together with re - injection of gas
to the bore holes, to increase the output of crude oil.
The first platforms were commissioned early in the seventies, and
platforms are continually being constructed. About 25 % of the
platforms (the biggest) have a concrete base, 75 YOsteel jacket.
The power consumption on a (big) platform may typically be as
follows in table 1.
Consumer types Power consumotion fMW)
Water injection I 12 to 25
Transportation 2 to 12
Re-injection of gas 2 to 10
Drilling (mainly from separate generators) 3 to 5
Processing I 1 to2
Generating of glycol 0.5 to 3
Living auarter 0.5 to 2
Heat and went I 0.3 to 3 and degree of monitoring. Normally one will particularly monitor
Emergency 0.5 to 6
The majority of the power comes from gas turbines via 60 Hz, 3
phase synchronous generators. However, there are also diesel
aggregates, especially for emergency. During the latest years, hydro
electric power by DC or AC from shore are considered. This is
mainly an effort to reduce the outlet of carbon dioxide. and the
1-
Magnus Dalva, Member IEEE
Rogaland University Center
Ullandhaug, 4004 Stavanger
Norway
economy in it is strongly dependent on economic politics, such as
dues. To begin with, it will be realized for platforms situated not
too far from the shore. As to choice of frequency, it will be known
that in general in Europe 50 Hz is adopted, except for ships and
platform where 60 Hz is more common. Now 50 Hz is considered
to be the future frequency all over, despite the equipment of that
reason being more heavy. Some platforms already have adopted 50
Hz. The Troll platform, for instance, will be supplied with 20 MW
of 50 Hz electric hydropower from shore by AC cables. DC
supply from shore is discussed, as well as different types of
interconnected grids between the platforms. The total power
consumption for a platform varies from some few kW for the
smallest and less complex installations, to nearly a hundred MW
for the biggest. The generator voltages vary from 440 V to 13.8
kV, and the consumers voltages from 230 V (mainly small
consumers) to 13.8 kV (mainly motors). For gas compression
converter fed synchronous motors up to as much as 15 MW are
applied. However, as a'thumb rule, drives of more than 8 MW
utilize gas turbines. For drilling (rotary tables, winches, mud pumps
etc.) motors of some hundreds of kW each are applied, and so far,
mostly thyristor fed DC motors. However, more and more
converter fed cage motors probably will be preferred.
Petrochemical industries, refineries and gas terminals onshore
are supplied with 50 Hz electric hydropower from the normal grid.
Table 2 shows examples of the number of squirrel cage motors
above 10 kW in the four types of plants included in this survey.
(The total number of motors in the survey is shown in table 3).
Planning of maintenance also demands relevant statistical data as
a base for deciding upon length of cycle, whether periodical
replacement or repair, and the question of the degree of monitoring.
The development of a fault versus time is decisive for the best type
- original condition, that equipment is correctly installed and
aligned
- after extensive maintenance or repair
- fatigue that may lead to cracks
- corrosion
- (normal) operation
9 4 - C H 3 4 5 1 - 2 / 9 4 / 0 0 0 0 - 0 0 0 1 $03.00 @ 1994 IEEE
Common methods for condition monitoring are [2,3]
- vibration monitoring
- current analysis
- surge tesuwinding diagnosis: direct current high potential
testing and high frequency surge testing
- temperature monitoring
- leakage flux (end winding leakage flux and axial flux)
- speed fluctuations
- oil particle analysis
- gas analysis
- partial discharges
- SPM (Shock Pulse Measurement), mainly for rolling element
bearings
Vibration monitoring is based on measuring accelerometers,
normally placed on the bearings for detecting mechanical faults.
However, by placing probes on the stator as well, it is also possible
to detect un- even air gap, winding faults and unbalanced supply
[3]. This is based on the fact that any change in the normal flux
distribution in the motor will cause a change in the vibration
spectrum. The measured or registered results are compared with
measurements registered when the machine was new (or in a
known condition). The sensitivity of the method is fairly high.
Current analysis may reveal damaged rotor bars. Faults in rotor
bars will introduce an harmonic current component in the supply
current to the stator. The frequency of this harmonic current
component is lower than the supply frequency by twice the slip
frequency, and the result is that an analog ammeter in the supply
lead will show slow fluctdations [2]. A spectrum analyzer will
provide more information. The ratio of harmonic current
component amplitude to that of the supply frequency component
gives an indication of the degree of fault or damage [2,8].
Measurements on the original condition is not necessary. However,
static and dynamic rotor eccentricity as well as mechanical faults
on driven equipment also will affect the harmonic current spectrum.
Surge test is a well known method for diagnosing of winding
faults. In the surge comparison test, two identical high voltage,
high frequency pulses are simultaneously imposed on two phases
of the motor winding, while the third phase is grounded. The
reflected pulses are compared on an oscilloscope [ 5 ] . The imposed
and the reflected pulses will cover each other provided all the
windings are healthy. Surge tests reveal insulation faults between
windings, coils and groups of coils, whereas most of the other
insulation test methods just measure the insulation condition against
earth or between the phases. A surge with steep front penetrating
a winding gives voltage differences between windings and coils so
that insulation faults are revealed.
Temperature measurements have a long tradition. Bearing
temperatures give useful information on possible friction problems,
and are surveyed on a routine basis. Coolant bulk outlet
temperature is often monitored, particularly when the machine is
stressed beyond its rated data.
Winding temperatures on the hottest spots are difficult to detect
because of insulation problems, especially in high voltage motors.
May be a fibre - optic system is an answer to that problem.
During normal condition the magnetic field in the air gap varies
sinusoidal in space and time. Some stator- and rotor faults cause
deviations from the sinusoidal variations. Rotor faults can be
detected by a search coil fixed to the stator. Changes of the air gap
flux density caused by rotor or stator will in addition produce an
axial flux which can be detected by a measuring coil around the
shaft. Faults are revealed by analysis of the frequency spectrum of
the measuring signal [2].
-2-
Speed fluctuations are fairly easy to detect. A digital speed
detector, developed in one of these authors institution, has made it
possible to detect the speed nearly momentarily (that is, many
times during a single revolution). Under normal operation the speed
is constant. Disturbances of the load or defects within the rotor
circuit will cause speed fluctuations that are possible to detect.
Oil particle analysis is not much in use for motors, but oil particle
monitors are available [2].
Gas analysis has, according to 121, shown to be a useful method
for large motors. The cooling air is analyzed for possible carbon
monoxide gas content from degradation of the electrical insulation,
and in this way one may detect overheating of the windings.
Measuring of partial discharges may provide a measure of the
insulation condition within a motor. It has, however, been some
uncertainty about the connection between the degree of partial
discharges and the remaining life time.
SURVEY RESPONSE
The present work reports from an investigation on faults and
failures on cage motors in offshore oil industries, petrochemical
industries, gas terminals and refineries. The following list
summarizes the magnitude of the response:
number of plants (or platforms): 11
number of companies: 8
number of "followed up" motors: 2596
total population (unit years): 25622
total failures: 1637
Contact between the companies and the authors has been
maintained partly by mail, and partly by short term visits to most
of the companies.
This survey has been encouraged by [l], a publication from The
Power Systems Reliability Subcommittee of IEEEIIAS, dealing
with AC and DC motors above 200 hp from a broad selection of
companies in USA.
The present survey is limited to oil- and oil related companies off-
and onshore in Norway, and includes cage motors above 10 kW.
The questionnaire forms used in this survey, is deliberatively made
very much like those in [l], so that certain comparisons of results
should be possible, and such a comparison is shown in table 19.
However, in some points, the degree of detailing regarding failure
initiator, -contributor and -underlaying cause has been too high
compared with reporting practice in the companies so far. The
result is the answer "not specified" to some of these questions.
SURVEY RESULTS
Table 3 shows the total number of motors in each power class.
These are all motors that have been "followed up" by the company,
so that their "history" and "health condition" are known, though not
in all details, as explained above.
Number of 1504
motors
Percent 57.94 13.94 11.36 8.98 3.39 4.39
Table 4 to 15 show different motor characteristics and drive Table 6 and 7 show relationship of failure rate with speed, 50 Hz
conditions versus failure rate (failuredunit year), sample size (unit and 60 Hz respectively. Although there are relatively few motors
year) and number of failures. of the lowest speeds, the tendency is fairly clear: the higher the
speed, the higher the failure rate. The higher failure rate for the 50
Power Hz motors, may be explained with a lower age for the 60 Hz
motors (offshore) than for 50 Hz motors (onshore).

11-50 51-100 101-200 201-500 501-

1000
I 1000- ~~

0-720

1 1 r: I r:
721-900 901- 1201- 1801-
1 Total

1 1 1 1 1 1
[kWl FWI [kWl FWl Wl [kWl 3600
Sample 15658 3402 2852 2305 650 755 rpm rpm rpm
size (unit

Sample 3084 12354

;“er 832 184 262 276 22 61 size
(unit
failures year)
Failure
rate
(failures/ I
0.0531

I
0.0541

I
0.0919

I
0.1197

I
0.0338

I
0.0808 Number
of
failures 171 I 443

1
unit year)
Failure 0.0554 0.0359
Table 4 Power versus failure rate rate
(faliures
The motors in group 201 - 500 kW have a somewhat higher failure /unit
rate than the others. year)
En7 Jeed versus failure rate, 60 Hz
Voltage

Table 5 shows a relationship of failure rate with voltage. Increasing Electrical protection
voltage clearly indicates higher failure rate. Despite the relatively
few high voltage motors, the reported faults are regarded reliable
as a result of careful documentation.

Thermall Thermal/electroma ThermaVelectromagnetic,

15000 electroma gnetic, fuses and fuses, build in
gnetic build in temperature sensors and
and fuses temperature vibration monitoring
Sample size (unit year) 3720
sensors
Number of failures 1207 11 419
~~ ~~ Sample size 21955 3272 395
Failure rate (failuredunit year) 0.0555 0.0786 0,1126 (unit year)

Number of 1553 66 18
failures
Within the power group of 101 - 200 kW there are 39 motors in Failure rate 0.0707 0.0202 0.0456
the voltage range of 5001 - 15000 V, and 256 up to or below (failuredunit
1000 v. year)

Speed

Enclosure
size
(unit
Y W
Number
of
763 I 5463

691
I 1194
Table 9 shows a relationship of failure rate with type of enclosure.
I Weather protected
I Totally enclosed (ex-
vroon
Sample size (unit year) 587 25035
failures
Number of failures 2 1635

1
0.1055 0.0900 Failure rate 0.0034 0.0653
(failuredunit year)
(failures
/unit

I
Since nearly all the motors were in the group totally enclosed, it is
Table 6 Speed versus falux rate, not relevant to draw any conclusion.

-3-
Duty application Not many sample sizes are reported to have "excellent"
maintenance. The estimation of the quality may vary somewhat
from plant to plant. As expected, a better maintenance gives a
lower failure rate.
Continuous Intermittent Not specified

Sample size (unit 25147 33 442 Power supply grounding type

ye4
Number of failures 1631 0 6

Failure rate 0.0649 0.0000 0.0136

(failuredunit year) Solid Impedance Ungrounded Not
specified

Sample size 22398 2216 0 1008

(unit year)
Total sample size is dominated by continuous duty that also shows
highest failure rate. I I I I
I I I I
Number of 1338 253 0
failures 46

Failure rate 0.0597 0.1142 0.0000 0.0456

(failureslunit
year)
Table 14 Power supply grounding type versus failure rate
1 or less

I I I
1-10 Not specified There was no response for ungrounded supply. Solid grounded
Sample size (unit 11802 13353 467 neutral point exhibits much lower failure rate than the impedance
year) grounded.
Number of 1109 522 6
failures Environment
Failure rate 0.0940 0.0391 0.0128
(failureslunit year)

Indoor Outdoor Not specified

Sample size (unit 847 I 24775 I 0

I
year)
Number of
failures
1633
~~ ~
Io~~

Failure rate 0.0047 0.0659 0.0000

Maintenance cycle (failuredunit
Ye4
Table 12 shows relationship of failure rate with maintenance cycle. Table 15 Environment versus fai ure rate

or less months or more specified In the types of plants included in this survey, the majority of the
motors are situated outdoor where the environment is extremely
14236
tough. This may explain the relative big difference between the
(unit year)
failure rate indoor and outdoor, and the inconsistency with thk
Number of survey in [l].
failures
~

Failure rate 0.0124 0.0506 0.0881 0.0364 Failed component

(failureslunit
year) Table 16 shows how the failures are distributed on the failed
components.

The survey response shows clearly that a cycle of up to 12 months Failed component Number of failures Percent
gives an extremely lower failure rate than for the next steps. Bearing 836 5 1.07

Stator windings 258 15.76

Maintenance quality Rotor bardrotor rings 77 4.70

Shaft or coupling 40 2.44

External device 255 15.58

Excellent Fair
Not specified I 171 10.45

Sample size (unit year) 1934 23688

Total I 1637
.. I inn
.
""

Table 16 Distribution of failures on failed component

Number of failures 24 1613
~

Failure rate (failuredunit 0.0124 0.0681 The result of the survey shows as expected that bearing faults count
year) for the majority of the failures, as much as about 51 YO.Faults on
stator winding and on extemal devices amounts to about 15 %

-4-
each, so that together these three adds to more than 80 % of all
faults that have led to a failure.
Stator windings - Causes of
- Number
failures of fail.
In table 17 the bearing failures are analyzed particularly.
However, because of high rate of "not specified" reasons, an Failure initiator
1) Transient overvoltages 9 3.49 7.03
additional column is added to show how the specified reasons are
2) Overheating 25 9.69 19.53
3) Other insulation breakdown 58 22.48 45.31
4) Mechanical breakage 19 7.36 14.84
Bearing - Causes of failures Number Percent Percent excl.
5) Electrical fault or malfunction 14 5.43 10.94
of failures not soecified
6) Stalled motor 3 1.16 2.34
Failure initiator 7) Not specified 130 50.39
I) Transient overvoltages 0 0 0
Failure contributor
2) Overheating 21 2.51 22.1 1
1) Persistent overloading 26 10.08 52.00
3) Other insulation breakdown 2 0.24 2.11
2) High ambient temperature 4 1.55 8.00
4) Mechanical breakage 67 8.01 70.53
3) Abnormal moisture 8 3.10 16.00
5) Electrical fault or malfunction 4 0.48 4.21
4) Abnormal voltage 2 0.78 4.00
6) Stalled motor 1 0.12 1.05
5) Abnormal frequency 0 0.00 0.00
7) Not specified 74 1 88.64
6) High vibration 3 1.16 6.00
Failure contributor 7) Aggressive chemicals 1 0.39 2.00
1) Persistent overloading 23 2.75 22.77 8) Poor lubrication 0 0.00 0.00
2) High ambient temperature I 0.12 0.99 9) Poor ventilation or cooling 2 0.78 4.00
3) Abnormal moisture 9 1 .08 8.91 10) Normal deterioration from age 4 1.55 8.00
4) Abnormal voltage 1 0.12 0.99 1 1 ) Not specified 208 80.62
5) Abnormal frequency 1 0.12 0.99
Failure underlying cause
6) High vibration 51 6.10 50.50
1) Defective component 12 22.64
7) Aggressive chemicals 1 0.12 0.99
2) Poor installation/testing 3
8) Poor lubrication 13 1.56 12.87
3) Inadequate maintenance 1
9) Poor ventilation or cooling 1 0.12 0.99
4) Improper operation 18 6.98 33.96
IO) Normal deterioration from age 0 0.00 0.00
5) Improper handling/shipping 0 0.00 0:oo
1 1 ) Not specified 735 87.92
6) Inadequate physical protection 5
Failure underlying cause 7) Inadequate electrical protection 12 4.65 22.64
I ) Defective component 22 2.63 27.50 8) Personnel error 0 0.00 0.00
2) Poor installation/testing 3 0.36 3.75 -
9) Outside agency not personnel 2 0.78 3.77
3) Inadequate maintenance 9 1 .os 11.25 10) Motor-driven equipment mism. 0 0.00 0.00
4) Improper operation
5) Improper handling/shipping
6) Inadequate physical protection
30
4
5
3.59
0.48
0.60
37.50
5.00
6.25
11) Not specified
Table 18 Stator windings fail = 205 79.46
:ir causes
7) Inadequate electrical protection 2 0.24 2.50
8) Personnel error 0 0.00 0.00
9) Outside agency - not personnel 3 0.36 3.75
10) Motor-driven equipment mism.
I I ) Not specified
2
756
Table 17 Bearing failures and heir causes
0.24
90.43
2.50 Total - Causes of failures
I Number
of fail.
Percent Percent excl.
not specified
Failure initiator
1) Transient overvoltages 10 0.61 2.20 (2.14)
Table 17 reveals that mechanical breakage and overheating are the 2) Overheating 72 4.40 15.86 (19.23)
most frequent failure initiators of bearing failures, whereas high 3) Other insulation breakdown 68 4.16 14.98 (17.95)
4) Mechanical breakage 139 8.50 30.62 (48.29)
vibration and persistent overloading are the most frequent failure 5) Electrical fault or malfunction 148 9.05 32.60 (11.11)
contributors. Improper operation and defective component are the 6) Stalled motor 17 1.04 3.74 (1.28)
major failure underlaying causes. 7) Not specified 1189 72.25
In table 18 the stator winding failures are analyzed particularly. Failure Contributor
And as for the bearings, the "not specified" percentage is high, so 1) Persistent overloading 80 4.89 27.03 (5.49)
that an additional column is added to show how the specified 2) High ambient temperature 10 0.61 3.38 (3.92)
reasons are distributed. 3) Abnormal moisture 23 1.41 7.77 (3.53)
Table 18 shows that overheating and other insulation breakdown 4) Abnormal voltage 8 0.49 2.70 (1.96)
are the major failure initiators. The major failure contributor is 5) Abnormal frequency 1 0.06 0.34 (0.78)
6) High vibration 83 5.07 28.04 (20.0)
persistent overloading, and the most frequent underlaying causes 7) Aggressive chemicals 43 2.63 14.53 (5.49)
are improper operation, defective component and inadequate 8) Poor lubrication 19 1.16 6.42 (19.61)
electrical protection. 9) Poor ventilation or cooling 8 0.49 2.70 (5.10)
IO) Normal deterioration from age 21 1.28 7.09 (34.20)
11) Not sDecified 1341 81.92
CAUSES OF FAILURES
Failure underlying cause
1) Defective component 105 6.41 35.47 (23.31)
Table 19 gives an overview of total number of causes of failures. 2) Poor installatiodtesting 10 0.61 3.38 (15.04)
For comparison, the figures from [l] are included in the last 3) Inadequate maintenance 13 0.79 4.39 (24.81)
column (in parenthesis). In this column the "not specified" replies 4) Improper operation 71 4.34 23.99 (4.14)
are excluded. The major all over failure initiators for the present 5) Improper handlingishipping 6 0.37 2.03 (0.75)
survey are electrical faults or malfunction, mechanical breakage, 6) Inadequate physical protection 48 2.93 16.22 (7.14)
7) Inadequate electrical protection 21 1.28 7.09 (6.77)
overheating and other insulation breakdown. As to failure 8) Personnel error 5 0.31 1.69 (7.89)
contributors high vibration, persistent overloading and aggressive -
9) Outside agency not personnel 13 0.79 4.39 (4.51)
chemicals are the most important. The most frequent underlaying IO) Motor-driven equipment mism. 4 0.24 1.35 (5.64)
causes are defective component, improper operation and inadequate 11) Not spxified 1341 8 1.92
physical protection. failure uses

-5-
 ~

Table 20 shows what are the underlying cause for a failure initiator COMPARISON WITH THE SURVEY IN [l]
for the total number of failures.
The results from the last column in Table 19 are also given in
O.in. Mech graphs 1 to 3. Certain discrepancies between the two surveys were
break break
expected because of the differences in selection of plants and motor
4 26 types and sizes.
comp.
-- The most distinct differences are within failure contributors. In the
0 2
present survey normal deterioration from age and poor lubrication
play small roles, whereas in [l] they are important.
install/t.
-
Inad.
main.
I I 0 1 0 6 % Failure underlying cause
._____ ~ ~~

I I
~

Improper 2 3 0 51
operation

lmpr.
handl/sh.
1 I o o 0
-
5

4 3
protect.
--
5 0
protect.

Person. 0 0 0 1
error

0ut.ag. 1 I o 3 0 0

I' I
not per. I I
Graph 3 Distribution of failure underlaying causes for two
Motor- 0 0 0
d.equip.
surveys
mismatc.

Not
specified
I I 2 43 55 45 COMMENTS ON HIGH VOLTAGE MOTORS

Sum IO 72
-
68 139
- G+tFtET In the voltage group 5001-15000 V one has the following motors:
101- 200 kW, 39 motors 90 failures
Table 20 Failure initi or ver: aIre underlying cause 201- 500 kW, 200 motors 250 failures
501- 1000 kW, 85 motors 20 failures
Over 1000 kW, 110 motors 59 failures
% Failure initiator
Table 21 shows how the failures are distributed on the failed
components for motors in voltage group 5001-15000 V.
40 '
Failed component Number of failures Percent
30
Bearing 175 41.77 (51.07)
-~

20 Stator windings I 54 I 12.89 (15.76)

Rotor badrotor rings I 32 I 7.64 (4.70)

10
Shaft or coupling 18 4.30 (2.44)

0 Extemal device 76 18.14 (15.58)

1
S Thissurvey W IEEE 1 Not specified I 64 I 15.27 (10.45)

Total 419 100 (100)

Graph 1 Distribution of failure initiators for two surveys
% Failure contributor
50 The result shows as expected that bearing faults count for the
majority of the failures, as much as 41.77%. Faults on stator
40 windings and on external devices amounts to 12.89% and 18.14%,
so that together these three add to 72.67% of all faults that have led
30 to a failure.
In parenthesis are repeated the values for all voltages, (table 16).
20
In table 22 the bearing failures are analyzed particularly for the
10
voltage group 5001-15000 V. Because of high rate of "not
specified" reasons, an additional column is added to show how the
specified reasons are distributed.
Table 22 reveals that mechanical breakage and overheating are the
most frequent failure initiators of bearing failures, whereas high
vibration are the most frequent failure contributor. Defective
Graph 2 Distribution of failure contributors for two surveys component are the major failure underlaying cause.

-6-
 In table 23 the stator windings failures are analyzed particularly.
Bearing - Causes of failures Number Percent Percent
of failures excl. not And as for the bearings, the "not specified percentage is high, so
specified that an additional column is added to show how the specified
reasons are distributed.
Failure initiator
1) Transient overvoltages 0 0 0
2) Overheating 16 9.14 43.24
3) Other insulation breakdown 0 0 0
Stator windings - Causes of Number Percent Percent
failures of failures excl. not
4) Mechanical breakage 19 10.86 51.35
5) Electrical fault or malfunction 2 1.14 specified
5.4
6) Stalled motor 0 0 0 Failure initiator
7) Not specified 138 78.86 I ) Transient overvoltages 5.56 8.33
2) Overheating 14.81 22.22
Failure contributor
3) Other insulation breakdown 24.07 36.1 1
1) Persistent overloading 3 1.71 9.38
4) Mechanical breakage 5.56 8.33
2) High ambient temperature 0 0 0
5 ) Electrical fault or malfunction 12.96 19.44
3) Abnormal moisture 4 2.29 12.50
6) Stalled motor 3.70 5.56
4) Abnormal voltage 1 0.57 3.13
7) Not smcified 33.33
5 ) Abnormal frequency 0 0 0
6) High vibration 17 9.71 53.13 Failure contributor
7) Aggressive chemicals 0 0 0 1) Persistent overloading 2 3.70 13.33
8) Poor lubrication 7 4.00 21.88 2) High ambient temperature 1 1.85 6.67
9) Poor ventilation or cooling 0 0 0 3) Abnormal moisture 4 7.41 26.67
IO) Normal deterioration from age 0 0 0 4) Abnormal voltage 2 3.70 13.33
11) Not specified 143 81.71 5) Abnormal frequency 0 0 0
6) High vibration 2 3.70 13.33
Failure underlying cause
7) Aggressive chemicals 1 1.85 6.67
1) Defective component IO 5.71 38.46
8) Poor lubrication 0 0 0
2) Poor installationhesting 2 1.14 7.69
9) Poor ventilation or cooling 2 3.70 13.33
3) Inadequate maintenance 4 2.29 15.38
10) Normal deterioration from age 1 1.85 6.67
4) Improper operation 2 1.14 7.69
1 I ) Not specified 39 72.22
5 ) Improper handlingkhipping 0 0 0
6) Inadequate physical protection 3 1.71 11.54 Failure underlying cause
7) Inadequate electrical protection 1 0.57 3.85 1) Defective component 8 14.81 33.33
8) Personnel error 0 0 0 2) Poor installationhesting 2 3.70 8.33
9) Outside agency - not personnel 2 1.14 7.69 3) Inadequate maintenance 1 1.85 4.17
IO) Motor-driven equipment mism. 2 1.14 7.69 4) Improper operation 1 1.85 4.17
, .
11) Not smcified I
149 85.14 I 5) Improper handlingkhipping 0 0 0
Table 22 Bearing failures and their causes, high voltage 6) Inadequate physical protection 5 9.26 20.83
7) Inadequate electrical protection 6 11.11 25.00
8) Personnel error 0 0 0
-
9) Outside agency not personnel 1 1.85 4.17
..
10) Motor-driven eauiument mism. 0 0 0
Total - Causes of failures Number 1 I ) Not specified 30 55.56
of fail.

Failure initiator Table 23 shows that- insulation breakdown, overheating and

1) Transient overvoltages 3 0.72 2.05 (2.14) electrical fault or malfunction are the major failure initiators. The
2) Overheating 36 8.59 24.66 (19.23)
3) Other insulation breakdown 17 4.06 11.64 (17.95)
major failure contributor is abnormal moisture, persistent
4) Mechanical breakage 42 10.02 28.77 (48.29) overloading, abnormal voltage, high vibration and poor ventilation.
5) Electrical fault or malfunction 45 10.74 30.82 (11.11) The most frequent underlaying causes are defective component,
6) Stalled motor 3 0.72 2.05 (1.28) inadequate electrical protection and inadequate physical protection.
7) Not specified 273 65.16
Table 24 gives tin overview of total number of causes of f d m s
Failure Contributor
1) Persistent overloading 9 2.15 10.00 (5.49) The figures from [l] are included in the last column (in
2) High ambient temperature 3 0.72 3.33 (3.92) parenthesis). In this column the "not specified" replies are
3) Abnormal moisture 10 2.39 11.11 (3.53) excluded. The major all over failure initiators for the voltage group
4) Abnormal voltage 5 1.19 5.56 (1.96)
0
5001-15000 V are electrical faults or malfunction, mechanical
5) Abnormal frequency 0 0 (0.78)
6) High vibration 31 7.40 34.44 (20.00) breakage, overheating and other insulation breakdown. As to failure
7) Aggressive chemicals 17 4.06 18.89 (5.49) contributors high vibration, aggressive chemicals, poor lubrication,
8) Poor lubrication 11 2.63 12.22 (19.61) abnormal moisture and persistent overloading are the most
9) Poor ventilation or cooling 2 0.48 2.22 (5.10) important. The most frequent underlaying causes are defective
10) Normal deterioration from age 2 0.48 2.22 (34.20)
78.52
component, inadequate physical and electrical protection.
11) Not specified 329

Failure underlying cause COMMENTS ON VARIABLE SPEED DRIVES

1) Defective component 42 10.02 43.75 (23.31)
2) Poor installatiodtesting 4
3) Inadequate maintenance 5 Most of the plants and platforms in this investigation were planned
4) Improper operation 6 in the seventies and early eighties, and hence not provided with
5 ) Improper handlinglshipping 0 0 (0.75) variable speed drives (VSD), that did not come into extensive use
6) Inadequate physical protection 22 22.92 (7.14)
before the end of the eighties.
7) Inadequate electrical protection IO 2.39 10.42 (6.77)
8) Personnel error 2 0.48 2.08 (7.89) The application of VSD affects the piping flow plants, and has to
-
9) Outside agency not personnel 3 0.72 3.13 (4.51) be included into the designing process on an early stage.
IO) Motor-driven equipment mism. 2 0.48 2.08 (5.64) Applicatir'n of VSD has several advantages in investment cost and
1 1 ) Not specified 323 77.09 running expenses, but not very many reliability surveys on VSD
Table 24 Distribution of tot. number of Jure causes, high voltage drives have been reported [13].

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 Appendix
The intention of this survey has been to investigate the failure rate,
to identify failures and their distribution according to motor data, ne has chosen the following groupings:
protection, duty and maintenance cycle and quality within Power kWl
~~~

petroleum related industry as a base for planning of maintenance w1: 1 - 10 W5: 201 500 -
and condition monitoring. The industry in this survey is strongly W2: 11 - 50 W6: 501 1000 -
biased towards the offshore oil industry, and a comparison has been W3: 51 - 100 w7: 1001 -
made with results from an IEEE survey within more general w4: 101 200 -
industry [l]. Frequency [Hz]
Voltage [VI

The results show a strong increase of failure rate with voltage (and v1: 0 1000- H1: 50
power), well in accordance with [l]. V2: 1001 5000 - H2: 60

A small increase in the failure rate is revealed from 4 to 2 pole

V3: 5001 15000- H3: variable

motors. The amount of data is too little to draw conclusions for

higher pole numbers. NI: 10 N4: 4
Increasing complexity of the protection leads to a strong reduction N2: 8 N5: 2
of the failure rates. An apparent increasing in the failure rate for N3: 6 N6: changeable (Dahlander)
motors equipped with vibration protection, must be a result of
uncertain (few) data.
A somewhat unexpected result was that the failure rate was 50 Hz 60 Hz
considerably higher with one start per day than with more starts. RI: 0 - 600 -
R6: 0 720
The Starting procedure, especially direct on line start, RZ: 601 - 750 R7: 721 900 -
causes extra stress on rotor, bearings and coil ends, so one would R3: 751 - 1000 R8: 901 - 1200
have expected another result. The explanation must be that fewer R4: 1001 - 1500 R9: 1201 - 1800
starts per day means longer duty time per day.
A maintenance cycle of 12 months ore shorter, as well as excellent Electrical protection:
quality of the maintenance, lead, as expected, to an extreme
PI: ThermaVelectromagnetic and fuses
reduction of failure rate. Also is recorded a considerably lower P2: Build in temperature sensors
failure rate with solid grounding of the neutral than with impedance P3: P1 + P 2
grounding. P4: Vibration monitoring + P I , P2 or P3
P5: Not specified
Distribution of failures on different components gives 51 % to the Enclosures
bearing, about the same as in [l]. Faults on stator windings and
external device amount to about 15 % each, somewhat higher than
in [l]. The deviation can probably be explained by the different
size limits, the present survey includes motors above 10 kW,
compared to 150 kW in that of [l]. Also the fact that the majority
of the motors in the present survey are situated offshore, and have
direct on line starting, may contribute to higher failure rates on
rotor and extemal device.

A more detailed analysis has been performed for bearing and stator
windings to provide more details as a base for revealing sources of
faults and to plan monitoring and protection. The faults are
frequently complex, and both electrical and mechanical.
The most frequent failure initiators for the bearing are mechanical
breakage and overheating, high vibration and persistent overloading
being the most frequent contributors. Failure underlying causes are
improper operation, defective component and inadequate
maintenance.
For the stator windings faults, the most important failure initiators Maintenance cycle Maintenance aualitv
are overheating, mechanical breakage and electrical fault. Several MI: 12 months or less 41: Excellent
faults on the motors are caused by unbalanced supply condition, for M2: 13 to 24 months 42: Fair
instance single phasing. Application of normal protection may M3: 25 months or more 43: Poor
exhibit problems in the effort to protect the motor over the whole M4: Not specified 44: Not specified
speed range from no load to full load.

Further work It is the intention to work in the continuation of

this survey. Contact has been established with relevant industrial
companies to map the development after the completion of this
survey (may 1993). Particularly we will look into the reliability of
high voltage motors (>6000V) with power exceeding 150 kW, Type of industry
usually the most important motors. The hope is to include more TI : Oil exploratiodproduction, refineries, petrochemical manufacturing
plants to increase the reliability of the survey. T2: Pulp and paper industry, wood conversion
Parallel to this, work will go on to investigate the reliability of T3: Aluminum plants
variable speed drives. T4: Not specified

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Environment

El: Indoor
E2: Outdoor
E3: Not specified

I
Period reported

Minimum value: 1
Maximum value: 100
____

Failed component I
:ti?kdings
Rotor bardrotor rings
Shaft or coupling
External device
Not specified Months since last maint.
Failure initiator How many times failed
~~

11: Transient overvoltages

12: Overheating
Reference
13: Other insulation breakdown
14: Mechanical breakage IEEE Committee Report, "Report of Large Motor Reliability
15: Electrical fault or malfunction Survey of Industrial and Commercial Installations, Part I"
16: Stalled motor and "Part 11", IEEE Transaction on Industry Applications,
17: Not specified
Vol.IA-21, No.4, JulyIAugust 1985, pages 853 - 872
Failure contributor P.J.Tavner, B.G.Gaydon, D.M.Ward,"Monitoring generators
and large motors", IEE Proceedings, Vo1.133, Pt.B., No.3,
High ambient temperature May 1986, pages 169 - 180.
F3: Abnormal moisture Poor ventilation or cooling R.A.Leonard,W.T.Thomsen,"Vibration and Stray Flux
F4: Abnormal voltage F 10: Normal deterioration from Monitoring for Unbalanced Supply and Inter-turn Winding
F5: Abnormal frequency
High vibration F1 1: Not specified
Fault Diagnosis in Induction Motors", British Journal of
NDT, July 1986, pages 21 1 - 215.
Failure underlying cause H.Yoshida, K.Umemoto, "Insulation Diagnosis for Rotating
Machine Insulation", IEEE Transactions on Electrical
Poor installatiodtesting protection Znsulation, Vol. EI-2 1,No.6, December 1986, pages 1021 -
Inadequate maintenance 1025.
Improper operation Outside agency other than S.Schlichting, "Stoss-spannungsprufg von Elektromotoren
Improper handlingkhipping personnel z u r F r u h e r k e n n u n g v o n I so 1a t i o n s f e h 1e r n " ,
Inadequate physical UIO: Motor-driven equipment
protection mismatch
Elektrizitatswitschaft, Jg.85, Heft 10, 1986, pages 406-409.
U 11: Not specified M.Krecke, R.Goffaux, "Attempt at Estimating the Residual
Life of the HV Insulation of AC Rotating Machines",

11
Time failure discovered

normal operation
CIGRE, 1988 Session, Paper 11-12, pages 1-8.
T.Usami, H.Teshima, S.Ohta, T.Koizumi, E.Ohno, "A

j
During routine maintenance or testing Dynamic Monitoring System for Bearings Vising a
Microprocessor", IECI-Annu.ConJProc. 6th.pages 24-128,
Not specified
March 1980.
Total Dopulation data form F.Filippetti, M.Martelli, G.Franceschini, C.Tassoni,
Identification number 1 2 - n Comments "Development of Expert System Knowledge Base to On-line
Diagnosis of Rotor Electrical Faults of Induction Motors",
Total number of motors IEEE Industry Applications Society Annual Meeting -
Power. W1 - W6. Conference Record, pages 92-99, 1992.
A.H.Bonnett, "Analysis of Winding Failures in Three-phase
Voltage, V1 - V6 Squirrel Cage Induction Motors", IEEE Transactions on
I I I I I

Frequency, HI - H3 Industry Applications, Vol.IA-14, No.3, MaylJune , pages

Pole number, NI - N6 223-226, 1978.
B.G.Gaydon, "An Instrument to Detect Induction Motor
RI - R5 Rotor Circuit Defects by Speed Fluctuation Measurements",
Speed
R6 - RIO IEE ConzPubl. 174, pages 5-8, 1979.
C.Hargis, B.G.Gaydon, K.Kamash, "The Detection of Rotor
El.protection, PI - P4 Defects in Induction Motors", IEE ConjPubl.213, pages
Enclosures, K1 - K5 216-220, 1982.
W.T.Thomson, R.A.Leonard, A.J.Milne, J.Penman, "Failure
Duty appl., A1 - A3
Identification of Offshore Induction Motor Systems using
Starts per day, S1 - S5 On-Condition Monitoring", Fourth National Reliability
Maint. c., MI - M4 Conference-Reliability '83, pages 2C1311-2C13111, 1983.
K. W.L.Burbidge, "Users View of Variable Speed Drives on
Maint. 4..Q1 - 44 Petrochemical Plant", IEE ConfPubl.376, pages 582-587,
Grounding, GI - G4 1993.

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