CSI Motor Overview With MotorView

Motor Theory &
Analysis
What is a Motor?
 A motor is a device that converts electrical
energy into mechanical energy
 A motor is a torque producing device
©2005, Emerson Process Management. 1

Principles of Magnetism
 Objects with dissimilar

polarities attract.
 Objects with similar
polarities repel.
 Lines of force are
concentrated at the
poles, either North or
South.
©2005, Emerson Process Management.

Magnets
 This is a device that demonstrates how
magnetic fields can transmit mechanical
torque without making contact. A change in
cranking speed would produce a change in
output speed.

Electromagnets
 Electromagnets are the same as permanent

magnets, except they only have magnetic
properties when electrical power is applied to
the coil.

Sine Wave
SINE WAVE OF SINGLE PHASE ALTERNATING
CURRENT
PEAK
PEAK
ONE CYCLE
0° 90° 180° 270° 360°

Induction Motors
 The induction motor is so named for the induced
current flowing in the secondary winding (the rotor)
by action of the primary winding. No direct
electrical connection is made; it is a result of the
magnetic field being established by the stator
winding.
 The principle purpose of the stator winding is to
establish a rotating magnetic field in the stator core
that will induce a voltage in the rotor core.
 The rotor “becomes” a magnet, with a North and
South pole, which in turn follows the moving
magnetic fields in the stator.

Electric Motor Development
1800 Volta Battery
1820 Oersted Magnetic field surrounds a conductor
1821 Faraday Electricity produces a magnetic field
and motion
1825 Sturgeon Electromagnet
1837 Davenport First patent on electric motor
1839 Dejacobi Electric motor propels a small boat
1879 Bailey First describes a rotating field in a
stationary stator
1882 Edison Pear Street Station - DC
1887 Tesla Invention of induction motor
1890 Generating stations - AC
1891 1st important polyphase induction motor
20 HP, nearly 5 feet high

Motor
Terminology
PARTS & FUNCTIONS
MOTOR TERMINOLOGY
 Rotor
 Stator
 End brackets
 Centrifugal actuator
 Stationary switch
 Capacitor

ROTOR
The rotating part of the motor which normally
includes the shaft.

STATOR
The stationary portion of the motor that includes the
stacked steel laminations, associated windings,
and leads. It can include a frame or shell,
winding supports, and temperature detectors.

Windings
 Comprised of turns of
copper wire that form a
coil.
 The coils are placed in the
slots of the core and
separated from one
another and the core by
insulation.
 The coils are then
connected to form a
phase.

3 Phase, 4 Pole Winding Diagram

The Revolving Field
 Three independent currents flow in a three
phase induction motor.
 The currents are displaced from each other
by exactly 120 electrical degrees.

END SHIELDS
A shield secured to the frame or shell to protect
the windings and to support the bearing. Also
called end bell or bracket or end frames.

BEARINGS
There are two types of bearings in general use in fractional horsepower
motors.
A ball bearing is used in motors subject to high thrust or axial loads.

Ball bearings cannot be relubricated. The normal lubricant is grease.
Farm duty motors use a grease with low-temperature properties
because most of the motors are subject to extreme low ambient
temperature.
A sleeve bearing is used in motors subject to moderate thrust or axial

loads. This includes many of the applications we are familiar with.
Sleeve bearings are considered less noisy, but with the quantity of
today’s ball bearings, the noise difference in most applications is
minimal. Sleeve bearings can usually be relubricated.

CENTRIFUGAL ACTUATOR
An actuator is a centrifugal device mounted on
the rotor which opens as the RPM increases.
The actuator works with the starting switch. As
the actuator opens, the sleeve of the actuator,
which touches a movable arm, allows the
movable arm to open the starting switch
contacts.

STARTING SWITCH (STATIONARY)
A device mounted either on the end shield or stator
assembly with contact points and a movable arm.

Motor Construction
WINDINGS STATOR ROTOR
CORE
END SHIELD
STATIONARY
SWITCH
SHAFT
CENTRIFIGAL
ACTUATOR BALL BEARING
ENCLOSURE RIGID BASE

Theory of Operation
 The conversion of electrical energy into
mechanical energy takes place in the rotor. The
conversion of power is transferred across the air
gap inductively. The relative motion between the
revolving field and the rotor causes the rotor bars
to be cut by the lines of flux. This generates a
rotor voltage causing current to flow in the rotor.
The rotor then rotates due to the developed
torque. The difference between the revolving field
and the rotor speed is called slip.

Theory of Operation

Why Motors?
 Workhorse of Industry
 Single most important capital asset - 10 to 20%
 Breakdowns impact production and increase
costs
 High cost to repair, replace, and maintain spares

Types of Motor Failures
 Mechanical Failures - primarily consists of
bearing failure or are the direct result of a bearing
problem
 Insulation Failures - approximately 20% of all
failures are usually a result of overload or phase
imbalance

Costs of Repair
 A 460v, 1800 rpm, 200 hp Motor costs $2725, on
national average, to rewind.
 Adding new bearings and balancing to the repair
brings the cost up to $3500.
 The largest cost is seen in downtime. Average
time for this type of repair is 40 hours which
converts to about 3 or 4 days of downtime.

Cost of New Motors
 A new 460v, 1800 rpm, 200 hp Motor lists for
$14,501.
 The life expectancy of a new 200 hp motor
running 10 hours a day in a relatively clean
environment is 7 years without repair.
 A large number of motor repair believe the life
expectancy of a new motor to be more on the
order of 5 years under actual plant conditions.

Factors Detrimental to Motor Life
 Temperature - a 10C rise in motor heating
reduces the life of the insulation by 50% (NEMA
Standard).
 Overload - causes temperature in the motor to
increase which in turn decreases the life of the
motor.
 Phase Imbalance - also causes insulation life to
decrease due to high temperatures.
 Starts - excessive hot starts shorten the life of the
motor.

Maintenance
Strategies
Types of Maintenance Strategies
 Run to failure
 Preventive maintenance
 Predictive maintenance
 Proactive Maintenance

Run to Failure
 Results in:
– Catastrophic machine damage
– Unscheduled maintenance
– Lost production revenue

Preventive Maintenance
 Better than “Run to failure”
 Results in:
– Excessive scheduled downtime
– Unnecessary maintenance
– Failures due to improper maintenance

Predictive Maintenance
 Maximizes motor life through abnormal operation
and fault detection.
 Reduces unscheduled downtime by alerting
users of degrading mechanical/electrical
conditions.
 Optimizes motor utilization.

Predictive Maintenance Methods
 Route based methods
– Vibration
– Tribology
– Shaft Current/Voltage
– Electric Current Analysis
– Temperature
– Flux
– Ultrasonics
– Infrared Thermography
– Wireless

Predictive Maintenance Methods
 Continuous (on-line) monitoring
 Off-line testing
– Motor circuit parameter testing
– Surge testing

Proactive Maintenance
 Identify repeat failures
 Determine root causes for these failures
 Correct root cause to eliminate future failures for
the same reason

Introduction to Vibration Objectives
 Define Vibration
– What is it, where does it come from?
 Describe measurement methods
 Discuss time and frequency
– Relationships between the two
 Examine amplitude measurements
– Differences between the three
 Choose proper transducer
– Right probe for the application

Introduction to Vibration
 Vibration :
– Movement of a body about a reference.
• Response to some form of excitation
• Forcing function

Amplitude
 3 ways to display  Velocity
– All three show severity – Measures the speed
– Some better than others – Time from point “A” to point
“B”
 Displacement
– rate of displacement
– Distance a body moves
– Point “A” to point “B”
 Acceleration
– Total force acting
– Change of direction

Sources of Vibration
 Imbalance  Looseness
 Misalignment  Electrical Anomalies
 Belts  Oil Instability
 Gears  Resonance
 Bearings
– Rolling Element
– Sleeve

Choose units for optimum data display
V
A
D
(D) isplacement Mils Peak-to-Peak

(V) elocity In/Sec Peak
(A) cceleration G’s RMS
Vibration Terms
 Phase
– relationship between two events relative to a reference
 Amplitude
– measurement of energy of a vibrating object
 Displacement
– distance a body travels
– units of mils (pk. to pk.)
 Velocity
– rate at which displacement occurs
– units of inches per second in/sec (pk.) or mm/sec RMS
 Acceleration
– rate of change of velocity
– units of G’s (RMS)

Vibration Terms, cont’d
 Frequency
– how often an event occurs per unit time
 Units
– CPS
• cycles per second ( Hz)
– CPM
• cycles per minute
– RPM
• revolutions per minute
– Orders
• multiples of Turning Speed

Measurement Parameters
2 Domains : TIME and FREQUENCY
FFT

Time domain data
 Helpful :
– Calculating frequencies
– Detect faults not frequency domain
– Confirm / deny suspected anomalies

Vibration – Overall Trend

Vibration – 1 x RPM
OCT
SEP
AUG
JUL

Vibration – High Frequency

Vibration – Bearing Frequencies
 High frequency peaks
– Usually non-synchronous peaks (with sidebands)

Vibration – Time Waveform
 Waveform useful for diagnosing bearing faults
– Impacts show as spikes

Vibration – Bearing in FFT
 Bearing faults generate peaks at specific
frequencies

An effective program...
 Choosing the transducer
– the right one for the best
data
 Signal processing
– time waveform or spectrum
 Problem detection
– examine both sets of data
– is there a problem?
 Diagnosis
– what is the source ?
– Root Cause

Transducers
 Function
– Convert mechanical signal to electrical
 Three basic types
– Displacement transducer
– Velocity transducer
– Accelerometer

Displacement Transducers
 Advantages +
– Measures relative movement
– good for sleeve brg. machines
– very good for heavy machines
 Disadvantages -
– permanently installed
– frequency response : DC to 1KHz
– power required

Displacement probes act much like a transformer.
Velocity Transducer
Connection
Case
Conductor Coil
Spring
Magnet
Damper

Velocity Transducer
 Advantages +  Disadvantages -
– best signal to severity ratio – usually big
– good signal to noise ratio – heavy
– no power required – freq. 10 to 2Kz
– single dif. / int. needed – temperature sensitive
– usually pretty hardy – comparatively expensive
– magnetic field sensitive
– orientation sensitive
– wear and temp. changes
calibration

Accelerometers

Accelerometers
 Advantages
– broad frequency range
– small, light, rugged
– ICP needs no signal conditioning
– easy to mount
 Disadvantages
– poor as a hand held
– limited signal to noise ratio
– reads acceleration
– power required
– double integration needed

Frequency Signature
Frequency signal is an X,Y plot. X represents the
frequency, Y represents the amplitude or magnitude of
the signal. The data is divided into 3 categories :
 Synchronous
– NxRPM where N is an integer (phase locked)
 Subsynchronous
– <1 x RPM
 Non-synchronous
– F x RPM where F is >1x RPM but not integer

Causes - Subsynchronous
 Another component in the machine
 Another machine
 Belt drives
 Hydraulic instability
– Oil whirl, oil whip
 Rubs
– rotor, shaft, wheel
 Cage
– fundamental train - rolling element brgs.

Causes - Synchronous
 Imbalance
 Pitch line run-out
 Misalignment
 Bent shaft
 Looseness
 Blade / vane pass
 Reciprocals
 Gears
 Slot / Rotor Bar pass

Causes - Nonsynchronous
 Another machine  Compressor surge
 Belt multiples  Detonation
 Bearings  Sliding surfaces
 Resonances  Lube pumps
 Electrical  Centrifugal clutches
 Chains  U-joints

Problem Detection: Difficult, but not
impossible!
 General layout  Belt data
– shaft diameters – Center to center
– bearings – Pitch diameters
 Operating frequencies – No. of belts
 Motor slip, slots, bars, etc  Gear info
– Train layout
 No. of blades, buckets,
etc – Types of gears
– No. of teeth / gear
 Coupling info

Reminders
 Consistency
 Directional faults  Look around
 2 radial, 1 axial  Cared for?
 Probe location  Foundation
 Structural integrity
 Probe orientation
 Weldments
 No fan covers  Leaks
 No sheet metal  Instrumentation
 Transmission path – pressure, temp, flow...

Reminders
 Talk to the machine  Alignment
 Talk to the operator – when
– last thing done – how
– shaft – who
– couplings, belts….  Work vibe related?
 History  Real problem?
 General Info  What is it?
– bearings, clearances,  How bad?
changed, etc
 Maintenance?

Motor Analysis
Techniques
Multiple Motor Analysis Techniques
 Rotor Bar Analysis

 Stator Analysis
 Temperature

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

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

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.

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
AMS SuiteTM
TM: Machinery HealthTM
TM Manager
MotorView II 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
30
side bands
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
Flux Monitoring
Monitoring
 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

FLUX
FLUX Notes
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
Flux Analysis
Analysis for
for Stator
Stator Faults
Faults
 Baseline flux reading mandatory

 Two Measurements required:
1) Low: Trend LF with sidebands of RPS.
2) High: Trend slot pass family
Slot Pass Freq. 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
dB FLUX-AU
70 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)
50%
Load 85% Load
Test Measurement #1
Induced Small Short in Stator
Surge Test Results
Close Up
Small Stator Short

Flux Reading with Small Short ac - motor w/ fixed stator faults
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

C2 FLUX COIL/CENTER/AXIAL/HIGH FREQ
Flux Reading - Change from Baseline

Slot Pass
2xLF
increase decrease
in flux in flux -4xLF
-2xLF 8xLF
4xLF
6xLF 10xLF
-10xLF -6xLF
-8xLF
1200
1200 1800
1800 2400
2400
We see 4.3 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
70 AMPL = 4.8288
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
Sizeable Increase in Sideband Values

c - motor w/ fixed stator faults
C2 Flux Reading - Change from Baseline
FLUX COIL/CENTER/AXIAL/HIGH FREQ
2xLF
Slot Pass
increase decrease
in flux in flux -2xLF
-4xLF 4xLF
-6xLF 6xLF8xLF
-10xLF
-8xLF 10xLF
1200 1800 2400

1200 1800 2400
Frequency in Hz
Frequency in Hz
Flux showed 8 times increase over baseline
Test Measurement #3
Induced Severe Short in Stator
Surge Test Results
Close Up
Small
Medium
Severe Stator Short

Flux Reading with Severe Short
70
Spectrum Display
04-JUN-97 14:14
60
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
Significant Increase in Sideband Value

2 FLUX COIL/CENTER/AXIAL/HIGH FREQ
Flux Reading - Change from Baseline
2xLF
Slot Pass
increase decrease -2xLF

in flux in flux -4xLF 4xLF
8xLF
6xLF
-6xLF 10xLF
-10xLF
-8xLF
1200
1200 1800
1800 2400
2400
Frequency in Hz
Frequency in Hz
D
23 X increase shown here
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
Conclusion: Flux vs. Surge Test
 Flux measurement:
• safer
• non-intrusive
• provides earliest indication of faults
• trendable

CSI Motor Overview With MotorView

Uploaded by

Copyright:

Available Formats

You might also like

CSI Motor Overview With MotorView

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

CSI Motor Overview With MotorView

Uploaded by

Copyright:

Available Formats

Motor Theory &

©2005, Emerson Process Management. 1

 Objects with dissimilar

©2005, Emerson Process Management.

©2005, Emerson Process Management. 2

 Electromagnets are the same as permanent

©2005, Emerson Process Management. 3

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

A ball bearing is used in motors subject to high thrust or axial loads.

A sleeve bearing is used in motors subject to moderate thrust or axial

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

ENCLOSURE RIGID BASE

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

(D) isplacement Mils Peak-to-Peak

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.

©2005, Emerson Process Management.