REPRINTED WITH PERMISSION OF TURBOMACHINERY INTERNATIONAL An On-Line, Computer-Based Current Monitoring System for Rotor Fault Diagnosis in 3-Phase Induction Motors W. T. THOMSON S. J. CHALMERS. Robert Gordon's Institute of Technology This paper presents an on-line current -monutoring system for detecting rotor faults in large. high-vottge 3-phase induction motors. The philosophy and peactiea! advantages of curreat monitoring are Aiscussea and samples of on-site case hustones wall venty the effectiveness of he ‘method for detecung broken rotor bars and amr gap eceentncaty an the indusinal fenvivonment A new. computerized diagnostic system wih expen system ‘capability sl also be described Large. 3-phase induction motors are used ta dave gas compressors. oll exporung pumps and se3 water imjecion pumps in olishore ei! production platforrns, To prevent the sudden fadure ofa large motor, whieh can be very costly and potentally dangerous, 11 essential that fault ‘mechanisms are detected at an exch stage. I ihis ean be dune by reltable on-line rmonstoring techniques, then the motor ean be removed from service and repaired at coovement time im order 10 a¥@K8 lost production and revenue. In addition, the fepatr can be planned when the manpower and component pans ate avarlable, tnus | OPtLmizing masntenance strategies "The on ine montioring techaques w hich ave normaly been used w astess the Dus papers enemas presenirwarine Tora Tusbwmachinen Mainiqnanee Camereis in Cadom, Enwiand October $-9 1982 Fon mare Iajormanin comune ti Tarhomachaners | Mownenani¢ Inunute $0 Das Siveet Swrsust FTO ACS 4 Tet Oils BSS ORIS Aberdeen, Scotland D. RANKIN Inspectorate EaE Aberdeen, Scotland condition of large HV squirrel-cage induction motors have been dedicated to | detecting rotor dynamic pzoblems and bearing wear (1), This 6 usually achieved by sensing the shalt movement sing displacement probes placed i the bearing housings. The technique has proved to be successful for detecting drwe fivsalagomeat, a beat shaft, oil whi bearing ecceninients and west (2) | However, an HV induction movorcan fa | due a other fault mechanisens which are not Simply mechanical or elecirial but are often interrelated and complex (3). For example, frequent ditect-on line staring ‘an cause broken rolar bars or end Tings due lo the large staring curreais 15 a umes full-load eurrend. producing high mechanical andibermal stresses onshe cage swinding (4). DOL staring also produces large end- winding forces and core vbeation dating the intial aasieat This can cause mechanical damage tose portion ofthe col In he slot and subsequent insuaon breakwown (3) ‘ ‘Another fauit which ¢an occur m6 3 | mechanical rub between the rotor and stator | hich results 39 damage W the stator core | and nding. This faule 1s due 10 aur-gap eecenineiy and unbalanced iagacic pull | 46a result of bert snaf, ravar resonance | bearing wear and shaft movement orator | care movement (69. This paper will sancemrate on the appicatin of current manitorng for detecung broken rotor bars Relerence will aka be mide 10 As use for Uiagnosang aie-pap eceentrcity Broken Rotor Bars Thelatge staring currents in an inducion | ‘motor oceur when cooling 1s minimal and ‘esult in the shermal and mechanical stresses being at maxamurn The nciserce ‘of eracksng inthe region ofthe barto-end rng jon is greatest whenthe star-up iar Is elauvely long and when tiequeat sans are required a8 part of 4 heawy duty ccie Development of damage o the roiarancr racking ofthe sor bar has staned usual, follows the following sequence 171 |) me cracked bar overheats around ine crack 2. the bar breaks and arcing occurs } theadhacent bars carry mote current and are subyecied to even greater hernal And mechanscalsiesses dusting sa up, 4 be high dhermal susesses. The possibilty of area ‘nv thatardous envionment 1 unacceptable. herm ¢ a reliable on le monitoring technique 1s requiced 10 o the onset of rotor winding faulls To facunate ease of use. the monkorne method should be as aon-ineasive sy possibie Previaus research bas stow hat when 040 wed broken roiar oarseusst, harmon Mlutesate produced inthe aiegap-which anducezuren Components it the sao wunding a1) = 7 fe FOtor laminations can be damaged io |fact modulated a1 + 256, 14), Te semphasized that this ater effect rot be detected using displacement probes sn the bearing housings since rotor slot harmonics are much higher than the frequencies detecied by displacement probes Even if accelerometers are used 21 ‘the benring pedestals, the vibrauon slot harmonics are greatly altenusted beeen the cove and bearings in large HV induction motors. hence the resulting information is luscless with respect to high-frequency ‘vibranen slot harmonic content, ‘The axial flux speciromalso exhibits the modulation effect around the supply Frequency component (8), It is also known that the torque will Moctuste due to broken tbars and results in a slightly fluctuating speed (9). Since broken bars produce changes m venous parameters. the problem canbe diagnosed bya numberof methods stator core vibration and perform hgh resolanon frequency analysis around the rotor sloe harmonies to detect the side-tand fe) Monitor the axial Nox using a coil around the shaft and perform 2 frequency analysis, Monutor speed Fluctuations via 3 once: er revolution transducer and perform addivonal processing 10 display the number of broken bars ‘is elear that methods (b). (cy and (1 Ihave # mayor drawback in that e655 15 required to the motor to install the appropriate transducer Unless the transducer and associated instromentauon ‘are certified intrinsically safe, then “hot work" permits have to be sssved Method (6) requires spectalist knowled ge ‘of the motor design and expertise in the analysis of the complex vibration signal s0 that the fault can be identified, Since the ‘mechanical response of stator corey will be different for each motor. the quantification Of the number of broken bars 1s extremely difficult and practical m industry The ‘nsrallation of vibrattontransducer onthe stator core requires modifications tothe motor'for the purposes of mounting and able access In method (the motor has ta be siopped to fia coil around the shaft in order to brain a rehable signal; results have not been published to verify dh the number of broken bars can he delermined i. the | dustrial environment “a 18 “wovemoetitiecemne! 1987 (current eet) gs 2 fa me are level) an ae ® at bs) Seeteoraasth Severe ‘2511 | Air-gep Eccentricity ‘Aar-gap eccentnenty in electrical imachines can aceut as ste or dynamic eccentricity, Stanic eccentricity can be | defined as the position of minimum radial air-pap length whichis fixed in space, This can be caused by stator core ovality or incorrect positioning of the roter or stator al the commissioning sage, Atte position of smirurmumsair-gxp there is an unbalanced magnetic pull which tres to deflect the -— Sdetere 2stoo rear. hus increasing the amount of 1-52 ha result of at gap eeceninicty can bea rub between the rotor and stor and coniequemial damage 10 the HY stator ‘winding. This can involve an expensive ‘epatt and an unaccepable downme Previous research by Cameron. Thomson, {a Dow have proved ibt unique signature pptiems can be identified im he current Spectre which are only characteris of airgap eccenunciy (6.10). The frequency Cauatvon for determining these components is: fag > {1008 # Where fy = supply frequency Hz fq = any uneper R= number of reir slots fig = any imeger (O for save elec) (1.2, for dynamic eceenancity) p= pole pairs 3 = pu. slip ws integer numbers: UBT By the use of current monitoring. the comhtaon ofthe rotor winding and the fdynarmic movement ofthe fro core nthe bir gap can be determined Laboratory Results: Predictloa of Broken Bars 1 has been venfied by ¥ number of researchers thal sidebands at (2 2sf,) appear around the supply current frequency ‘component ({,) when motor winding faults ‘occur. An estimation of the number of broken bars can be developed from Fundamental eleetneal machine tncory (9 Mb Previous research has concentrated on detecting ro.or winding fas when the moror was delivering full-load output (4 9). This ts, of course. not the case in an Industrial installation, whete the motor indy be operating at any Koad condition “depending on the process demand. A comprehensive companson between the predicted numberof broken rior bars and the actual number has oor been researched. Inaddition. an evaluation ofthe preaicuons asthe load a vaned with given number of broken bars 1s also necessary Table 1 VARIATION IN dB DIFFERENCE (N) BETWEEN SIDEBAND AND $8 Bix COMPONENT WITH ONE BROKEN ROTOR BAR AS A FUNCTION OF LOAD VARIATIONS. Carrent Speed ‘amps rpm. 242 1420 1164) 2a 4430 156 195 1440 147 m4 1490 437 isa 1460 12. 43 1470 M9 be 1430 102 b 1490 09 Mf umerous case histones show that an ‘empirical factor can be included which yields a realistic predicuon. thea the “Ubagnoutts technique can be used with confidence. In exvence. expert knowledge feanbe used tn the analysts and included ‘computerized diagnostic package. Thecase hhsiones prove the effectiveness of foattoning current to detect broken rotor boar. (See pages 00-00.) ‘A special frul-producing test og was designed sad consiructed 10 anvesigete ‘vanous types of faut mechanisms in 3- phase indvction motors. The test ng hus the facilites t-condoct controlled experiments withthe Following faults: © broken rotor bars flatic and dynamic eccemtrciy © ator winding faulis ‘A new Salat xquirrel-cage rotor was used for the investigation. Figure | shows the zoom FFT analysis of the eurrent signal around Ure 50 Hz component when the tmocor was dehivenng full-load output. The (1-25)f, sideband is 64 dB down on the supply Frequency {1,) component. The laren tel) S0Hrcom- Lower band dB difference) event Bx tp pooent @B Hx eight SS eE ati 2a olde Nip Taetght “ us n aa 45.25 n us “« a 45.7 6.15 6 ay 4735 as ag “a os sa 465 56.7 BS 9.35 06 a3 predicted aumber of broken bars is 0.046, the presence of + 2sf, components isduei0 normal tolerance variations in the ‘esisiance of the bars and the bar to end rng Joints. One rotor bar vas subsequendly ‘broken at the joing between the bar andthe short circuiing end ring. “The new spoctrurn with dhe increased sideband content ts shown in Figure 2 when the motor was also delivering full-loud ‘output a rated speed. Using he dhoorevcal predictors (4.9, 11) the predicted mumber Br broken bars is 0.6, which is 40% lower than the actual ousnber: his verifies thatthe prediction waderestimaies the actual Condition, A variable load test was Subsequently earned out with one broken fotor bar and the resus are presented i Fable |. Figure 3 shows the current spectrum at 9 reduced current (14.5 A. 1470 ¢-p.m.) "A comparison berween Figures 2 and 3 highlights the change an the spectra 38 the fond varied. Using the predicted theory (11) the number of broken bars has been reduced {ror 0,6100,27, hence the predicuon atthe she tupomactineryintescarens) 19‘winch t& 30% lower than 2, At half tull-toad the prediction has dropped (0 0.6. Thus using only theory to predict the conditwen fives insccurate results. parteularty atthe Iaghter loads. ‘Clearly, load condition has 10 be ‘considered in the prediction: however, ‘hat has fo be stressed os thatthe umgue pattern shown in Figures 2, 3 and 4 only ‘ecurs with broken bars. “The research results can be verified by scwal on-site case histories Cnet ‘Motor detail: J-phase, SCIM. 127/708". 415 V, 2001504, 14807740 RPM, 30 He. fobricered copper care rotor. ‘Duty: Hearydury ceele, 2-speed miter motor, 88 rotor bars. “The motors are used in miner drives “which operate at wo speeds under a heavir- duty eyele, Twenty-Four starts per hour was typical, There had been history of broken rotor bars: bara were being replaced regularly every two years and inmany case the ume of failure was unpredicuble “The current was monitored atthe low and bhigh speeds. The specira for one wf the motors are shown ih Figures $ and 6: the theoretical prediction of the number f [broken barsae the iow and high speeds gives (0.68 and 3.7. respectively. The renwns for the difference te thatthe bars have fad tre to beat up and the effect of centrifugal forces reuulted in more bars loxing contact swith the end ring at the higher speed. ‘Based on the theoretical prediction. ‘operating dury and previous case histones, Wt was correctly estimated that there Were five broken bars. Figure 7 shows the (aulty ’A change of design of the rotor end rang assembly has been implemented 0 1ry Solve the inherent problem of failures dve to the many sian and consequent high thermal and enechanieal stresses, The motors are now being monitnred 00 + tezular basis to assess the effectiveness of the design change and to prevent 4 sodden faslure Case 2 Motor detaits: Jophuse. large SCIM, 168 MW. 11.000, 1104, 1487 RPA. 50 H, fobneaned copper euee rit ‘Duty: Crude onl purap drive meee. onshere mtultanern ‘The movor current wins mmanatred v3 the instrument CT inthe yehstatinn aod the sy shown in Fapure leary cvwdent at During the test the ox for 61 i the fallad current “The mato tasty operated 9 srs sat 20. NovemoenDecemper #1 & larrn lel guy 6 88 a 8 ty feurent eet oF B38 Seorbana (2f)— 7 Sattar st) sore eee Ww Shsh se w 2 3 2 Frecsency Fre Current spectrin hen speedtd hunt been subjecedion hwy y cycle In was decnled to inspect the four a the on-site Workshop. a conslcrable ‘undertaking because ofthe ste af the rotor However. the motor was operating in » harandous area and the cht wanted know the rotor's condition ‘The ro1or was mounted inthe workshop balancing maching to give fee access the short enruit ring and all wor bar connections athe drive ard nor-drve nds. The predicted number of broken rotor bars was 15 Ss ‘The drive-end connections all looked sound and the short circuit ing was of uniform thickness. The disunce benweea the rotor core and end ring faces was measured around the circumference ast was found to be oqual. The measuremens ‘were repeated atthe non-dive ened, but the ‘results showed thal the nor-dnve end sbon circu rng was lying 2 mmoffserrtauive to the rotor core face, and the thickness ofthe ae ring Yaned from top 1 bomiom by 15 me. Whete the distnce between the core face and the end ring face i largest five ovnts were suspect i-was poticeable on the good joints that thebrazing materal had flowed evenly with beat, This was the case atthe drive end and atthe good joints on he non-deive end. The five fauly joins had spikes and were severally 2 rough state compared to the = Seiten others. This would unply dat the suspect area had pot been heated to the same temperate. Itmuy have been tbe case that ‘when the unt was gged for brazing during, mmanulacure that movement had occurred Fig, 7 Feud rotor tease Wy __~ Sidetana | oS a8 8 ai yr | (This would explain why tere was a 5 aa differences the ing thckness around 3s Coreumference, since Mel that sher 48 Cares sper 185 MW moor ph enmance pons Sree see te ‘machined 1a remove surplus matenals and Improve ns appearance, ) Having taken the trouble 1o remove the rotor, the question had lo be answered How good 3 connection di the bars have 10 the end ning atthe faulty jomnts? Aa NDT ey ‘contractor on the site was called to perform Sect ulieasome tests and gamma radiography on 163, the suspect area. The ulirasonic test was 5m foun 19 be inconclusive: however, whe amma caiography revealed voc nde ramped Figure 9iusraesthe problem: A vord is See, situated 19 ram from he front eige ofthe ’ Shar exc rng and has wala 110 3 sw: Tn Seayet megan poe engi for joining of 3 Sun, the rng only 23.3 tu we at he pou Ti Fring aren cou be erie alee : pea having a complete il of he angular trove Inbeeucot a réierarvacie ie agecrasn cacao gin as Bel wnvinchswel. tilede sons art Compound then the joing length mtx Fig. 9 Ravor oar to shore ceca ng you! Mlstravon, be oniy 1.5 t0 2 mm. Furoomachnery iernavonasduagnosis did prove that the rotor was faulty, The operator now knows the rotor is subsandard and should not be subjected 10 ‘numerous start-ups and heavy-duty cycles Proper quality contol using the analysis technique presented would have detected ‘the substandard joints athe manufacturing stage, It i worth noting that in Figure 8, there sare multiple sidebands at 4 4sf,: whether this i characteristic of high-resistance joints for tha particular type of rotor ‘construction is unknown at this sage. Case 3 Motor details: 3-phaze. lorae SCIM. 3.6 MW, 6600V.. 374A, 3580 RPM, fabricased ‘copper coge rotor. Duty: Seo-water injection pump drive. ‘offshore installarion ‘The current was monitored and analyzed inthe usual manner, Figures 10 and 11 show the current zoom analysis from on- site tests, Figure 10 has a sideband level indicative of high-resistance Joins Follewing the analysis presented in Figure 10, the motor was resutveyed sfer 12 months, Figure 1 shows that there was an increase of 20 dB in the sideband height ‘This is. im fact, a 10-foldinerease in absolute terms Th was recommended that the motor be shut down and the rotor removed for tnapection, since it was predicted thatthe rotor had many broken bars. Figure 12 ‘lustrates the faulty rotor, Upon inspection. the roior was found to be severely deteriorated: in fact. there were 20 broken bars out of 2 (otal of 46, The decision to shut down the motor had prevented the likely siuaion of 4 sudden failure and possible secondary damage 0 the stator winding Ins worth noung tha he vibration levels atthe bearings were acceptable. and from. vibration point of view the motor #2 in sansfactory running condition ‘Clearly, that was not the case, as stlystrated by Figure 12 Case 4 ‘Motor details: 3 phase. SCIM, 134 4W (150 apt, #40 ¥, 210A, 1485 r p.m, 50 He, 0.88 pf. ¥ connected. ungle-cage dhe au aluminum rolor. 5B roror slots Duty: compressor dewe motor, offshore installanon Too comprestor units were driven by r@entical motors and the client had reported that one of the motars ws producang pulsating vibrations and an audible beatin, NovemoersDecemoes 1987 ab (current Lev) 2 Fig, 11 Resurvey,broten bars Pia 12 Fauin secon nf svor case Shee effect. Before we were invited jo monitor fhe motor Abad been remaved from service fice aad i bearings ropinced each time. load. Thi is because yery lithe exrrent flows in the motor winding dusing no-load, hence the rosor asymmetry problem is not sexcciabie. mowoy? The client ‘ridence toresolve the dikemms, This could pe achievod by analyzing the curreas ripmal to deveramine if broken bars were presen. ‘one-day visit was arranged 10 the and Ga CT wes installed inthe ywitchear room {which is safe area) and the inconvesience of igzuing “*bot-work ‘was not required. The resulting zoom analysis ppecera ase shown in Figures 13 and 14 for the faulty and bealthy motor, respectively ‘During che tec. the faulty momo wat taking 120 A (57% ofthe ful-boed current Of210 A). ‘The motor was aso opersun gon light on/off dury (5-10 minutes on end | our off in to the normal duty cyele of 15 mimes on and 15 mare off She presicied aumber ofbroken bars was 2,6, Our research work hs proved thatthe theory underesamsiea the condition on full toad, and that on reduced losd of a axor of the size being epted the predicted valve will bbe considerably Jess than the acual ‘condition, Taking this and previous industrial expervence into account. it was Delieved thal the rotor could have up to & broken bass. ‘On the basis of our analysis and advice, the clea decided to purchase anew motor. During the 4-10 6-week delivery ime, the bealihy motor was run on full-toad and the faulty soouar operated ine standby or light load made, Afier the new motor was Gelivered. nsialed and commissioned, the folly moor was removed from the platform 10 3 abore-based workshop ‘On siip-down and visual inspection. 90 cage faulls were evident as us sown 10 Figure 85, Based purely on this visual inspecwon a fepait workshop would have ‘concluded that the rotor was healthy andin $ serveceable conduion, However, the pectrum analysis had provided scientific to loceront teeth "Os a 2 Fig D Fo ‘evidence that dhe rotor cage was faulty. I twas decided that the rotor bars to end ring [extions shouldbe inspected. This was done by machining through the Laminated core and cage close to Une end cing. Figure 16 Indicates the major defective area. A complete ins portion reveakcd te following fouls: ‘© 10 broken bars and spark erosion; +a number of parially broken bars and pak erosion: 1 Blow holes inthe dic casting of rotor ‘cage end. ring secti00. “Tins case hintory proves that by using, only thooresical predictions the respls will De unacceptable: This means factors such af (ype of rotor, duty eysle and toad condition Rive to be considered when making the diagnosis as to how many bars are broken. The theory provides the result for inital diagnons. In essence, the concept of doveloping a computer-based expertsystem bnased on acientific research work and fpumerous case histories is the way ahead for electrical machine fanlt diagnosis Fig. 14 Healing motor. BL KW Hote Garvent Spactrum mater wath rotor come demo Fig 1S Decas rr ose Jeroomactinery tateroxvorsFit 16 Fouiryrsor reno (ete 4), Dingnontic Package The on-line diagnosis of roeor winding malfunctions and airgap cccemtncity canbe obtained using high-resolution spectrum snalysts in conjunction with professional expertise, However twas recognized tht the research work, onsite experience, and 25: histones gained from monoring more than 600 motors should be sed to devclops computerized online motor monnor with expen system capabilites ‘This hasbeen developed sch that the on- line diagnosis t software driven and the ddiagnoste rouimes and expert knowledge {rcan megral puro the software package ‘The development of the computeraed fmemiorng system came 1 friion de to the combination of esearch work. field experience andthe collaboration benween industry and an academic insttuion ‘The end result isthe provision ofan slecuie motor mositoring system (Figure 17) which users can operate to prevent clectrical machine failures, and hence improve maymtenance strategies, reduce downtime and t8ve money in the operation ‘oftheir plams and processes, Conchesions ‘The research results tnd on-tite stories hhave verified that curremt monitoring tnd Analysis is an effective method for monitoring the condition of }-phise Induction motors. The succeas of the ‘diagnosis is based on the combination of Scientific theory, operating condition, and ‘motor design, Field experience and expert knowledge hhave beea used to develop 4 computer ‘based diagnostic analysis system which includes expert system software routines ee Pre ouchrn who ackmoriede thease pvenby rx Alison Rendall and Mr hace phony 1A paver Ofhhore mdiuction mosor sy:meme aLeg O@-lime eee Recent inches boos ac peor es gee ienactere stores Meese See eee 3. Leonard, Tho, W.Va ‘coy fat monsorng fe unileced phy Sd ner Wid la agi a rs ‘moto, Frcendgs of It UK Inert ‘eels oa Condtnts Monsees, Usitaty olka of Swamet Sesh. I hd TUL, Fy MOMS. ad hs doa nr oe Borer Femat bly 9b, Fp BYE § Cheer. Tama, WT. tad Bows A 1h: "Vibe socom tome or ‘dec trp exon arp eros FProcengs TEE vol 133-p BN), Nay ab 188163, Garde 8G. od peed. D1. Fae lie eed alang won, Elernend enews, Val 08, Ha, a, Gasner 19H, pp H emia. 1a: “Comoe mansonet of dices,” Pro TEER. B Vel 185 No 3 oes baited Harp... eyo, 3-6. sd Kamas, ~The orcoon of ror aeecs st nso tes, ‘rs KEE Conlerese on Becta! Masons — Dest tnd Appear, 1982 No. 213 pp. Thomson WT. Caron.) A. tad Dw Af "Oman penis o emcee NATO: AAW! Catstic Uncerry of Laren, ‘August 1906 pied i he HATO Air Sec, Frere 1981 Mitchel 1. “Sud ot ne hd trams enn sti cnet for rt eae ak ein." RS: Hass Pet, Ren Coren liso of Tcheogy, #980 ELECTRIC COMPUTER DISC STORAE some 2 INTERFACE RECORDS aes: | MOTOR REC ‘SIGNAL SPECTRUM AM ALYSER PERSONAL COMPUTOR COMOMONNG = p-— 6% Rear] lea 00 eae l L baa sere CFE November®ecember 1987 motarmonitonns salem