Cuprins Linia de instrumente SKF Baker SKF De ce trebuie efectuata o analiza statica si dinamica a motoarelor electrice Discutie asupra izolatiei unui motor electric si caracteristicile dielectricului Evidentierea modului in care motoarele electrice se defecteaza Solutii tehnice statice (in atelier) pentru determinarea stariid e functionare a izolatiei si circuti motorului electric Solutii tehnice dinamice (in functionare) pentru determinarea calitatii alimentarii, sarcina si problemele mecanice October 30, 2007 SKF Group Slide 2 Exemple de echipamente SKF pentru managementul motoarelor electrice in scopuri predictive si asigurarea calitatii in exploatare SKF Portable Dynamic Motor Analyzer Exp 4000 Static Motor Analyzer AWAIV SKF On-line Motor Analysis System NetEP October 30, 2007 SKF Group Slide 3 De ce ar trebui facuta analiza statica si dinamica la motoare electrice October 30, 2007 SKF Group Slide 4 Salvari de costuri Reducerea opririlor accidentale Indicarea cauzei defectului Salvari de costuri cu energia Analiza: Volt Frequency Detection: Asigurarea calitatii motoarelor Reducerea timpului de evaluare a starii de functionare October 30, 2007 SKF Group Slide 5 Motor MCC Load Analiza completa a sistemului October 30, 2007 SKF Group Slide 6 Motor MCC Load 1. frequency 2. speed 3. Torque 4. Power 5. Voltage 6. Current Lantul de evenimente October 30, 2007 SKF Group Slide 7 Caracteristica de izolatie a motoarelor electrice Cum se defecteaza motoarele electrice si de ce ? Intrebarea nu este DACA motorul se va defecta ci CAND se va defecta! October 30, 2007 SKF Group Slide 8 Incidenta modurilor de defectare la motoarele electrice: Bearing 44% Rotor 8% Other 22% Stator 26% Bearing 41% Other 14% Rotor 9% Stator 36% IEEE Study EPRI Study October 30, 2007 SKF Group Slide 9 Cauzele defectarii motoarelor electrice: Studiu IEEE 0% 20% 40% 60% 80% 100% Bearing Winding Electrical Fault Mechanical Breakage Insulation Breakdown Overheating October 30, 2007 SKF Group Slide 10 Etapele tipice defectarii unui motor electric datorate scurtcircuitului electric (1) Izolatia electrica a unui motor nou este foarte bune (2) Motorul este supus unei imbatraniri naturale Termic Chimic Mecanic (3) Capacitatea de izolatie Spira- Spira scade sub nivelul rezistentei la tensiunea si curentul de functionare Arcuri electrice de strapungere apar la pornire October 30, 2007 SKF Group Slide 11 (4) Insulatia incepe sa se strapunga din ce in ce mai des (5) Rezistenta de izolatie Spira- Spira scade sub tensiunea de functionare Motorul intrerupe la supracurent (6) Spirele strapunse cauzeaza o incarcare mai mare cu curent a infasuratorii temperatura ridicata , curent absorbit de circa 16-20 ori mai mare decat sarcina nominala (7) Defectare rapida (deobicei de ordinul minutelor) Etapele tipice defectarii unui motor electric datorate scurtcircuitului electric October 30, 2007 SKF Group Slide 12 Modul de defectare: scurtcircuit Spira-Spira 80% dintre defectele motoarelor electrice incep datorita scurtcircuitului inspre spire Majoritatea se vor defecta prin scurtcircuit la carcasa insa originea defectului ramane scurtcircuitul Spira-Spira Sursa: General Electric Paper October 30, 2007 SKF Group Slide 13 Cauzele pentru care cele mai dese defecte sutn datorate scurtcircuitului Spira-Spira Spira este cea mai slaba izolatie din circuitul electric al motorului Depunerile si coroziunea chimica distrug in timp izolatia Miscarile dintre spire (la pornire) distrug izolatia (o crapa) D.E. Crawford\General Electric October 30, 2007 SKF Group Slide 14 Solutii tehnice pentru determinarea starii de functionare a izolatiei circuitului motoarelor electrice October 30, 2007 SKF Group Slide 15 Teste complete de sarcina electrica Echipamentul BAKER Surge Test este unica metoda de efectuare a unui set complet de teste electrice, in conformitate cu standardele IEEE ce permit tehnicianului sa prevada starea de functionare a motorului electric. October 30, 2007 SKF Group Slide 16 1. Surge Test Testarea permite descoperirea Izolatiei slabite (PPM, QA, TS) Spira-Spira Faza-Faza Bobina - Bobina In atelier: Lista de defecte posibile Izolatie slabita Spira-Spira, Faza-Faza, Bobina Bobina (QA, TS, PPM) Bobine inversate (QA) Scurtcircuit intre spire (QA,) Numar diferit de spire in bobine (QA) Dimensiune diferita a litei de bobinare a bobinelor (QA) Izolatie defecta infasuratoare - carcasa (QA) October 30, 2007 SKF Group Slide 17 Surge ring October 30, 2007 SKF Group Slide 18 Izolatie defecta Spira-Spira October 30, 2007 SKF Group Slide 19 432-1992 IEEE guide for insulation maintenance for rotating electric machinery (5 hp to less than 10 000 hp) IEEE Guide for Insulation Maintenance for Rotating Electric Machinery (5 hp to less than 10,000 hp) Scope This insulation maintenance guide is applicable to industrial air-cooled rotating electric machines rated from 5 hp to 10 000 hp. The procedures detailed herein may also be useful for other types of machines. 7.4 Interturn Insulation Tests Film insulation usually provides high dielectric strength but, in many cases, the interturn insulation on motor coils is porous in nature. Fibrous insulation effectively provides a physical separation of the turns of the order of 0.010 to 0.025 in (0.250.635 mm) for motors, and the electric strength between the turns is essentially provided by the insulating value of the gas (air, hydrogen, etc.) contained between these bers. Micaceous insulations are commonly used in high-voltage machines. To provide a useful service in checking the adequacy of the insulation between turns, the test level selected must be greater than the minimum sparking potential of the air at the minimum permissible spacing. The test potential will often, therefore, be several times normal operating volts per turn. A test of about 500 V rms per turn is considered average for a new machine, while for maintenance tests potentials of one-half to two-thirds of the new coil turn test, eight to ten times normal operating volts per turn, are usually considered adequate to provide insurance from the possibilities of marginal insulation and contains allowance for switching transients and for surges likely to be encountered in service. The normal operating volts per turn are often up to about 30 V for motors, while turbine and water-wheel generators are substantially above that value. The test methods used include forms of surge comparison tests. A steep-front surge is applied to all or part of a winding, or by induction to individual coils within a winding. The resultant waveforms are viewed on an oscilloscope screen and interpretation of the patterns or amplitudes permits detection of short-circuited turns. The surge comparison test applied directly to the winding terminals is limited, in the case of windings consisting of many coils in series, by the magnitude of the voltage that can be applied to the ground insulation without exceeding its specified test voltage. This limitation can be overcome by placing a surge coil in the bore over the coil to be tested and by applying directly into it a voltage appropriate to the induced volts per turn required in the stator coil. For additional information on procedures and requirements for interturn insulation tests, see IEEE Std 522-1992 [10]. See [B14] for detailed information on surge comparison testing. October 30, 2007 SKF Group Slide 20 IEEE Standard for Petroleum and Chemical Industry Severe Duty Totally Enclosed Fan-Cooled (TEFC) Squirrel Cage Induction Motors Up to and Including 370 kW (500 hp)
d) The 2300 V and 4000 V designs shall use vacuum-pressure-
impregnated form windings, capable of withstanding a voltage surge of 3.5 per unit at a rise time of 0.1 s to 0.2 s and of 5 per unit at a rise time of 1.2 s or longer. (One per unit equals 0.8165 V L-L .)The test method and instrumentation used shall be per IEEE Std 522-1992. When specified by the purchaser, this requirement shall also apply to form windings supplied for voltages 575 V and below on motors rated above 150 kW (200 hp). October 30, 2007 SKF Group Slide 21 2. Teste electrice generale 2.1 Rezistenta infasuratorii (PPM, QA, TS) 2.2 Masurarea rezistentei cu Mega-Ohm (PPM, TS) 2.3 Testul de polarizare a dielectricului (PPM, QA) 2.4 Teste la niveluri crescute de tensiune (PPM, QA, TS) October 30, 2007 SKF Group Slide 22 2.1 Probleme legate de masurarea rezistentei infasuratorii Echilibrul intre infasuratorile fazelor (PPM, QA, TS) Dezechilibru intre faze (QA) Diametrul litei de bobinare (QA) Conexiuni cu rezistenta electrica marita (PPM, TS, QA) Scurtcircuit bobine (TS, QA, PPM) Bobine cu defecte de conectare (TS, QA,) October 30, 2007 SKF Group Slide 23 2.2 Meg-Ohm Test Meg-Ohm-Meter Permite: Determinarea faptului ca motorul da la masa. (TS) Motor murdar (mecanic, chimc) scurgeri de curent (PPM) Evolutia in timp (PPM) Meg-Ohm-Meter Determina: Daca motorul este buna de functionare Defecte de bobinare Infasuratori slabite eletric Defecte intre faze October 30, 2007 SKF Group Slide 24 2.3 Index de polarizare, Teste de absorbtie a dielectricului Poate detecta- Izolatie deteriorata intre spira si carcasa (PPM, QA) Uscata / casanta, dura, sau exfoliata la carcasa (PPM, QA) Umezeala si contaminare October 30, 2007 SKF Group Slide 25 2.4 Teste la niveluri crescute de tensiune Poate descopri Izolatie slabita la carcasa (PPM, QA, TS) Probleme de slabire a conexiunilor (PPM, QA, TS) October 30, 2007 SKF Group Slide 26 Case Study: Weak Insulation Turn - Turn Low Voltage Tests Show all good October 30, 2007 SKF Group Slide 27 Case Study: Weak Insulation Turn - Turn Low Voltage Tests Show all good October 30, 2007 SKF Group Slide 28 Case Study: Weak Insulation Turn - Turn Surge test is the only test capable of finding weak insulation turn to turn Phase 1 & 2 are good October 30, 2007 SKF Group Slide 29 Case Study: Weak Insulation Turn - Turn Phase 3 shows weak insulation Turn Turn at about 1,000 volts. Now this is not a Turn Turn Short but this will be within weeks ! If it was the winding resistance would be unbalanced and it is not No other technology can find this fault October 30, 2007 SKF Group Slide 30 Case Study: Contamination in J-Box Motor 7200 volt 1000 Hp 3600 RPM Motor October 30, 2007 SKF Group Slide 31 Case Study: Contamination of J-Box October 30, 2007 SKF Group Slide 32 Case Study: Contamination of J-Box October 30, 2007 SKF Group Slide 33 Case Study: Contamination of J-Box October 30, 2007 SKF Group Slide 34 Case Study: Contamination of J-Box Results after the J-Box was cleaned October 30, 2007 SKF Group Slide 35 Summary of Contamination Case Study Only by elevating the voltage above operating voltage did we see a problem Voltage spikes could track and cause a failure October 30, 2007 SKF Group Slide 36 Case Study: Step Voltage Test at Higher Voltage Found Unstable Ground Wall Insulation 4160 Volt Motor 300 HP 1770 speed Tested 4 identical motors at a power plant October 30, 2007 SKF Group Slide 37 Case Study: Step Voltage Test at Higher Voltage Found Unstable Ground Wall Insulation October 30, 2007 SKF Group Slide 38 Case Study: Step Voltage Test at Higher Voltage Found Unstable Ground Wall Insulation October 30, 2007 SKF Group Slide 39 Case Study: Step Voltage Test at Higher Voltage Found Unstable Ground Wall Insulation October 30, 2007 SKF Group Slide 40 Case Study: Step Voltage Test at Higher Voltage Found Unstable Ground Wall Insulation October 30, 2007 SKF Group Slide 41 Case Study: Step Voltage Test at Higher Voltage Found Unstable Ground Wall Insulation Last step at 8,960 Volts shows unstable ground wall insulation The step test allows the operator to see and trend the current leakage October 30, 2007 SKF Group Slide 42 Solutie dinamica pentru determinarea puterii, sarcinii si a problemelor mecanice ale motoarelor electrice October 30, 2007 SKF Group Slide 43 EXP3000 and EXP3000R Echipamente mobile Echipamente permanente October 30, 2007 SKF Group Slide 44 Safety and Connecting: Low Voltage (Less than 600V) Motor MCC Load Breaker Step one: Running motor Step two: STOP motor Step three: Connect MPM Step four: Run and test Step five: STOP motor Step six: Disconnect MPM Exp October 30, 2007 SKF Group Slide 45 Safety and Connecting: Medium and High Voltage (More than 600V) Connect into Secondary Pts and Cts Motor Load CTs Breaker Step one: Motor is running Step two: Connect Explorer CTs Step three: Connect Explorer PTs Explorer PTs October 30, 2007 SKF Group Slide 46 Motor CTs Breaker PTs EP Explorer First Energy RC Pump 1 of 700+ EPs at one customer Acquire Data: Safe, Fast & Easy W/ EP-1 October 30, 2007 SKF Group Slide 47 SKF Online Motor Monitoring NetEP - Overview NetEP is a fully automated, network connected, electrical motor monitoring system. It continuously collects data on the health and performance of electric motors. The NetEP is a permanently installed system. Permanent voltage and current sense connections are required for each motor. The NetEP monitors over 40 electrical parameters of electric motors and compares the results to limits, displaying alerts if limits have been exceeded. The NetEP can be configured, monitored and operated from any network connection. October 30, 2007 SKF Group Slide 48 SKF Online Motor Monitoring NetEP - Overview NetEP Networked Electrical Processor Up to 32 motors (96 CTs) 5A to 2000A Calibrated, from Baker Up to 150 CT signal runs on CAT 5 cable 25 KHz signal acquisition Up to 7 different voltage busses Up to 1000V direct input, or PTs. Line to line, line to neutral, External Disconnect Required MCC mounted box 20 x 30 x 8, ~ 65 lbs CAT III, NEMA 12 Enclosure LAN and AC power (110V 240V) required Computers for data storage and Network based monitoring Provided by customer (IT compatibility) Test all 32 motors every 10 sec (Basic Motor Monitoring) October 30, 2007 SKF Group Slide 49 Power Quality Analysis PQ Capabilities Voltage and Current level, unbalance distortions Kvars, KVA, KWs, Power factor, Crest factor, Harmonic bar chart ect. October 30, 2007 SKF Group Slide 50 Faults Explorer & AWA will Identify Power Quality Poorly performing Transformers Short, medium, long, range trip settings Connection issues (Junction Box, In motor) Lead Line Insulation deterioration Turn-Turn, Phase-Phase, Coil-Coil insulation weakness Ground Wall Insulation Weakness Dirt Moisture Dry Rotted, Brittle Cracks Motor Circuit TurnTurn Shorts, Opens Reversed Coils Phase Unbalanced (turn count) Phase Unbalanced (wire size) Rotor Cracked Bars Poor Welds Broken Bars Eccentricity (Dynamic, Static) Loading Issues Over load Process Mechanical Bearing faults Miss Alignment Fan Unbalances Belt frequencies Worn Impellers Gear Mesh Frequencies VFD Power Quality Shorted IGBTs Feed Back loop Process Information Tuning / Set up Soft Start Tuning / Set up Trouble shooting Ect. STATIC DINAMIC DINAMIC October 30, 2007 SKF Group Slide 51 Motor Overheating I 2 R Losses Motor Currents 100% rated Current 100% rated Temperature 110% rated Current 121% rated Temperature October 30, 2007 SKF Group Slide 52 Voltage quality NEMA derating Voltage Unbalance & Harmonic Distortions October 30, 2007 SKF Group Slide 53 Test station 300 hp 3570 rpm Eff. s.f. = % NEMA derating % Load Effective s.f. October 30, 2007 SKF Group Slide 54 Temperature (C) Full Load 1.15 SF 1.25 SF 49 64 77 56 75 91 75 102 128 64 80 94 69 89 106 Horsepower 10 20 50 100 200 * Courtesy U S Motors Motor Performance: Service Factor and Temperature October 30, 2007 SKF Group Slide 55 Effective s.f. Pulp & Paper Industry: Operating RMS values Voltage Level 658.2 V 99.7% Current Level 378.4 A 91.4% Load Level 312.6 kW 78.1% All OK? Voltage Unbalance 3.66% Voltage Distortion 9.80% NEMA derating % 0.6 Eff. s.f. 1.28 October 30, 2007 SKF Group Slide 56 Power Quality Analysis Importance Poor power quality causes increase heat For every ten degrees rise in temperature the life of the motor is reduced in half. October 30, 2007 SKF Group Slide 57 Fan 1 hp 1740 rpm Motor Condition: Broken Rotorbar October 30, 2007 SKF Group Slide 58 Torque Analysis Great tool for Separating between electrical and mechanical issues (solve fighting between mechanics and Electricians) Reason the load is what causes more or less torque from the motor If a torque signature looks out of the ordinary the problem is most likely in the load October 30, 2007 SKF Group Slide 59 4160V submersible pump Torque Signature: October 30, 2007 SKF Group Slide 60 Mechanical FFT Analysis Diagnose mechanical issues from the MCC Bearing Outer Race Inner Race Cage fr. Fan Unbalance Ect. October 30, 2007 SKF Group Slide 61 VFD: Variable Frequency Drive Analysis Benefits Tune in drive Load analysis Faulty IGBTS Feed back loop issues October 30, 2007 SKF Group Slide 62 Transient Analysis Set up short medium and long range trip settings Set up Soft Starts Diagnose Pump and Fan issues Worn impellers Binding pumps Power Issues Rotor Issues October 30, 2007 SKF Group Slide 63 Continuous Monitoring Software Excellent Trouble Shooting Tool October 30, 2007 SKF Group Slide 64 Organizations Backing Testing IEEE 522 IEC 34-15 NEMA MG1 NFPA 70B EASA October 30, 2007 SKF Group Slide 65 Easy Automatic Analysis of Results October 30, 2007 SKF Group Slide 66 Sumarul prezentarii Analiza dinamica a motoarelor electrice asigura informatii despre calitatea puterii, sarcinii, defectelor electrice la motorul electric / MCC / masina antrenata. Analiza statica a motoarelor electrice asigura masurarea integritatii sistemului de izolatie a motorului si a circuitului sau electric. Impreuna cele doua metode asigura metode complementare de indentificare a satrii de functionare a motoarelor electrice , diagnoza precisa a defectelor si prevad / prezic eliminarea defectelor. Cresterea calitatii inspectiei motoarelor electrice concura la eliminarea defectelor si la predictia lor. Eliminarea defetelor: pentru a nu trimite in camp motoare defecte. Predictia defectelor: masuri pentru evaluarea starii de functionare si eliminarea opririor accidentale. Questions?