CI R ED

20 th International Conference on Electricity Distribution

Prague, 8-11 June 2009 Paper 0227

INCREASING THE RELIABILITY OF INDUCTION MOTORS WITH POWER MONITORING SYSTEMS

Jon BICKEL Schneider Electric - USA jon.bickel@us.schneider-electric.com Franck GRUFFAZ Schneider Electric - France franck.gruffaz@fr.schneider-electric.com This paper discusses the effects of various anomalous voltage conditions at an induction motor's terminals and the proper configuration ofmonitoring devices based on widely accepted standards.

ABSTRACT
The most common type ofmotor utilized today in industrial facilities is the poly-phase induction motor, which is used in a myriad ofapplications. In many instances, these motors are critical components in industrial processes; their reliability is essential to a facility's bottom line. Though generally robust, induction motors can prematurelyfail due to many factors. Permanently installed power monitoring devices provide a great deal ofinformation about a motor's operating parameters, and thus can be an indispensable piece ofpreventive maintenance equipment for industrial facilities. This article discusses standards and methods that can complement the work ofa power monitoring device to help mitigate these factors.

Voltage Deviations
Deviations above or below a motor's rated nameplate voltage produce will have a detrimental effect on induction motors. Figure I illustrates the effects of typical motor characteristics as a motor 's terminal voltage is increased or decreased from its rated voltage. [1]
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INTRODUCTION
The workhorses ofindustry, motors are critical components in industrial processes. The most prevalent poly-phase induction motor-the squirrel-cage induction motor-is used because of its low cost, reliability, and basic design. Although very robust, squirrel-cage induction motors can fail when operated outside of their design constraints. Although motor failures can have many causes, the most typical is not operating them according to their intended purpose and constraints. Misapplications of induction motors include: operating a motor in an inappropriate environment, using an improper lubricant, selecting an unsuitable motor for a specific application, and providing an inadequate electrical source input. Each of these misapplications causes excessive heat in a component ofthe motor-such as the bearings or motor windings-resulting in reduced operating life or even catastrophic failure. Although it is an important task, it can be difficult to recognize when a motor is not being operated as intended. By monitoring the electrical parameters at a motor 's terminals, end users have information that helps determine the motor's health. Because motors are essential to the productivity of industry, many standards have been written to address different aspects related to the proper design and operation of poly-phase motors. The standards provide design constraints for these motors, and thus give the enduser appropriate restrictions for the electrical power system's operational parameters as they relate to the motors.

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Figure 1. Effects of Voltage Variations on a Motor's Oneratlon.

One consequence of deviating from the rated voltage is an increase in the motor 's current. Operating outside a motor's required voltage range for prolonged periods generates heat in the motor's core. This can damage the motor's insulation. The starting current and starting torque are also affected as shown in Figure I. The torque at a given speed is proportional to the square of the applied voltage. Thus, if the stator's voltage decreases by 5%, the torque at every speed will decrease by approximately 10%. If the reduced torque is inadequate to drive the load, attempting to start an induction motor during low voltage conditions may cause the motor to stall. Figure 1 also illustrates how voltage deviations can affect such characteristics as the efficiency and power factor of the motor. Using a motor that is not intended for an application , or is not provided a suitable terminal voltage, will likely result in elevated temperatures, ultimately shortening the motor's life.

CIRED2009 Session 2

Paper No 0227

CI RED

20 th International Conference on Electricity Distribution

Prague, 8-11 June 2009 Paper 0227

NEMA MG-1 (Motors and Generators) and lEe 60034 -1 (Rotating Electrical Machines - Part 1: Rating and Performance) [2], [3] provide guidelines for the operating voltages at an induction motor's terminals. NEMA specifies a voltage range of 10% of a motor's nameplate rating, and the IEC specifies a voltage range of 5% of a motor's nameplate rating. In both cases, it is assumed that the electrical system is operating at the motor's rated frequency.
Most monitoring devices can detect and alarm upon voltage deviations. In some monitoring devices, it is possible to set up multiple alarms with a unique priority level for each alarm. The user can be notified by a lower priority alarm when a threshold is being approached and by a higher priority alarm when that threshold is exceeded.

operation of a single-phase protective device, such as a fuse. Voltage unbalance is the primary source of motor failure when single-phase protection is not incorporated. The damaging effects of voltage unbalance in three-phase induction motors arise from the resulting current unbalance, which increases at a much higher rate. Because the motor's impedance is kept relatively constant, increases in the current through the motor will generate additional heat due to the 12R losses. This can damage the motor's insulation, reducing the operating life of the motor. Both IEC 60034-1 and NEMA MG 1 prescribe voltage unbalance limitations for three-phase induction motors. IEC 60034-1 restricts a three-phase system's negative-sequence component to 1% ofthe positive-sequence component over a long period, or to 1.5% for a short period (not to exceed a few minutes). The zero-sequence component is also restricted to 1% of the positive-sequence component. NEMA MG 1 allows for a greater degree of voltage unbalance than IEC 60034-1, provided the motor is adequately derated. A motor's load should be reduced (the motor should be derated) when the voltage unbalance exceeds 1%. The maximum allowable motor derating by NEMA (without de-energizing the motor) is 25% for a voltage unbalance of 5%. Although the IEC and NEMA methods for calculating voltage unbalance are different, many metering devices are able to detect, log, and alarm on voltage unbalance using one or both standards and their respective prescribed limitations.

Frequency Deviation
Large interconnected power systems have considerable inertia, which helps stabilize the system frequency. This makes it difficult to perturb the frequency by any substantial amount. On the other hand, isolated power systems, such as those operated independently from the utility grid, can experience considerable swings during significant load fluctuations or fault conditions. A significant effect of frequency changes to induction motors is a subsequent change in the motor's speed: a 3% increase in the power system frequency results in a 3 % increase in a motor's speed. Motors rated at 60 Hertz will run approximately 17% slower on a 50 Hertz electrical system. Alternatively, motors rated at 50 Hertz will run 20% faster on a 60 Hertz electrical system. Both the IEC and NEMA standards provide frequency limitations for induction motors that include a voltage dynamic. Many monitoring devices can evaluate the voltages and frequency separately and notify the end user when the threshold is exceeded for either parameter. A few monitoring devices allow the end user to configure Boolean alarms so that the end user is notified only when specific combinations of the voltage and frequency thresholds are exceeded. Due consideration should be given to the voltage drop between the monitoring device and the motor when configuring the monitoring device's alarm thresholds

Waveform Distortion
Waveform distortion of the source voltage can generate additional heat in the windings of an induction motor, shortening the operating life of the motor. Waveform distortion is defined by IEEE 1159-1995 as "a steady-state deviation from an ideal sine wave of power frequency principally characterized by the spectral content of the deviation." [4] This definition encompasses several subcategories including harmonics, interharmonics, notching, de offset, and noise. Although each of these subcategories can contribute to elevated winding temperatures, this article will focus on harmonics. A harmonic is an integer multiple frequency of the fundamental frequency. Voltage harmonics produce additional eddy currents, hysteresis, and 12R losses due to the resulting harmonic currents. In a three-phase power system, there are three sets of symmetrical componentspositive, negative, and zero sequence-for both voltages and currents. The positive-sequence set is equal in magnitude and 1200 apart. The negative-sequence set is also equal in magnitude and 1200 apart; however, they are counter-rotational with respect to the positive-sequence components. The zero-sequence set is equal in both magnitude and phase. In a completely balanced (or

Voltage Unbalance
Not only should motors be operated within a narrow range around their rated voltage, each phase of a three-phase motor should also be of similar magnitude and 1200 apart from each other; in other words, they should be balanced. There are many opportunities to introduce voltage unbalance into an electrical system between the utility's generator and the end user's motor. The most harmful form ofvoltage unbalance occurs when one ofthe three phases is completely removed. This is typically caused by the

CIRED2009 Session 2

Paper No 0227

CI RED

20 th International Conference on Electricity Distribution

Prague, 8-11 June 2009 Paper 0227

symmetrical) three-phase system, the fundamental frequency is assumed to be a positive-sequence set (+), with all other sets being relative to it. Thus, the second harmonic would be a negative-sequence set (-), the third harmonic would be a zero-sequence (0). The sequential sets repeat for additional harmonics (i.e., the 4th harmonic is (+), the 5th harmonic is (-), and so forth). This is important because different harmonics affect an induction motor differently. Positive-sequence currents provide positive rotational torque in a motor because they rotate the same direction as the fundamental frequency, which is also positive sequence. Negative-sequence currents provide counter-rotational torque in an induction motor (with respect to the fundamental current), and they produce additional heating. Zero-sequence currents do not directly affect a motor's torque, but they can produce additional losses in a motor's core. Note: In an unbalanced three-phase system, this model is not valid because each sequential current can produce its own set of sequential voltage drops. To minimize the temperature rise in motors exposed to harmonic distortion, both NEMA and the IEC provide guidelines for derating a motor based on the harmonic content of its supply voltage. NEMA developed a derating curve that helps establish the extent by which a motor's rated horsepower should be reduced in the presence of harmonic distortion. This curve assumes that only odd harmonic components (excluding those divisible by three with respect to the fundamental frequency) exist at the motor's terminals. The equation that NEMA specifies to calculate the harmonic voltage factor is:

sequence component to 1% of the positive-sequence component over a long period, or to 1.5% for a short period (a few minutes). The zero-sequence component is also limited to 1% of the positive-sequence component. High-end monitoring systems provide a plethora of information about an electrical system's harmonic distortion. This can include total harmonic distortion of voltages and currents, individual harmonic component information, and, in some cases, harmonic power flows. System impedance plays an important role in determining the level of voltage distortion, so locating the monitoring device near the load in question is usually a good practice.

Voltage Sags and Swells

Voltage sags (lEC terminology is "voltage dip") are defined by IEEE as "an rms reduction in the ac voltage at the power frequency for durations from ~ cycle to a few seconds." [4] Typical values for voltage sags are 0.9 p.u. or less. Voltage swells are defined by IEEE as "an rms increase in the ac voltage at the power frequency for durations from ~ cycle to 1 minute with typical values of 1.1 p.u. to 1.8 p.u." [4] Although both voltage sags and swells can influence a motor's performance, voltage sags probably occur more often than any other type of event discussed in this paper. Voltage sags can affect a motor's operation both directly and indirectly. Voltage sags directly affect a motor by causing a decrease in their torque and speed. Once the fault is cleared, motors draw high reactive currents in an attempt to return their pre-event speed. The increase in reactive current prolongs the total duration ofthe voltage sag event. Mechanical and electrical stresses are produced in the motor due to the motor's interaction with both its load and the electrical system. Ultimately, many variables influence the effects of voltage sags on a motor, and, consequently, how the motor affects adjacent equipment during these events. Voltage sags indirectly affect a motor's operation and reliability through the motor's controls. Magnetic contactors, which open and close a motor's circuit, are susceptible to voltage sag events on the electrical system. Magnetic contactors use solenoid action (via a coil) to open and close a set of contacts, thus opening and closing the motor's circuit. As voltage decreases, the solenoid's magnetic field weakens, allowing the armature to move into the open position, separating the contacts. After voltage is restored, the solenoid's magnetic field pulls the armature back into the closed position, connecting the contacts. As voltage sags approach the limit of the solenoid's ability to keep the armature in place, the contacts may bounce, generating heat on the contacts' surface. The result is deformation and deterioration of the contacts, which may then fail to operate as designed. Rapid opening and closing of the contacts can damage the motor's controls (which consequently risks damaging the motor), but it can also generate transient events at the

HVF
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where n is the order of odd harmonic (not including those divisible by three) and Vn is the per-unit magnitude of the voltage at the nthharmonic frequency. After the HVF NE MA is calculated, the referenced NEMA derating curve is used to determine the percentage by which the motor load should be reduced. The IEC uses a slightly different formula to compute the allowable harmonic distortion values at an induction motor:

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where Un is the ratio ofthe harmonic voltage U, to the rated voltage UN, n is the order of the harmonic (not divisible by three in the case of three-phase a.c. motors), and k is 13. The IEC limits the HVF IEC of most induction motors to 0.02. Further IEC restrictions include limiting the negative-

CIRED2009 Session 2

Paper No 0227

CI RED

20 th International Conference on Electricity Distribution

Prague, 8-11 June 2009 Paper 0227

motor's terminals. As the contacts open, the motor begins to decrease its speed while still retaining its magnetic field. If the contacts are reclosed quickly (as is the case during contact bouncing), the motor's magnetic field may be out of phase with the source voltage. High voltages may develop due to this phase difference, potentially damaging the windings of the motor. To increase a motor's longevity, it is important to minimize voltage sag and voltage swell events. Both the IEC and NEMA rate contactors, albeit with different objectives. IEC contactors are smaller per motor horsepower rating than NEMA contactors. The smaller contactor rating by IEC provides a less expensive contactor for the application; however, the operational life of the IEC contactor can be shorter. Applying IEC contactors requires a greater knowledge of the specific application, while NEMA contactors may be sized with fewer considerations. In the end, both types of contactors serve a useful function, as long as their difference is understood by the end user. Monitoring thresholds for voltage sags are similar to those for overvoltage and undervoltage conditions. Monitoring devices must sample the voltage and current waveforms at a fast enough rate to ensure that all relevant information is captured. Information that is useful in determining the presence of contact bouncing may include: the event's magnitude, its respective duration, and any associated high frequency components.

Metering devices typically use one of two techniques to detect transient overvoltages. The first method, peak detection, can provide the user with information related to a transient overvoltage time of occurrence, magnitude, and duration. The peak detection method is less expensive, but it does not provide a waveform capture of the event. Waveform captures are useful in troubleshooting the source of a transient overvoltage event. The second method is achieved using a high-speed digital-sampling AID converter. Although high-speed AID converters are more expensive, they can perform waveform captures oftransient overvoltage events. Transient overvoltage events have a tendency to attenuate quickly in electrical power systems due to the inductive nature of the system. Therefore, it is advantageous to place the metering device close to a motor's terminals for a more precise measurement of the effects of a transient overvoltage event on the motor. IEC Standard 60034-15 also provides some useful information for monitoring overvoltage transients in larger motors.

CONCLUSIONS
International standards provide useful guidelines that will help you achieve a long and productive life for your induction motor. A key component in ensuring that an induction motor operates within a standard's recommended guidelines is a properly configured power monitoring device. When configured properly, a power monitoring device can alert the end user to anomalous electrical system parameters at the motor, ultimately reducing the motor's vulnerability to damage or inefficient operation.

Overvoltage Transients
IEC Standard 61000-2-4 (2002) [6] defines a transient overvoltage as an oscillatory or non-oscillatory overvoltage, highly damped and up to a few ms in duration with a rise time from less than 1usee to a few msec. These transient overvoltages can originate inside a facility or on the utility's grid, and can propagate through various levels of electrical and data systems. Sources of destructive transient overvoltage events can range from the obvious-such as a lightning stroke strike during a thunderstorm, to the subtle-such as the electrostatic discharge from a human finger. Transient overvoltages that exceed insulation ratings can stress a motor's insulation, leading to a gradual or even abrupt breakdown ofthe dielectric. Industrial facilities may experience many transient overvoltage events every hour, with voltage impulses exceeding 10 times the nominal system voltage. For obvious reasons, reducing the magnitude and duration of voltage transient overvoltage events can extend the life of motor insulation. Because the inductance of a motor is a natural low-pass filter for the high frequency components associated with transient overvoltage events, the first turn or two of a motor's stator windings absorb the brunt of the transient's energy.

REFERENCES
[1] Bickel, Jon, June 2006, "Monitoring Induction Motors to Drive Power Quality" Plant Engineering Magazine, 47-51. [2] ANSI/NEMA Standard MG-I-2003, Revision 12004, "Motors and Generators," Revision 1. [3] IEC Standard 60034-1, 2004,"Rotating Electrical Machines - Part 1: Rating and Performance." [4] IEEE Standard 1159, 1995, "IEEE Recommended Practice for Monitoring Electric Power Quality." [5] IEC Standard 60034-15, 1995, "Rotating Electrical Machines - Part 15: Impulse Voltage Withstand Levels of Rotating A.C. Machines with Form-Wound Coils." [6] IEC Standard 61000-2-4, 2002, "Electromagnetic Compatibility Part 2-4: Environment - Compatibility levels for low-frequency conducted disturbances."

CIRED2009 Session 2

Paper No 0227