Motor Health Monitoring using GE Multilin 869 Relay

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Single Line Diagram of the Plant
Pilot Motor
Manufacturer ABB
Type Induction Motor
Rating 750 KW
Rated Voltage 6600 V
Full Load Current 83 A
Speed 595 RPM
Frequency 50 Hz
DE Bearing 6330C3
NDE Bearing 6324C3
Application Coal Pulverizing
Factors considered for the study

Failure modes
1. Bearing Faults
2. Mechanical Faults (Foundation Looseness, Eccentricity, Misalignment)
3. Rotor Bar

Operating conditions
1. Motor running on load
2. Motor running on no-load
3. Motor not running

External factors
1. Nature of the load on motor
2. Motor power supply
Bearing and Mechanical Faults

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ESA Plots - Motor on Load

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ESA Plot - 9th February, 14:58 hrs
• Motor on load - Harmonics due to load oscillations detected by the Relay
• Pickup at F1
ESA Plot - 7th February, 17:24 hrs
• Motor on load - Harmonics due to load oscillations detected by the Relay
• Pickup at F1
ESA Plot - 5th February, 16:55 hrs
• Motor on load - Relatively cleaner plot indicating no load oscillations at that time
• No Pickup
ESA Plots - Motor on No Load

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 ESA Plot - 9th February, 15:18 hrs
• Motor on No Load; Cleaner plot indicating as there is no load to cause oscillations
• No Pickup
ESA Plot - 9th February, 20:08 hrs
• Motor on No Load; Cleaner plot indicating as there is no load to cause oscillations
• No Pickup
Study of component fault levels
compared to baseline values

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 Bearing Fault

MONITORI MONITORI MONITORI DIFFERENCE DIFFERENCE DIFFERENCE

BASELINE BASELINEBe BASELINEBe BASELINEBe BASELINEBe MONITORI MONITORI MONITORI NGBearing - NG Bearing NG Bearing DIFFERENCE DIFFERENCE DIFFERENCE Bearing - Bearing - Bearing -
Bearing - Bearing - aring - Avg aring - Avg aring - Avg aring - Avg NG Bearing NG Bearing NG Bearing Avg Energy - Avg - Avg Bearing - Bearing - Bearing - Avg Energy Avg Energy Avg Energy
Time of Avg Norm Avg Norm Norm Peak Energy at Energy at Energy at - Avg Norm - Avg Norm - Avg Norm at Peak Energy at Energy at Avg Norm Avg Norm Avg Norm at Peak at Peak at Peak
Baseline Peak Mag Peak Mag Mag @k=3 Peak Mag Peak Mag Peak Mag Time of Fault Peak Mag Peak Mag Peak Mag Mag @k=1 Peak Mag Peak Mag Peak Mag Peak Mag Peak Mag Mag @k=1 Mag @k=2 Mag @k=3 Estimated
Computation @k=1 (dB) @k=2 (dB) (dB) @k=1 (dB) @k=2 (dB) @k=3 (dB) Load Bin Computation @k=1 (dB) @k=2 (dB) @k=3 (dB) (dB) @k=2 (dB) @k=3 (dB) @k=1 (dB) @k=2 (dB) @k=3 (dB) (dB) (dB) (dB) Load Bin Speed (RPM)

1/30/2019 -63.4 -48.9 -51.1 -62.9 -49.4 -51.5 6 1/31/2019 -77.2 -63.2 -66 -80.8 -67.1 -67.1 -13.4 -8.7 -11.9 -17 -13.6 -15.5 6 598

1/30/2019 -63.4 -48.9 -51.1 -62.9 -49.4 -51.5 6 2/1/2019 -70 -54.9 -55.6 -69.7 -55.8 -57 -5.8 -6 -4.5 -6.8 -6.4 -5.5 6 596

1/30/2019 -63.4 -48.9 -51.1 -62.9 -49.4 -51.5 6 2/4/2109 -76.2 -62.3 -60.8 -79.1 -63.5 -64.9 -12.4 -12.5 -8.7 -15.3 -14 -12 6 598

1/30/2019 -63.4 -48.9 -51.1 -62.9 -49.4 -51.5 6 2/5/2019 -71.8 -58.7 -60.1 -72.7 -60 -61.5 -8 -7.3 -7.8 -8.9 -10.7 -10.6 6 599

1/30/2019 -63.4 -48.9 -51.1 -62.9 -49.4 -51.5 6 2/19/2019 -68.5 -52.9 -53 -68 -52.7 -54.3 -3.7 -3.1 -1.9 -3.5 -3.2 -2.8 6 599

Observations
• The changes in the dB values from the Baseline value are less than pickup threshold values at the time of
recording the values
• The last recorded value indicates a reduced margin of the pickup threshold value over the baseline value
 Mechanical Fault
MONITO MONITO MONITO MONITO MONITO MONITO
BASELINE BASELINE BASELINE BASELINE BASELINE BASELINE RING RING RING RING RING RING DIFFEREN DIFFEREN DIFFEREN DIFFEREN DIFFEREN DIFFEREN
Mech Mech Mech Mech Mech Mech Mech Mech Mech Mech Mech Mech CE Mech CE Mech CE Mech CE Mech CE Mech CE Mech
Fault - Fault - Fault - Fault - Fault - Fault - Fault - Fault - Fault - Fault - Fault - Fault - Fault - Fault - Fault - Fault - Fault - Fault -
Avg Avg Avg Avg Avg Avg Avg Avg Avg Avg Avg Avg Avg Avg Avg Avg Avg Avg
Time of Norm Norm Norm Energy at Energy at Energy at Time of Norm Norm Norm Energy at Energy at Energy at Norm Norm Norm Energy at Energy at Energy at
Baseline Peak Mag Peak Mag Peak Mag Peak Mag Peak Mag Peak Mag Fault Peak Mag Peak Mag Peak Mag Peak Mag Peak Mag Peak Mag Peak Mag Peak Mag Peak Mag Peak Mag Peak Mag Peak Mag Estimate
computatio @k=1 @k=2 @k=3 @k=1 @k=2 @k=3 Computati @k=1 @k=2 @k=3 @k=1 @k=2 @k=3 @k=1 @k=2 @k=3 @k=1 @k=2 @k=3 d Speed
n (dB) (dB) (dB) (dB) (dB) (dB) Load Bin on (dB) (dB) (dB) (dB) (dB) (dB) (dB) (dB) (dB) (dB) (dB) (dB) Load Bin (RPM)
1/30/2019 -52.6 -59.5 -62 -53.6 -59.4 -61.9 6 1/31/2019 -67.1 -75.8 -75.7 -72.1 -76.6 -78.4 -14.5 -15.7 -13.6 -18.5 -16.7 -16.9 6 598
1/30/2019 -52.6 -59.5 -62 -53.6 -59.4 -61.9 6 2/1/2019 -59.8 -66.3 -68.5 -61.9 -66.3 -69.6 -6.5 -6.8 -6.5 -7.7 -6.9 -7.7 6 596
1/30/2019 -52.6 -59.5 -62 -53.6 -59.4 -61.9 6 2/4/2109 -65.5 -74 -72.4 -69.2 -75.7 -76.2 -12.8 -13.9 -9.3 -14.7 -15.8 -13.1 6 598
1/30/2019 -52.6 -59.5 -62 -53.6 -59.4 -61.9 6 2/5/2019 -62.4 -68.5 -69.9 -62.8 -69 -71 -9.8 -9 -7.9 -9.2 -9.6 -9.1 6 599
1/30/2019 -52.6 -59.5 -62 -53.6 -59.4 -61.9 6 2/19/2019 -56.1 -63.6 -66.8 -57 -63.2 -66.9 -2.8 -3.5 -3.7 -2.8 -3.3 -3.8 6 599

Observations
• The changes in the dB values from the Baseline value are less than pickup threshold values at the time of
recording the values
• The last recorded value indicates a reduced margin of the pickup threshold value over the baseline value
Conclusions

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Bearing Faults and Mechanical Faults - Conclusions

• Load oscillations
 Presence of load oscillations is observed by analyzing the electrical current signatures of the motor
under load and no load conditions
 The occurrence of the load oscillations is generally random with respect to time
 Harmonics due to load oscillations are spread across the bearing fault and mechanical fault frequency
spectrum

• Power supply quality

 Voltage harmonics are observed in the power supply, probably due to the power electronics devices
connected to the bus. Influence of these harmonics is not observed on relay pickup

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Rotor Bar Health Analysis

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Initial observations on Rotor bar
component levels

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Broken Rotor Bar

RotorBar - RotorBar -
RotorBar - Load RotorBar - Maximu RotorBar -
RotorBar - Motor Dev. At Maximu m Motor RotorBar -
RotorBar - Compon Load at BRB RotorBar - m Compon Load at Load dev. RotorBar -
Compon ent BRB Calculati Time of Compon ent BRB At BRB Time of
ent level Frequenc calculatio on (x BRB ent level Frequenc maximu Maximu Maximum
Date (dB) y (Hz) n (x FLA) FLA) Calculation (dB) y (Hz) m (x FLA) m (x FLA) BRB
31-Jan -69.8 50.37 0.59 0 1/31/2019 -43.3 50.41 0.57 0.01 1/31/2019

Observation
• The Maximum value of the rotor bar component level is high

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Power Supply Quality Analysis

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Va, Ia and Va* Ia Signal Analysis
01Feb2019_OSC10

~ 5sec data, Voltage Signal is clean, Current GE

and Va*Ia picks up low frequency load oscillations
Internal
Va, Ia and Va* Ia Signal Analysis
13Feb2019_Transient record_06aual trigger_on load

~ 9 sec data, Voltage Signal is clean, Current and Va*Ia picks up low frequency load oscillations
GE Internal
Va, Ia and Va* Ia Signal Analysis
13Feb2019_Transient record_03_ no load

~16 Sec, Voltage Signal is clean, Current and Va*Ia picks up low frequency load oscillations
GE Internal
Va, Ia and Va* Ia Signal Analysis
Voltage Harmonics @ Multiple of Fundamental

01Feb2019_OSC10 13Feb2019_Transient record_06aual trigger_on load 13Feb2019_Transient record_03_ no load

Voltage Harmonics present at odd multiples of fundamental frequency

But this will not affect broken bar algorithm

GE Internal
Conclusions

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Rotor Bar Health - Conclusions

• The rotor bar component levels are found to be high based on the limited data
available

• The load oscillations found to be influencing the rotor bar pickup values at lower
frequencies (in Va*Ia signal)

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Conclusions
 Presence of load oscillations is observed by analyzing the electrical
current signatures of the motor under load conditions.

 The occurrence of the load oscillations is generally random with

respect to time. The load oscillations are affecting the pickup values of
the relay

 Voltage Harmonics are present at odd multiples of fundamental

frequency though the impact of these harmonics on relay pick up is not
observed

 Adopt OP elements instead of PKP elements and observe the current

signature trends and comment on the health of the motor.

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