IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL 3. NO, SEPTEMBERIOCTOBER 1985, A Survey of Faults on Induction Motors in Offshore Oil Industry, Petrochemical Industry, Gas Terminals, and Oil Refineries Olav Vaag Thorsen, Senior Member, IEEE, and Magnus Dalva, Member, IEEE Absiract—This report presents a survey of the reliability of squirrel cage motors on board drilling, production, and other platforms offshore, together with cage motors in’ the petro- chemical 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, electrical protection, maintenance, and so on, and further analyzes failure-initiators, Contributors, and underlying causes. Comparisons between this survey and a survey from the IEEE Motor Reliability Working Group [8] have been done. The report also pays some attention to methods for monitoring of machinery and detecting of faults. 1. InRopucTION |HE il industries 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 «de motors in large drilling and injection drives. There is also @ substantial amount of smaller and medium-size 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 60 stationary platforms for drilling, production, storing, pumping, and quartering. ‘Water injection has been more and more important, together ‘with reinjection of gas to the bore holes, to increase the output of crude oil ‘The first platforms were commissioned early in the 1970's, and platforms are continually being constructed. About 25% of the platforms (the biggest) have a concrete base, 75% have a steel jacket. ‘The power consumption on a (big) platform may typically be as follows in Table I. The majority of the power comes from ‘gas turbines via 60-Hz, three-phase synchronous generators. However, there are also diesel aggregates, especially for ‘emergencies. In recent years, hydroelectric power by de or Paper PID 95-01, approved by the Petoeum and Chemical Industry Commitee of te IEEE Indartry Applications Society for presentation st the, 1904 IEEE Petroleum and Chemical Industry Technical Confrence (CIC "34, Vancouver, Canada, September 12-14, Manuscript seleased for publication May 1, 1995, (0. V. Thorson swith Bergen College, SOD8 Bergen, Norway M, Dala is vith Stvangor College, 4020 Stavanger, Norway. TEBE Log Number 9413179 TABLE | ExasrLe oF Powe Consort oN A PLATFORM ‘Comaner pet ever emmaapon O4W) Wer econ 2 ws “Tramporatin 2 on Reisen of oa 2 Dring alaty fue pute pwr) | 3 w 3 eae of ot ses eat nd we 363 oeeeey os ws tac from shore has been considered. This is mainly an effort to reduce the outlet of carbon dioxide, and the 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 tha, in general, in Europe, 50 Hz is adopted, except for ships and platforms where 60 Hz is more common, Now SO 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, 52-kV hydroelectric power from shore by a 67-km ac cable. The Troll is a gigantic ‘concrete gravity base structure used mainly for gas production, drilling, and quartering. It was towed to its site northwest off Bergen in May 1995. ‘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 a few kilowatts for the smallest and less complex installations, to nearly a hundred megawatts for the biggest. The generator voltages vary from 440 V-13.8 kV, and the consumers’ voltages from 230 V (mainly small consumers) to 13.8 kV (mainly motors). For gas compression converter fed syn- chronous motors, up t0 as much as 15 MW are applied. However, as rule of thumb, drives of more than 8 MW utilize ‘gas turbines. For drilling (rotary tables, winches, mud pumps etc.) motors of some hundreds of kilowatts each are applied, and so far, mostly thyristor fed de motors. However, more and more converter fed cage motors probably will be preferred. (ne -oHSS04.00 © 1995 TERE[THORSEN AND BALVA: A SURVEY OF FAULTS ON INDUCTION MOTORS. ExaMrurs oF None oF Cac MoroRs ts FoR TYRES OF PLANTS te _| tr | oor | tr _| fo | (i _| feo» | fen | i | | ee ec ft | tm Jitter | Yee | ay ne TABLE it owen Versus NeMMR OF Morons use | | ior | ae | oe | 0 too | 200 | ‘so | ico | “ten om {ov | ow] vn | ow Pacer sim [os [nize [eee [a3 [aos Petrochemical industries, refineries and gas terminals on. shore are supplied with 50-Hz electric hydropower from the normal grid, Table II shows examples of the number of squirrel sage 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 ID. ‘The various faults on motors are grouped as follows: 1) bearings; 2) stator windings; 3) rotor bars and end rings; 4) shaft or couplings; 5) external devices. Fault detection is based on more methods. The main groups are mechanical, like vibrations, shock pulses, acoustic, speed fluctuations, and electromechanical, like currents, surges, par tial discharges, and leakage fluxes. In addition are temperature, oil particle, gas analysis and performance, and visual methods. However, a motor represents a complex electromagnetic system, and hence the faults and fault reasons, are also. so involved that a reliable fault detection must be based on more ‘methods, 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 and degree of monitoring, Normally, fone will particularly monitor 1) original condition, that equipment is correctly installed and aligned; 2) after extensive maintenance or repair; 3) fatigue that may lead 10 cracks; 4) corrosion; 5) (normal) operation. Common methods for condition monitoring are (21, (3) 1) performance monitoring: 2) vibration monitoring: ue 3) current analysis; 4) surge test winding diagnosis: direct current high- potential testing and high-frequency surge testing: 5) temperature monitoring: 6) leakage flux (end winding leakage flux and axial ux) ‘monitoring; 17) speed fluctuation monitoring; 8) oll particle analysis, 9) gas analysis; 10) partial discharge analysis; 11) SPM (Shock Pulse Measurement), mainly for rolling clement bearings; 12) acoustic emission monitoring; 13) visual monitoring. Performance monitoring is on-line measuring of the motor parameters like supply voltage and current, input and output power, mechanical stress in couplings, and so on. Vibration monizoring is based on vibration transducers, virtual measuring accelerometers of piezoresitive types with Tinear frequency spectrum, normally placed on the bearings for detecting mechanical faulis. However, by placing probes on the stator as wel, its also possible to detect an uneven ait 2, Stator winding or rotor faults, asymmetrical power supply and unbalances in the driven load (3). This is based on the fact that any change in the normal flux distribution in the motor will cause change in the vibration spectrum. The measured or registered results are compared with measurements registered ‘when the machine was new (or in 2 known condition). The Sensitivity of the method is faint high Current analysis deals with analysis of the motor’s supply current because this, to a great extent, is influenced by the motor's condition. Current analysis may reveal damaged rotor bars. Faults in rotor bars will introduce different frequency ‘current components in the supply current 10 the stator. The frequency ofthis harmonic current components will separate from the supply frequency by multiples of twice the slip frequency, and the result is that an analog ammeter in the supply lead will show slow fluctuations (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 ofthe degree of fault or damage 2), (81. “Measurements on the original condition are not necessary. However, static and dynamic rotor eccentricity as well as ‘mechanical faults on driven equipment also will affect the harmonic current spectrum. ‘The magnitudes of the above described frequency compo- rents are small compared with the main supply frequency component, and therefore difficult to detect. Particularly at low load oF no load, these frequency components are close to the mains frequency, and that also leads to measuring complications Surge testis @ well-known method for the diagnosis of winding faults. Inthe surge comparison test, two identical high-voltage, high-frequency pulses are simultaneously im- posed 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ns 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 a 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 prob- Jems, 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 10 detect because of insulation problems, especially in high- voltage motors. It may be that a fiber-optic system is an answer to that problem, During normal condition the magnetic field in the air gap varies sinusoidally 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 a rotor or stator will, in addition, produce an axial flux which can be detected by @ measuring coil around the shaft. Faults are revealed by analysis ofthe frequency spectrum of the measuring signal [2]. By monitoring the axial leakage fluxes, it is possible to identify various asymmetries and fault conditions as broken ‘olor bars, stator winding interturn shor circuit, loss of a phase, cecentricity, and so on. Speed fluctuations can detect defects by measuring fluctu- ations in the rotational period of the motor. The method is particularly useful at rotor faults. However, in most cases, the motor has a load of variable torque, and the measur- ing instruments must be capable of distinguishing between load fluctuations and fluctuations of twice the slip frequency, indicating rotor faults. Oil particle analysis is not much in use for motors, but in particular cases with a circulatory lubricant system, it may be a valuable supplement [2]. The analysis aims to examine the oil for particles of metal, fibers, or dust. The causes of the particles may be ftiction of streaming oil, bearing wear and ‘ear, or partial discharges or corona, or they can originate from chemical impurities like water or oxides, Gas analysis has been shown, according to [2], 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. There has, however, been some uncertainty about the connection between the degree of partial discharges and the remaining lifetime. For measurements of PD in high-voltage machines on line, high (radio) frequency current transformers (RECT) are clamped on the machine’s supply cables. For machines sup- plied by a bus duct system, the sensoring is more complicated, ‘The cable itself serves as noise suppressor for noise from the mains. The so-called phase resolved partial discharge analysis applies to very fast responding computer techniques, so that IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 31, NO. 5, SEPTEMBEROCTOBER 195 it has been made possible to analyze the PD as to number of discharges, the charge in each of them, and, if supplied with other sensors in addition to the RECT, the location of the PD in the motor and the type of fault that has led to PD. In addition to the principle that noise pulses from the mains will be suppressed by cables or condensers, one applies the principle that PD pulses and noise pulses are given different distances to travel to the sensors Acoustic emission monitoring works with ultrasonic as well as audible frequencies. Contact between rolling elements with and without cracks generates waves that propagate through the ‘machine with the speed of sound. The waves have litle energy, but their high frequencies can be detected by piezoelectric or capacitive transducers. The method is particularly promising for the detection of bearing faults Visual monitoring means either inspection with the bare eye or closed circuit television cameras, or by a photography or videotape to record trends Tl. SURVEY RESPONSE ‘The present work reports from an investigation on faults and failures on cage motors in offshore oil industries, petrochemi- cal industries, gas terminals, and refineries. The following list summarizes the magnitude of the response: 1) Number of plants (or platforms): 11 2) Number of companies: 8, 3) Number of “followed up” motors: 2596, 4) Total population (unit years): 25.622 5) Total failures: 1637 Contact between the companies and the authors has been maintained partly by mail, and partly by short-term visits 10 most of the companies. ‘This survey has been encouraged by [1], publication from The Power Systems Reliability Subcommittee of the IEEE Industry Applications Society, dealing with ac and de motors above 200 hp from a broad selection of companies in the U.S. ‘The present survey is limited to oil and oil-related com- panies off and onshore in Norway, and includes cage motors above 10 KW. ‘The questionnaire forms used in this survey are deliberatively made very much like those in [1], s0 that certain comparisons of results should be possible, and such a comparison is shown in Table XIX. However, in some points, the degree of detail regarding failure initiator, contributor, and. underlaying cause has been too high compared with reporting practice in the companies so far. The result isthe answer “not specified” to some of these questions. UL. Survey REsuLTs ‘Table TIT 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. ‘Tables IV-XV show different motor characteristics and drive conditions versus failure rate (failures/unit year), sample size (unit year), and number of failures."THORSEN AND DALVA: A SURVEY OF FAULTS ON INDUCTION MOTORS. ‘TABLE V Power VERSUS FAILURE RATE a wim [ans [on [io ito ovr _fow tow [ow | oon | non sume [ese [oon [ann [amos [oo [ss sre ma new fa fm fae [ow [a a * ‘rine [oort [oom [oon [ou | ome | ooo (we eee TABLE V Vouraoe Vers Fann RATE 199 TABLE VIL Sr Vensus FAIRE Rane 60 Hz nm fam [om fam | nm sew fs fim usr [om [oom [eam ‘ome ye face (fee at yeu) ‘TABLE vit Execrnical PROTECTON VERSUS FAILURE RATE co aor [oe old == —_ mM mM. ™ ‘eecroma | gaetic, fumes and | fase, tuibd in 7 =a oa 2a | ae Sn ee Seip st a a | wo [oro She |She — | Storms ee oe van [un [a = Taine ne carey) Lows [nore [eas spe fom fm > ‘nate vt tase ao | oom ro sip Vie Pe Ram 0 He a oe | 01-750 | 751- wor. | tot | toad Seeenssesmssssemissemssesemetscensesssnessses a en = ve 7 TABLE IX. teow [as faa [rm [te Pos mae ncxoun Te Worl Fant Rare = Weste peooet enya = Tame seme fo fe fe fo fon [om Re a [a a i oom om Tae Journ Touma Yous [our [orm [om fats yy = Sey Sm Sesat ‘TABLE X me Dury Appuicknion VeRUS FAILURE RATE Conner [een [pcr Tap mn [ase an 18 Power no Table IV shows the relationship of fale rte with power, _nawerarmaoe [oi | A The motos in group 101-S00 KW have a somewhat highet “hae [ow fous aone eee Sect | | Votage Speed ‘Table V shows the relationship of failure rate with voltage. Increasing voltage clearly indicates a higher failure rate. De- spite the relatively few high-voltage motors, the reported faults are regarded as reliable as a result of careful documentation, ‘Within the power group of 101-200 kW, there are 39 motors in the voltage range of 5001-15000 V, and 256 up to or below 1000 V. ‘Tables VI and VII show the relationship of failure rate ‘with speed, 50 and 60 Hz, respectively. Although there are relatively few motors 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-Hz motors may be explained with a lower age for the 60-Hz motors (offshore) than for 50-Hz motors (onshore).‘TABLE XI ‘Avenact NewBER oF STARTS Pex Dav Vests FALURE RATE Tore [140 Not pecifed Sole ne ce | 11002 385 va, Namie of 08 Ey ‘ Tite ae —_| 0.0080 0.0381 oon (tases yea) IEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 31, NO. 5, SEPTEMBERVOCTOBER 1955, ‘TABLE XIV Power Surry Ground TYPE Vunsus FARE RATE ‘a Tepecce | Unum | Net ‘eagle aoe [zoe | mat6 ° 1008 (wt yea enter of | 8 28 ° * ruue me [oan [oi | oom — | o0nse (nrc et an x ace Coe Wes FARE Ros aa xv yvonne Vins FALIRE RAE Tose [oun [Some [a — EE Seo tet | Same | ates oe Omer | nope Soa ee genre le eee or es ° uit year) yea) . ‘inter or [> 2 am |e anes = ° tance oom [oome fom owe Tamme [ene cos [eon Cate Cates = = —_|__. TABLE XII -Manstesasce QUALITY VERUS FAILURE RATE —— eee Seape ae wtye | 8 ee ante of are By 68 Tria a rv | 0124 ro a a Electrical Protection ‘Table VIII shows the relationship of failure rate with elec trical protection. The apparent high failure rate for the best protected motors must be a result of too low numbers of registered faults Enclosure “Table IX shows the relationship of failure rate with type of enclosure. Since nearly all the motors were in the group totally enclosed, it is not relevant to draw any conclusion. Duty Application ‘Table X shows the relationship of failure rate. with duty application. Total sample size is dominated by continuous duty that also shows highest failure rate. ‘Average Number of Starts Per Day ‘Table XI shows the relationship of failure rate with average ‘number of starts per day. Only the lowest groups of the ‘numbers starting per day were reported. The motors with the lowest number of starts per day show the highest failure rate, probably because of longer running time per day. Maintenance Cycle ‘Table XII shows the relationship of failure rate with main- tenance eycle, The survey response shows clearly that a cycle cof up to 12 months gives an extremely lower failure rate than for the next steps. ‘Maintenance Quality ‘Table XIII shows the relationship of failure rate with main- tenance quality. Not many sample sizes are reported 0 have excellent” maintenance, The estimation of the quality may vary somewhat from plant to plant. As expected, a better maintenance gives 2 lower failure rate. Power Supply Grounding Type ‘Table XIV shows the relationship of the failure rate with a power supply grounding type. There was no response for an ungrounded supply. The solid grounded neutral point exhibits ‘a much lower failure rate than the impedance grounded, Environment Table XV shows the relationship of failure rate with envi- ronment. In the types of plants included in this survey, the majority of the motors are situated outdoors where the envi- ronment is extremely tough. This may explain the relatively big difference between the failure rate indoor and outdoor, and the inconsistency with the survey in {1}. Failed Component “Tuble XVI shows how the failures are distributed on the failed components. The result of the survey shows, as ex: pected, that bearing faults count for the majority ofthe failures, as much as about $1%, Faults on stator windings and on external devices amount to about 15% each, so that together"THORSEN AND DALVA: A SURVEY OF FAULTS ON INDUCTION MOTORS, TABLE XVI Dsrninu0N OF FALURES ON FAILED CoMPONENT Fale component | Nuaber of fates | Peres Besa 36 S107 Suse wines 238 1376 oe brs ings | 71 47 Sat occomina | 40 2 ‘Bera device 2S 1558 ‘ot eid 1m 045 Toa 197 100 ‘TABLE XVIt BEARING FAILURES ax THER CAUSES Tearing Came oftatares | Nanter | Poca] Percent exch are tanto D Traneetoveretuge ° 2 Overeating mu 5) Ober nmin Wesionn zit 1) Mecha esta ns 5 Beal ao mation Gr 8 Sued woe tos Ne mete ater contner Persian eon an 2) High sabes tempers om 5) Abormal moire a3 5 Abooma volnge a9 5) Abra eqetey a9 0 Bg brabon soz 1) Aggro coecicals ase 1 Poor nication ae 9) Poor elton 0 sosing a9 10) Noma tron fn age om 1) Nat este are uaderying cae 1) Deteve enone no 2) Pow macareng vs 5) maton aimee has 2 tnprope open a0 5) prope ting ping Soo 1 latent pyc proton os 5) mtogne cereal poeta ie 5) Peso ee om 9) outde agen 0 persone 35 10) Mor arven eit ian. ae 1) Not peste hese three add to more than 80% of all faults that have led to a failure. In Table XVII, the bearing failures are analyzed particularly. However, because of a high rate of “not specified” reasons, an additional column is added to show how the specified reasons are distributed. “Table XVII reveals that mechanical breakage and overheat- ‘ng are the most frequent failure initiators of bearing failures, ‘whereas high vibration and persistent overloading are the most frequent failure contributors. Improper operation and defective ‘components are the major failure underlaying causes. In Table XVII, the stator winding failures are analyzed particularly. And as for the bearings, the “not specified” percentage is high, so that an additional column is added to show how the specified reasons are distributed. ust TABLE XVI Srarom Wxncs FAltns Axo Thain Cavses Stuer wadings - Comes of | Nasber | Perce | Percent exc tare ori a ec Pare itor 1) Teast oerohagse 9 Ia |r 2 Overheating as |e Liss 5) Oder inion beatown = | 38 [aus | 453 ‘) Mectaial estas | 36 5) Review actor taitocion | Sis | tose © Salle mer 3 te | a3 1 Net wesied 0__| 5039 1) Perinat overating 2s Jin | se 2) High amben teopersre | 4 rss | Roo 5) Abeomal mesure & [ate | een ‘5 atonal votage 2 fom | aeo 5) Abormal Fegpeey 0 foc — | ovo ih neon 3 tis | ea0 5 aapeaaive ceils t on [2m 1 or bein 0 few — | ea Peo vesinion costing 120.8 | 400 {oy Normal derioran frm age | & 13s | 800 1) Not meted ae | an 2 tie | S06 i 03 fie ° O00 5 38 2 mw ° om 2 a7 ° om tas [Soe ‘Table XVII shows that overheating and other insulation breakdowns are the major failure initiators. The major failure contributor is persistent overloading, and the most frequent un- derlying causes are improper operation, defective component and inadequate electrical protection. IV. CAUSES oF FAILURES ‘Table XIX gives an overview of total number of causes of failures. For comparison, the figures from [1) are in- cluded in the last column (in parentheses). In this column the “not specified” replies are excluded. The major all-over failure initiators for the present survey are electrical faults ‘or malfunctions, mechanical breakage, overheating, and other insulation breakdowns. As to the failure contributors’ high vibration, persistent overloading and aggressive chemicals are the most important. The most frequent underlying causes are defective components, improper operation, and inadequate physical protection ‘Table XX shows the underlying causes for a failure initiator for the total number of failures. V. COMPARISON WITH THE SURVEY IN [1] ‘The results from the last column in Table XIX are also given in Figs. 1-3. Certain discrepancies between the two surveys ‘were expected because of the differences in selection of plants ‘and motor types and sizes.use IEE TRANSACTIONS ON INDUSTRY APVLICATIONS, VOL 3, NO 5 SEPTEMBERIOCTOBER 1985 TABLE x0 TABLE XX isms or Tor Men OF FALIRE COS smununow of anus th Faz Cour Hat Vora rea ore a Faclcompece [vemos [Peet ear om ‘Bearing us. A177 G19 Dene ete w [on | 220.0% Sour vinis | 4 a9 (870 2 owes ny [ato | isaeaszy oor enor ge 14 3) Other insulation deeakdown o 416 | 14.98 07.99 2 om 2 nec wenge fe [ho | mousy Sta ig 2000 Mecano (ie [a [ROD Cae ©) Stalled motor 7 1.04 | 3.74 (1.28) eens 6 10.14 05.39) 1 No pied uisy__| ras ot wectiog « 1527 (049 rates eee =e (Secs et wo [aw [noc pre owen | fest [3309 3) ator ere BS [is [ares 2 Aor ag Flom [2m a0 ‘TABLE xxIt 5; Anal eer 1 [Soe Bena Fuunss av TER CAUSES HoH VouIAGe 8 rte nb [Se Sy newest ice 3 jie Tame Cows abe [Micew [Pee | Pee 3 Pow unason B [te [cease perl Site ‘herrea weoaia | | Jou | oi sae Thins seerrace toma [21 [tae | 08 04a nee fn __[ tae aes Dione ornotags o fo fo Taher were ue Dowhence f [Bn [fae Betas camera wes fea | sserasan Semreeemees le seleas la 2 Po ance wr [aa [358 Gs00 2 wean wens [ios [Stas Pisacence = [ts Jom | 429 axa SMe emamin [2 fie [36 2 egret peo nan | avai, 8 sate mr a [et fe Sieger Since [6 oar | 308 075 naps ta__| rae Qin pee [Se [2m | lean come gues ecm, {8 LES [teem remem fs fam fase 2 Pmt ee 3 fom [18 oa ponent eee Heme wrey open |i [m9 | G30 BM seen eer ee Te neces. Ja [oss | 138.00 2 Anema lee ss Ty nocaetes in [tie poy ie eae —_— Ce eee han [Su Sac cae [en fe 3 how rca $a [Suan Deri cosy fo [OL TABLE Xx ees ior ce Fanune Inaror Vests Fane UnoenLyoo Cas abe trig ae sn fua|aw an |= [om Doster caver w [an [aw ous, et | bee [| me 2 Pow maonse PLM [is 3 tame sme i [te Lisbe met fw fe dae fos fe fae fee 2 lapses gem 3 LEN [xe om Serr Catan fo [oo Summ metite, |S fin | tse ve fo («fe [2 [* [eo fo |» Sinesres capone [i fosr [388 in Breen aor o> fen fe thee eed Decent lade la noeecacecereme | te |u| = 111) Not specified 148 85.14 moet? > fo fs fe fe |e [™ ees eee me. (fe f(t [te |e ‘The mos distinct differences are within failure contsibutrs. = In the present survey, normal deterioration from age and poor wwe fo [ee fe ef |e it lubrication plays a small role, whereas in [1] it is important. awa) oie |e eee ee |ee aloes rose VL. Contents on HiGH Vottace Moros wom fo fe fe fe [tie |? | Inthe voltage group 5001-15 000 V, there are the following Ou o [3 jo ° 2 ° 7 2 motors sree 101-200 kW, 39 motors 90 faitures tow fe fo fo fo fe fo [+ |« 201-500 KW. 200 motors 250 failures oat ‘501-1000 KW, 85 motors 20 failures ‘Over 1000 EW, 110 motors 59 failures. wm fz fe fs fe fe fw fans [oa we ‘Table XXI shows how the failures are distributed in the “xe Le [a Toe [oes Poe [ir nes [126 ited components for motors in voltage group 5001-15000 V.[THORSEN AND DALVA: A SURVEY OF FAULTS ON INDUCTION MOTORS, ‘TABLE 20a Sraron WisG FAILURES AND THER CAUSES, Hit Vourncs ‘Str windings ~ Cowes of | Nanber | Perea | Perce fares rare el at ‘posites are air 1) Tree overages 3 an 2 Ovebexing * un 53) Ober ison bean, | 13 3 6 Mest! reste 3 a 5) eral fat ar matinsion | 7 tase | toe 9) sates moor 2 am se 1 No ec mw _| 333 are contributor Ip Remote oeadng 2 sm [ax 2 High ambien emperaze | 1 a fea 5) Abana irae 4 wa | ter 4) Abnormal volage| 2 am | as 5) Abra Feeney a ° o 8 Migs tran 2 sm | bs 1 Agen denies 1 tas | 6or 1) Por aban ° ° ° 5) Por veindon or cootg | 2 am | ba 10) Normal deiration fom age | 4 tas | eer 1) Net pecies » na Fare underpin case 1 Defestive component ® was | mas 2) Poor omaaotering 2 am fas 2) Idee mserance 1 tes [an 9) agree operon r us |a7 5) improper bnsiaestiping | 0 ° ° 8 teteqate peje proweton |S bas | doe 7) tategute secre prowcson | 6 han | 3500 1) Peron enor ° o ° 9) Outage agency - nt persone | 1 tas | kar It) Moor driven spn en. | 0 o ° 1) No sect 30 5556 The results show, as expected, that bearing faults count for the majority of the failures, as much as 41.77%, Faults on stator windings and on external devices amount to 12,89 and 18.14%, so that together, these three add to 72.67% of all faults that have led to a failure. In parentheses are repeated the values for all voltages (see Table XVI). In Table XXU, the bearing failures are analyzed pasticularly for the voltage group 5001-15 000 V. Because of the high rate ‘of “not specified” reasons, an additional column is added 10 show how the specified reasons are distributed, ‘Table XXII reveals that mechanical breakage and overheat- ing are the most frequent failure initiators of bearing failures, ‘whereas high vibration is the most frequent failure contributor. A defective component is the major failure’s underlying cause. In Table XXIM, the stator winding failures are analyzed particularly. And as for the bearings, the “not specified” percentage is high, so that an additional column is added 10 show how the specified reasons are distributed. Table XXIII shows that insulation breakdown, overheating, ‘and an electrical fault or malfunction are the major failure initiators. The major failure contributors are abnormal mois- ture, persistent overloading, abnormal voltage, high vibration, ‘and poor ventilation, The most frequent underlying causes are 1a defective component, inadequate electrical protection, and inadequate physical protection. Table XXIV gives an overview of the total number of causes of failures. The figures from [1] are included in the last ‘TABLE XXIV Distmuuiov op Tor. NeM@ut of Paine Causes, Hic Vout “Tl — Came fers Tranter | Fee | Pec ex ot Stipe Patere ftir ‘Trane overlaps > fom |20s ar 2 Overning je | 855 | Sekstanam Somer inndaion weastown [17 | oe | inc795, 1) Mechel wetage 2 [tom | arasan, 3 Beal tormitsion [2s [tone | anaaniy 6 Salled owe 3 fan’ | 20s c.2m 1 Nx pet 2 | ete ater courte 1) Pein vei 9 [ais | wen Biipanbien weperme = |3 fom fsa G3 5) Adora mare [239 finnesp *) Abra vonage 3 ris | 336.90 5) Abarat Regency 0 ov Jo om © His veto 51 |340 | Seen ano 5) Aero chicas 7 | 40s | ins eay 5) Poo tino un | | aargsey 9) Poor veoeaon coning [2 fdas [222 G0) 10) Normal eanoraton tor aes [2 [as | 222 0430 1) Ne ete sy | ras Par weer cae I) Dette somgonet| a {2m | arse 2) Pow iain © lose | Pir gsao 5) ada msc s [ats | S31 een 4 Kaper operon © fxs | 3s G4o) Sy Improper ainpippig 0 FO JO 5) O imtaqae pymeal presen [22 [52s | negiw imdecane ec raccoon |10 | 239 | 1042679 1 Persone oor 2 Joa [208 cam, Shouse sgrey-eotgenomt [3 fon | 33 as Tomar devon eqaperct mim. {2 oas | 2a8 Gas) 11) Not ected Sas column (in parentheses). In this column, the “not specified” replies are excluded. The major all-over failure initiators for the voltage group 5001-15000 V are electrical faults ‘or malfunction, mechanical breakage, overheating, and other insulation breakdowns. AS (0 the failure contributors’ high vibration, aggressive chemicals, poor lubrication, abnormal moisture, and persistent overloading are the most important ‘The most frequent underlying causes are defective components and inadequate physical and electrical protection. VII, COMMENTS ON VARIABLE SPEED DRIVES Most of the plants and platforms in this investigation were planned in the 1970's and early 1980's, and hence not provided ‘with variable speed drives (VSD's) that did not come into extensive use before the end of the 1980's The application of VSD's affects the piping flow plants, and has to be included into the designing process in an early stage. Application of VSD's has several advantages in investment cost and running expenses, but not very many reliability surveys on VSD's have been reported {13}. vin, The intention of this survey has been to investigate the failure rate, to identify failures and their distribution according to motor data, protection, duty and maintenance cycles, and ‘quality within the pewoleum-related industry as a base for the planning of maintenance and condition monitoring. The ConctusionsIEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL 3, NO. 5 SEPTEMBERIOCTOBER 1955 TABLE 2V owe WI . ae Maneaaee oe Maiseane ey we ne We: 51 1000 Mi: 12mm ore ar: Wo: 51 00 won Xo: 02 monn wah Ne: 25 monn or more &: = Na_Nereatee SNe pcites Yatoee V1 regency el i 5 ‘roading pe of Pome py Vi 0- 190 WH VE 101-50 2 a) $5: 501 15900 Brie apts oh Unranie Pole uber pl Oe: Naveen N10 wea he tints me NS 2 ms No ctangnie (Debate) Ti: Ot aprtonproducin, efit, pvocbenieal mansion Th: Pepa poe ny, ond comveron Syed BSc pe sone one mm a Ri 0 6 Rs 0-7 A 1-950 Rr 72 900 noe fe 351-100 Re 5011209 Our F101 1500 0 Es Re pect BS 1301 3000 | Risto eto aaa eal oecton = Minima vale 1 PL: Termaviocromseic an ae Masia ale 100 Palin epee ane mn led compet Pe: Viadon monitoring +71, 2073 eae Ps: Noe mec Kir Open 1: Wester protected KS) Toally enone (tly encod fred cot. explosion poo, that gion pond Ke: Tel enlns (ticle) KS: Toul enlod (aa one) Ke _Notapeites Day ppicaion 2 ier Bec peced wee FE Fess oveoating Fr: Auremive cee si erie Fi: High anbiew temperature | PR: Poor ratoe S11 Fs Aborma owe 5 Poor veon of coi s: 1-30 Fe Abnormal yotage Flo: Nonna deearaton fo 8 Hormone Es Abnormal eeoesy we S5i_ Not ected ie _High wrauon Fit: _ Rec west © Shor wings Ck Stal copie Co Necipecte 1 Traent overages TD: Oveneaine TB Oter nlsion teaown Meshal reste 1S. Becta! fal or lfncton Te_ Notes ile coho @ industry in this survey is strongly biased towards the offshore oil industry, and a comparison has been made with results from an IEEE survey within more general industry [1]. The results show a strong increase of failure rate with voltage (and power), well in accordance with [1] ‘A smmall increase in the failure rate is revealed from four- to two-pole motors. The amount of data is too small to draw conclusions for higher pole numbers. Increasing complexity of the protection leads to a strong reduction of the failure rates. An apparent increase in the failure rate for motors equipped with vibration protection shows that this method detects more faults that otherwise ‘would not have been found. 'A somewhat unexpected result was thatthe failure rate was considerably highet with one start per day than with more starts, The starting procedure, especially direct on line start, ‘causes extra stress on rotors, bearings, and coil ends, so one would have expected another result. The explanation must be that fewer starts per day means longer duty time per day. 'A maintenance eycle of 12 months or shorter, as well as fan excellent quality of the maintenance, lead, as expected, t0 ‘an extreme reduction of the failure rate. Also is recorded a considerably lower failure rate with solid grounding of the neutral than with impedance grounding. Distribution of failures on different components gives 51% to the bearing, about the same as in {1}. Faults on stator"THORSEN AND PALVA: A SURVEY OF FAULTS ON INDUCTION MOTORS. TABLE XX (Conrasveo) Pare uri cae ULL Defeive Component v7 $8 Uk, Apropo operation US, proper boi ing Us: Lneqne papi eoecion ue uur: _Netiecioa iss Failure Initiator “Tine fare cover DE: Darag orm operation Da; Dana route eon o ting Dé: Nocmecfed Minima vate: 0 Masa va: 1000 © TABLE XXVL ‘Total popaation data fort “Toa mambr of tne ‘Vonage, VI V6 Frequency. =H Pole mabe, NI 6 RRS Spee RoR Expracion PP Failure undertying cause Day ppAl AS Ma. MIM Maint. 9.1 = 6 ‘Grout, 1 =O “Type ot ind TTA avronet, El ES Perio repaid eee tre daa form Fale comp. C6 Fire cot, FL FL Tene fue. DI- De windings and extemal devices amount to about 15% each, somewhat higher than in [1]. The deviation can probably Fit 3. Disuibution of fulue undying causes fr two surveys be explained by the different size limits; the present survey ineludes motors above 10 kW, compared to 150 kW in that of [1]. 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 external devices. ‘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1196 ‘The most frequent failure initiators for the bearing are mechanical breakage and overheating, high vibration, and persistent overloading. Failure underlying causes are improper ‘operation, defective components, and inadequate maintenance. For the stator winding faults, the most important failure initiators are overheating, mechanical breakage, and insula- tion breakdown, Several faults on the motors are caused by unbalanced supply condition, for instance, single phasing, Application of normal protection may exhibit problems in the effort to protect the motor over the whole speed range from. rno load to full load. ‘The study has been followed up by a new survey of the reliability of motors exceeding 150 kW and 6000 V, to reveal the connection between motor parameters, condition monitor- ing methods, maintenance philosophy and different types of faults. Contact has been established with relevant industrial companies to map the development after the completion of this survey (May 1993). Parallel to this, work is going on 10 investigate the reliability of variable speed drives. APPENDIX ‘The following groupings have been chosen (see Tables XXV(a}-(c) and XXVD, REFERENCES [1] IEEE Commitee Report, “Repor of lage motor slaty survey of Jindal and commercial instalation Pet and Pat” EEE Trans. nd, Applicat ol, 1421, 203, pp. HS3-872,July/Avg, 1985. [2] Pod. ner, B.G. Gaydon, and D. M. Ward, "Monitoring generators land large motors” HEE Proc, vl. 133, pt Bo. 3, pp. 168-180, May 19K. (9) ROA. Leonaed and W. T. Thomsen, “Wibraton aod stray fx mositring forunbalanced supply and inter-ur winding out ingnosis in induction motor” British J"NDT. pp. 211-215, July 1986 (4) B. Yoshida and, Unemto, Snsalation diagnosis for rotating machine inealation,” EEE Trans, Elec Iasi, vl. E21, no. 6, pp 1021-1025, Des, 1986, "Schlichting, “Stosespannungsprufung_ von Elektomotores 2 Fruherkennung von lsolaorstenern,” Elekriztaetslnschaf 3g 88, pp. 406-408, Heh 10, 1986, [61 34 Krecke and R: Goffau, "Atempt at estimating the residual ie ff the HV insulation of ae rotating machines,” CIORE, 1988 Sesion, Paper 11-12 pp. 1-8 "Tsun, H. Pshma, . Obs, T: Koizumi, and E. Oto, “A dyna monitoring system for bearing visings microprocessor," in JECT Ana. Conf, Pro. bth, Mac, 1980, pp. 24-128 is 0 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL 1, NO. 5, SEPTEMBERVOCTOBER 1985 [81 F. Flippeti, M. Marelli, G. Franceschi, and C. Tsson, “Develop tment of exper system knowledge base to on-line diagnosis of rotor ‘Hetrial tals of induction motor,” IEEE Ind. Apia. Soc. Annie Meeting Con Ree. 1982, pp. 92-99. (9) ACH Boonen. “Anslyis of winding files in de-phase squizel ee induction moors.” IEEE Trans. Tad. Applicat, vol 1A-I4, 803, pp. 223-226, May/luse 1978 EPG. Gaydon, "An insrument to detect induction ota rotor circuit defect by speed fscustion mearuremens,” IEE Covf Pub. vo. 174, pp. 5-8, 1979 Pag B-G. Gaydon, and K, Kamash “The detection of rotor defects Jin induction motors." IEE Conf Pub vol. 213, pp. 216.220, 1982 W.'T. Thommen, R.A. Leonard, A. i. Mile, and J.’ Penman, “Fale Mention of offshore induction mol systems using Ot condition mentoring,” Fourth Nat Rel. Conf-Relt. 83, 1983, pp dewieacnn KL W.L, Burbidge, “User” view of variable speed drives on petochem {eal pan.” IEE Conf Publ, vol 376, pp. 582-387, 1993, (19) an na 13) P {Olay Vang Moreen (88S) graduate from the Univesity of Trondheim, Norwegian Insite of ‘Technology, in 1963. From 1963 t0 1965, he worked as a research and: evelopmest engineer with the A/S National Industy io te fell of elec machines. Since 1965, eis been with Bergen College, where, rom OWS to 1987, he was an Associate Profesor, and since 1987, be has been a Professor in electrical Engineering. He has aso been an elected member ofthe administrative tam of the colegs, incline Head of Department of Electrics! Engneaing. He bas paricipated as a ‘consultant in indus projets, published eight TEEE papers and isthe author fof textbooks in electical engineering, His research interests include elect ‘machine, power electronics, and high-voltage technology Prof. Thoren is & Registered Professional Engineer. ‘Magnus Dalva (92) graduated from the Univer sig of Trondheim, Norwegian Insitute of Techno ony. in 1963, "From 1963 to 1965, he worked as a research and development engineer withthe Norwegian Bcc land Brown Bovert A/S in the eld of elecc ftmchin. Since 1968, he has been with Stavanger Coleg, except from 1970 to 1972, when be was fn Asian Profeece a the University of Naira, Kenya. Sine 1984, he hs been an Atsoviate Pro fessor in electrical power engineering. He has also ‘ben an elected member of the administrative tam ofthe college, including Head of Deparment of Science and Technology. His teaching and research lnclode electri machines, power elecronics, and high-voltage echaoiogy. He has published eight IEEE prpers, and san autho of extooks in his Reds