Motor Analysis

Motor Analysis Techniques
Reliability Based Maintenance

Multiple Motor Analysis Techniques
 Rotor Bar Analysis

 Stator Analysis
 Voltage Imbalance
 Shaft Voltage/Current Measurement
 Temperature

Rotor Bar Analysis
 Can be performed by two methods:
1) Current Measurement
2) Flux Measurement

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

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

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

Let’s look at an example
450 HP forced draft fan motor

35 dB down shows broken rotor bars
MTR - Forced Draft w/ Broken Bars
450 HP MTR-FC1 FLUX COIL OUTBOARD END
70
Spectrum Display
27-SEP-91 09:04
60
AMPL = .0027
50 LOAD = 71%
dB AMPS
40
30
20 RPM = 711.
RPS = 11.85
10
0
Freq: 66.04
50 52 54 56 58 60 62 64 66 68 70
Ordr: 5.575
Frequency in Hz Spec: -9.142

Label: MOTOR WITH 4 BROKEN ROTOR BARS
MotorView ll Diagnosed Data

Repaired Rotor Bars on Same Machine
450 HP MTR-FC1 FLUX COIL OUTBOARD END
70
Spectrum Display
01-DEC-92 15:11
60
AMPL = .0016
50 LOAD = 65%
dB AMPS
40
side bands
30
20 RPM = 712.
RPS = 11.86
10
50 52 54 56 58 60 62 64 66 68 70
Frequency in Hz
Label: MOTOR WITH BROKEN BARS REPAIRED

Bad Rotor Bars On Same Machine
450 HP MTR-RB1 Current Rotor Bar Analysis Ph=1
70
Spectrum Display
07-DEC-90 09:25
60
AMPS = 43.32
50 LOAD = 65%
dB AMPS
40
30
20 RPM = 711.
RPS = 11.85
10
50 52 54 56 58 60 62 64 66 68 70
Frequency in Hz
Label: MOTOR WITH 4 BROKEN ROTOR BARS

Good Rotor Bars on Same Machine
450 HP MTR-RB1 Current Rotor Bar Analysis Ph=1
70
Spectrum Display
01-DEC-92 12:47
60
AMPS = 38.91
50 LOAD = 59%
dB AMPS
40
30
20 RPM = 712.
RPS = 11.87
10
50 52 54 56 58 60 62 64 66 68 70
Frequency in Hz
Label: MOTOR WITH BROKEN BARS REPAIRED

FLUX
 Use 343 Flux Coil
 Mount 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

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

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

Using Flux to Analyze Motor Problems

Flux Analysis for Stator Faults
 Baseline flux reading mandatory
 Two Measurements required:
 1) Low: Trend LF with sidebands of RPS.
 2) High: Trend slot pass family
Slot Pass Frequency with sidebands of
2xLF
 All readings from the same location
 Watch for change from baseline.

Empirical Test of Flux

Empirical Test
 150 HP Motor
 Wound To Allow
Three Levels Of Turn
to Turn Shorts

Baseline Flux Reading
ac - motor w/ fixed stator faults
stator prb-FC2 FLUX COIL/CENTER/AXIAL/HIGH FREQ
90
Spectrum Display
04-JUN-97 09:24
80
AMPL = 3.4593
70
dB FLUX-AU
LOAD = 102%
60
50
40 RPM = 1185.
RPS = 19.75
30
20
Freq: 1757.8
0 600 1200 1800 2400 3000
Ordr: 89.02
Frequency in Hz Spec: 63.78
Label: no stator fault Dfrq: 120.00
Looking for significant change in 120 Hz side band of PSP

Readings Repeated Under Different Loads
No significant change in values noted
Reliability Based Maintenance 50% Load 85% Load

Test Measurement #1
Induced Small Short in Stator

Surge Test Results

Small Stator Short
Flux Reading with Small Short
80
Spectrum Display
03-JUN-97 18:44
70
AMPL = 9.3242
60 LOAD = 100%
dB FLUX-AU
50
40
30 RPM = 1185.
RPS = 19.75
20
10
Freq: 1758.8
0 600 1200 1800 2400 3000
Ordr: 89.03
Label: stator fault coils A to B Dfrq: 120.00
Increase in Sideband Values

or prb-FC2 FLUX COIL/CENTER/AXI
Flux Reading - Change from Baseline
2xLF
Slot Pass
increase decrease
in flux in flux -4xLF
-2xLF 8xLF
4xLF
6xLF 10xLF
-10xLF -6xLF
-8xLF
1200
1200 1800
1800 24
24
Frequency
Frequency in Hz
in Hz
3 Times Increase In Flux Data

Test Measurement #2
Induced Medium Short in Stator

Surge Test Results
Close Up
Small
Medium Stator Short

Flux Reading with Medium Short
90
Spectrum Display
80 04-JUN-97 08:24
Sizeable Increase in Sideband ValuesAMPL = 4.8288

70
LOAD = 98%
dB FLUX-AU
60
50
40
RPM = 1186.
30
RPS = 19.76
20
10
Freq: 1519.7
0 600 1200 1800 2400 3000
Ordr: 76.91
Label: stator fault coils B to C Dfrq: 120.00

or prb-FC2 FLUX COIL/CENTER/AXI
2xLF
Slot Pass
increase decrease
-4xLF 4xLF
8xLF
-6xLF 6xLF
-10xLF
-8xLF 10xLF
1200 1800 24
1200 1800 24
Frequency in Hz
R
ault B
eliability M
ased B
coils
Frequency in Hz
aintenance
to C
Flux Shows 5 Times Increase Over Baseline

Test Measurement #3
Induced Severe Short in Stator

Surge Test Results
Small
Medium
Severe Stator Short
Close Up

Flux Reading With Severe Short
70
Spectrum Display
04-JUN-97 14:14
60
Significant Increase in Sideband Value AMPL = 53.26

50
dB FLUX-AU
LOAD = 96%
40
30
20 RPM = 1186.
RPS = 19.77
10
0
Freq: 1759.7
0 600 1200 1800 2400 3000
Ordr: 89.02
Label: stator fault/severe coils C to D Dfrq: 120.00

r prb-FC2 FLUX COIL/CENTER/AXIA
2xLF
Slot Pass
increase decrease
-4xLF 4xLF
6xLF8xLF
-6xLF
-10xLF 10xLF
-8xLF
1200
1200 1800
1800 240
240
Frequency in Hz
Frequency in Hz
R eliability B ased M aintenance
eliability ased
ult/severe aintenance
coils C to D
14 X Increase Shown Here

Trend of 2xLF Sideband of Slot Pass
25
23.5
Ratio to Baseline 20
15
10
8.1
5 4.3
0 1.1
rt
t
t
or
Sm ort
or
ho
Sh
Sh
Sh
lS
re
al
m
o
N
ve
iu
ed
Se
M

Conclusion: Flux Vs. Surge Test
 Flux measurement:
 safer
 non-intrusive
 provides earliest indication of faults
 trendable

Voltage Imbalance

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.

Trend of Voltage Unbalance
Motor Frequency Measurement
Amplitude (dB)
Stator in Good Condition
35
LF
30
25 LF + 1 x RPM
20 LF - I x RPM
15
LF + 2 x RPM
10
5
0 % Unbalance
Shaft Current/Voltage Measurement

Shaft Current and Voltage
 Faulty Rotor Isolation
 Current travels through bearing to ground

causing bearing damage
 Measure current
and voltage
present on shaft

Measure Directly on Shaft

Shaft Measurement Technology

Frosted Bearing from EDM

Fluted Bearing from EDM

Fluting with Spalling

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

MotorSTATUS
Goals
 Maximize the motor life cycle
 Identify the operational and environmental factors that
reduce the life of the motor
 Reduce unscheduled downtime by alerting users of
degrading mechanical and electrical conditions
 Optimize motor utilization

The Motor Status System
Monitoring Data Collection Software

 Incorporates three different technologies (flux, vibration,
temperature) in order to give early warning of
mechanical or electrical degradation.
 Uses load, start, and temperature information to warn of
operational and environmental factors which will shorten
the life of the motor.
Features
INFRARED FLASHING
COMMUNICATION PORT ALARM LED
Features (2) ‘D’ SIZE

ALKALINE
BATTERIES
‘Smart Sensor’ Array
Rugged Molded Enclosure
LED Alarm Indicator AMBIENT
TEMPERATURE
Self-contained SENSOR
VIBRATION
Data Acquisition & Storage SENSOR
OPTIONAL
RTD
RS- 485
POWER
ENVIRONMENTAL FRAME FLUX

TEMPERATURE COIL
-20C to 80C (alkaline batteries) SENSOR
MOUNTS W/
3/8” STUD SENSOR
-20C to 100C (line powered or lithium batteries)
Resistant to static and electrical discharge (machine must be grounded)
Watertight enclosure
Intrinsically safe rating (future)

Smart Sensor Measurements
Operational
starts
load
run time
Temperature
frame
ambient
motor heating
Electrical
flux
Mechanical
vibration
Historical
lubrication
maintenance log

Mounting Configuration
Mounting Configuration
One MotorSTATUS unit per motor.
Mount mid-motor on side near electrical J-box.
Temporary mounting in eyebolt hole is acceptable.
A prepared plate attached with an epoxy is preferred.
MotorSTATUS
Operational measurements are not location TERMINAL BOX ENCLOSURE
dependent.
Trend parameter and temperature measurements may
be enhanced or hindered depending on location.
PERMANENT MOUNT

STATUSReport Software
Information management and reporting software

for ‘smart sensor’
condition monitoring
Provides:
• Data Management
• Alarm / Report Summaries
• Trend / Spectrum Analysis
Stand-alone System
CSI RBMWare 4.0 software
Windows 95 or NT PC’s

Pulper Pump Case History
Data was acquired over a 2 month period. Load,

vibration, and temperature problems occurred during
the monitoring period. Status acquisition was set at
“monthly trend.”
Load was spiking due to a process problem,

which was corrected on 11/4/97.

 Motor fan clogged with pulp.

 Motor heating (frame-ambient) increased by 11oC.
 Motor was cleaned 11/19/97.

 Vibration problem was fixed 11/7/97.

 Corrected alignment, greased coupling, repacked
pump.
 Spikes after correction are believed to be cavitation
by the analyst.
Approvals and Ratings
- Rating acquired 8/5/98.
- Rating acquired 9/2/98.
IS - In progress at CSA. Anticipated Q1-99.
FM - Paperwork will be sent from CSA.

Anticipated Q2-99.

Motor Analysis
Conclusion
Back to the
RBM TOOLBOX

Motor Analysis

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Motor Analysis Techniques

Reliability Based Maintenance

 Rotor Bar Analysis

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

450 HP forced draft fan motor

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Looking for significant change in 120 Hz side band of PSP

No significant change in values noted

Reliability Based Maintenance 50% Load 85% Load

Induced Small Short in Stator

Reliability Based Maintenance

Reliability Based Maintenance

Increase in Sideband Values

Flux Reading - Change from Baseline

Reliability Based Maintenance

Induced Medium Short in Stator

Reliability Based Maintenance

Reliability Based Maintenance

Sizeable Increase in Sideband ValuesAMPL = 4.8288

Reliability Based Maintenance

Reliability Based Maintenance

Induced Severe Short in Stator

Reliability Based Maintenance

Severe Stator Short

Reliability Based Maintenance

Significant Increase in Sideband Value AMPL = 53.26

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

 Must take baseline flux reading. All trending flux

Reliability Based Maintenance

Reliability Based Maintenance

 Current travels through bearing to ground

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Reliability Based Maintenance

Monitoring Data Collection Software

Features (2) ‘D’ SIZE

ENVIRONMENTAL FRAME FLUX

Reliability Based Maintenance