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On-line Motor Monitoring
Joe GeimanJoe GeimanBaker Instrument Co.Baker Instrument Co.
What are we really after?Induction motor and VFD applications
Reduce unscheduled downtimeReduce unscheduled downtime Indicates root cause analysisIndicates root cause analysis Save $ $ $Save $ $ $
Motor Failure Areas:IEEE Study EPRI Study
Motor Failure Areas:IEEE Study EPRI Study
Bearing44%
Rotor8%
Other22%
Stator26%
Bearing41%
Other14% Rotor
9%
Stator36%
Motor Failure Causes:IEEE Study
Motor Failure Causes:IEEE Study
0%
20%
40%
60%
80%
100%
Bearing Winding
Electrical FaultMechanical BreakageInsulation BreakdownOverheating
Safety and Connecting:Low Voltage (Less than 600V)
Motor
MCC
LoadBreaker
Step one: Running motorStep two: STOP motorStep three: Connect ExplorerStep four: Run and testStep five: STOP motorStep six: Disconnect Explorer
Explorer
Safety and Connecting:Medium and High Voltage (More
than 600V)
Motor
Load
CTs
Breaker
Step one: Motor is runningStep two: Connect Explorer CTsStep three: Connect Explorer PTs
Explorer
PTs
Motor
CTs
Breaker
PTs
EP
Explorer
First EnergyRC Pump
1 of 700+ EPs at one customer
Acquire Data:Safe, Fast & Easy W/ EP-1
Power Quality Analysis
PQ CapabilitiesPQ CapabilitiesVoltage and Current level, unbalanceVoltage and Current level, unbalance
distortionsdistortionsKvarsKvars, KVA, KW’s, Power factor, Crest, KVA, KW’s, Power factor, Crest
factor, Harmonic bar chartfactor, Harmonic bar chart ectect..
Motor Overheating
II22R LossesR Losses Motor CurrentsMotor Currents 100% rated Current100% rated Current 100% rated Temperature100% rated Temperature 110% rated Current110% rated Current 121% rated Temperature121% rated Temperature
Fan 1 hp 1740 rpm
Motor Condition: Broken Rotorbar
Rotorbar Frequency:
slip Synchronous rotor bar freq.% [RPM] [Hz]0.1 1798.2 59.880.2 1796.4 59.760.3 1794.6 59.640.4 1792.8 59.520.5 1791 59.40.6 1789.2 59.280.7 1787.4 59.160.8 1785.6 59.040.9 1783.8 58.921.0 1782 58.8
.
..
.
slip
21
synch
operatsynch
fundrotorbar
RPM
RPMRPMs
sff
Depends on SLIP!
•Harder to assess with lesser load
•Harder to assess with bigger motor
•Harder to assess with more efficient motor
Increasing Lines of Resolution:Increasing Lines of Resolution:
New Rotorbar y-axis Scale
AmA
dB
lfundamentasignal
dBres
30042
log105.38
log10].[down'dB'
Good Rotor Bar
Bad Rotor Bar
Case Study 1
2A High Pressure Pump2A High Pressure Pump ProblemProblem
Serious vibrationSerious vibration Vibration ReadingVibration Reading
•• High 7200High 7200•• Turn off motor 7200 peek disappearsTurn off motor 7200 peek disappears
Electricians do not believe it could be a rotor barElectricians do not believe it could be a rotor bar•• They have never seen a rotor problemThey have never seen a rotor problem•• Electricians have no way to confirm or deny theElectricians have no way to confirm or deny the
allegations of the mechanicsallegations of the mechanics
Show Data
2A high Pressure Pump2A high Pressure PumpBroken Rotor BarBroken Rotor Bar
1C high Pressure Pump1C high Pressure PumpGood Rotor BarGood Rotor Bar
2A High Pressure PumpBroken Rotor Bar
2A High Pressure PumpBroken Rotor Bar
1C High Pressure PumpGood Rotor Bar (comparison)
1C High Pressure PumpGood Rotor Bar (comparison)
Conclusion2A High Pressure Pump
Recommendation to customerRecommendation to customer It appeared to be a brokenIt appeared to be a brokenAll thought, only slightly into the cautionAll thought, only slightly into the caution
we questioned how saver the problemwe questioned how saver the problemwaswas
Results2A High Pressure Pump3 Broken Rotor Bars
Results2A High Pressure Pump3 Broken Rotor Bars
Case Study 24a PA Fan
Problem Slight vibrationProblem Slight vibration
Broken Rotor Bar
Broken Rotor Bar
Case Study 3
Rotor IssueRotor Issue Show need for higher acquisitionShow need for higher acquisition Show other places in spectrum toShow other places in spectrum to
represent or confirm rotor issuesrepresent or confirm rotor issues
Low Resolution DataNo Assessment Can Be Made
Low Resolution DataNo Assessment Can Be Made
High Resolution DataAssessment Can Be Made
High Resolution DataAssessment Can Be Made
Results
Inspection found brazing issues at theInspection found brazing issues at theend ring causing high resistance joints.end ring causing high resistance joints.
Epoxy Melting Off Rotor BarsRepresenting Excessive Heat
Cracked End Ring (Case Study 4)
Motor Current Signature AnalysisValues From Technical Associates.
54 – 60 dB Excellent54 – 60 dB Excellent 48 – 54 dB Good condition48 – 54 dB Good condition 42 – 48 dB Moderate condition42 – 48 dB Moderate condition 36 – 42 dB Rotor bar crack36 – 42 dB Rotor bar crack
developing ordeveloping or highhighresistance joints.resistance joints.
30 – 36 dB multiple cracked / broken30 – 36 dB multiple cracked / brokenbars or end – ringsbars or end – rings
indicatedindicated < 30 dB multiple cracked /< 30 dB multiple cracked /
broken bars orbroken bars orend-rings very likelyend-rings very likely
Current signature: FFT vs. DFLL
Amplitude: 20dB
Amplitude: 60dB
Resolution: 0.13Hz Resolution: 0.005Hz
FFT DFLL
Need: High Amplitude and Frequency Resolution
• Requires constant torque level• Torque ripple• Next one breaks sooner• Current increases• Temperature increases• Insulation life shortens• Typically non-immediate death
Motor Condition:Broken Rotorbar issues
Motor
MCC
Load1. frequency 2. speed
3. Torque4. Power
5. Voltage
6. Current
Chain of events:Cause and effect
N
SF
F
I
I
F : Force
I : Current
: Flux
Calculating Torque:
Flux: Generated by stator Voltage
Rotor Current: Monitored with Stator Current
TT(t) = f( V(t), I(t) )
According to Park’s theory, 1920.
RotorStator
Calculating Torque:
Explorer showed that not all motors run at constantExplorer showed that not all motors run at constantoperating condition. The 4 motors at the center displayoperating condition. The 4 motors at the center displaya larger variability to their operation. These are thea larger variability to their operation. These are thelocations which’ motors break with unusually highlocations which’ motors break with unusually highfrequency.frequency.
• The maintenance supervisor noted that some stirringpool motors (decontamination and recycling process)break with unusually high frequency.
Case study I: Hydro-mechanical resonance. Brewery.Case study I: Hydro-mechanical resonance. Brewery.
Case study I: Hydro-mechanical resonance. Brewery.Case study I: Hydro-mechanical resonance. Brewery.
• The maintenance supervisor noted that some stirringpool motors (decontamination and recycling process)break with unusually high frequency.
• The Explorer showed that not all motors run atconstant operating condition. The 4 motors at thecenter display a larger variability to their operation.These are the locations which’ motors break withunusually high frequency.
• The Torque Ripple graphs clarified the source of theoperation’s variability.
Case study I: Hydro-mechanical resonance. Brewery.Case study I: Hydro-mechanical resonance. Brewery.
Case study I: Hydro-mechanical resonance. Brewery.Case study I: Hydro-mechanical resonance. Brewery.
Corrective action:
4160V submersible pump
Torque Signature:
Torque Ripple vs. Time
Hzssperiodtime
soccurrencefrequency 2.3
11.073.02
_#
Torque Ripple vs. TimeHz
ssperiodtimesoccurrence
frequency 2.311.073.0
2_
#
Torque vs. Frequency:Mechanical Imbalance
• Investigating vibration and torque forinaccessible loads:
Comparison of Duct-Mounted Vibration and InstantaneousAirgap Torque Signals for Predictive Maintenance of Vane Axial
Fans .
Comparison of Duct-Mounted Vibration and InstantaneousAirgap Torque Signals for Predictive Maintenance of Vane Axial
Fans .
Don DoanTexas Utilities
Ernesto WiedenbrugBaker Instrument Company
Don DoanDon DoanTexas UtilitiesTexas Utilities
Ernesto WiedenbrugErnesto WiedenbrugBaker Instrument CompanyBaker Instrument Company
Presented in IEEE CMD / 2005Ulsan, Korea
Presented in IEEE CMD / 2005Ulsan, Korea
Problem Application:Problem Application:
A Vane Axial Fan’s failure can result inunplanned outages, health and safety costs, andextensive damage to surrounding equipment.
A Vane Axial Fan’s failure can result inA Vane Axial Fan’s failure can result in
unplanned outages, health and safety costs, andunplanned outages, health and safety costs, and
extensive damage to surrounding equipment.extensive damage to surrounding equipment.
• Vane Axial Fans are commonin nuclear environments
• It is almost impossible topredict bearing faults for
Vane Axial Fans.
• Vane Axial Fans are commonin nuclear environments
• It is almost impossible topredict bearing faults for
Vane Axial Fans.Nuclear Comanche Peak Station
TXU Electric
HorizontalApplication
VerticalApplication
Vane-axial Fan Maintenance Challenge:Vane-axial Fan Maintenance Challenge:
Application frequently called: “Fan-in-a-can”
Impossible to monitor with preferred technology(vibration on bearing housing)
Cost prohibitive to issue a “change in design”for all Vane axial Fans for this Nuclear PowerPlant. (Nuclear Industry in U.S. average cost permeter of retrofitted wire > U$ 5,000)
Application frequently called: “Fan-in-a-can”Application frequently called: “Fan-in-a-can”
Impossible to monitor with preferred technologyImpossible to monitor with preferred technology
(vibration on bearing housing)(vibration on bearing housing)
Cost prohibitive to issue a “change in design”Cost prohibitive to issue a “change in design”
for all Vane axial Fans for this Nuclear Powerfor all Vane axial Fans for this Nuclear Power
Plant. (Nuclear Industry in U.S. average cost perPlant. (Nuclear Industry in U.S. average cost per
meter of retrofitted wire > U$ 5,000)meter of retrofitted wire > U$ 5,000)
Laboratory Investigation:Laboratory Investigation:
Set up a Vane Axial Fan in a Laboratory, and create:• Healthy operation (baseline data)• Advanced Bearing fault (Stage III)
Gathering Data:• Vibration data obtained from the bearing housing – preferred
diagnostic method – (used as benchmark of planted faults).• Accelerometers connected to the outside of the duct.• Calculated Instantaneous Airgap Torque using Park’s theory.
Statistical Data Analysis:• Statistical evaluation using “single sided experiment design”.• 9 samples needed for certainties exceeding 95% and 90% for
errors type I, and type II, respectively.
Set up a Vane Axial Fan in a Laboratory, and create:Set up a Vane Axial Fan in a Laboratory, and create:
•• Healthy operation (baseline data)Healthy operation (baseline data)
•• Advanced Bearing fault (Stage III)Advanced Bearing fault (Stage III)
Gathering Data:Gathering Data:
•• Vibration data obtained from the bearing housing – preferredVibration data obtained from the bearing housing – preferred
diagnostic method – (used as benchmark of planted faults).diagnostic method – (used as benchmark of planted faults).
•• Accelerometers connected to the outside of the duct.Accelerometers connected to the outside of the duct.
•• Calculated Instantaneous Airgap Torque using Park’s theory.Calculated Instantaneous Airgap Torque using Park’s theory.
Statistical Data Analysis:Statistical Data Analysis:
•• Statistical evaluation using “single sided experiment design”.Statistical evaluation using “single sided experiment design”.
•• 9 samples needed for certainties exceeding 95% and 90% for9 samples needed for certainties exceeding 95% and 90% for
errors type I, and type II, respectively.errors type I, and type II, respectively.
Chosen Fan / Motor:Chosen Fan / Motor:
Motor: Baldor 3.7kW (5hp),4-pole, 480V.
Fan: Aerovent 304 mm (24 in). System used in the Exhaust of
the Electrical Control Room.
Motor:Motor: BaldorBaldor 3.7kW (5hp),3.7kW (5hp),
4-pole, 480V.4-pole, 480V.
Fan:Fan: AeroventAerovent 304 mm (24 in).304 mm (24 in).
System used in the Exhaust ofSystem used in the Exhaust of
the Electrical Control Room.the Electrical Control Room.
Note: The support system of this motor/fan has along transmission path – which may dampenmechanical signals on their way to the duct.
Note: The support system of this motor/fan has along transmission path – which may dampenmechanical signals on their way to the duct.
The “known good” Signals:The “known good” Signals:
Redundant verification: Accelerometers: 100mV/g ICP Cognitive Systems CV395B Analyzer Bentley Nevada ADRE 208P SWANTECH stress wave analysis
Redundant verification:Redundant verification: Accelerometers: 100mV/g ICPAccelerometers: 100mV/g ICP
Cognitive Systems CV395B AnalyzerCognitive Systems CV395B Analyzer
Bentley Nevada ADRE 208PBentley Nevada ADRE 208P
SWANTECH stress wave analysisSWANTECH stress wave analysis
Additional Instrumentationensuring constant operating condition:
Airfolow Meters Humidity Meter ThermocouplesCurrent Meters Laser tachometers
Additional Instrumentationensuring constant operating condition:
Airfolow Meters Humidity Meter ThermocouplesCurrent Meters Laser tachometers
Field-friendly alternative #1:Duct-mounted Accelerometers
Field-friendly alternative #1:Duct-mounted Accelerometers
Vibration Transducers 100mV/g ICP.
Cognitive Systems Spectrum Analyzer
Accelerometers mounted directly at Mounting Rod on the Duct.
Vibration Transducers 100mV/g ICP.Vibration Transducers 100mV/g ICP.
Cognitive Systems Spectrum AnalyzerCognitive Systems Spectrum Analyzer
Accelerometers mounted directly at Mounting Rod on the Duct.Accelerometers mounted directly at Mounting Rod on the Duct.
Field-friendly alternative #2:Torque Signature Analyzer
Field-friendly alternative #2:Torque Signature Analyzer
Explorer II (Baker Instrument Company)
Measures 3 currents and 3 voltages at MCC.
Calculates airgap torque (Park 1929).
Obtains operating speed from current and torquesignatures.
Monitoring Imbalances: 1x mechanical frequencies inairgap torque spectrum.
Explorer II (Baker Instrument Company)Explorer II (Baker Instrument Company)
Measures 3 currents and 3 voltages at MCC.Measures 3 currents and 3 voltages at MCC.
Calculates airgap torqueCalculates airgap torque (Park 1929)(Park 1929)..
Obtains operating speed from current and torqueObtains operating speed from current and torquesignatures.signatures.
Monitoring Imbalances: 1x mechanical frequencies inMonitoring Imbalances: 1x mechanical frequencies inairgap torque spectrum.airgap torque spectrum.
• 7.6 grams create 0.39 gm (0.54 oz in) imbalance.
• Comparing amplitudes of 1 x mechanical frequenciesfor “unfaulted” vs. “faulted” data.
• 7.6 grams create 0.39 gm (0.54 oz in) imbalance.
• Comparing amplitudes of 1 x mechanical frequenciesfor “unfaulted” vs. “faulted” data.
• Start: Precision balancedfan (baseline).
• Planted Fault: 7.6 gramsimbalance.
• Start: Precision balancedfan (baseline).
• Planted Fault: 7.6 gramsimbalance.
Fault 1: Mechanical ImbalanceFault 1: Mechanical Imbalance
Comparison of the amplitudes of 29.9Hz (1x mechanical)frequencies for 1 set of balanced data, with one set ofimbalanced operation:
Comparison of the amplitudes of 29.9Hz (1x mechanical)Comparison of the amplitudes of 29.9Hz (1x mechanical)frequencies for 1 set of balanced data, with one set offrequencies for 1 set of balanced data, with one set ofimbalanced operation:imbalanced operation:
Fault 1: Mechanical ImbalanceFault 1: Mechanical ImbalanceResults:
Duct Accelerometer:Duct Accelerometer:-- 99% certain that imbalanced data has higher99% certain that imbalanced data has higher
amplitude.amplitude.-- Amplitude is only 6.7% higher.Amplitude is only 6.7% higher.
Conclusion:Conclusion:This methodThis method “could”“could” be used, but the very low amplitudebe used, but the very low amplitudegain renders it unfeasible for maintenance.gain renders it unfeasible for maintenance.
Airgap Torque Method:Airgap Torque Method:
99% certain that imbalanced data has higher amplitude.99% certain that imbalanced data has higher amplitude.
Amplitude is 150 times higher ( >40dB ).Amplitude is 150 times higher ( >40dB ).
Conclusion:Conclusion:According to this experiment, this methodAccording to this experiment, this method CANCAN bebeused for maintenance.used for maintenance.The large amplitude gain makes it very robust andThe large amplitude gain makes it very robust andeasy to interpret.easy to interpret.
Fault 1: Mechanical ImbalanceFault 1: Mechanical ImbalanceResults:
Bearing Signature Analysis
•• Mechanical world:Mechanical world: Stage II:Stage II:
nnmm = Mechanical (shaft) speed= Mechanical (shaft) speed i,ki,k = 1,2,3,…= 1,2,3,…
•• Electrical world:Electrical world: Stage II:Stage II:
nnfundfund = fundamental electrical frequency= fundamental electrical frequency i,ki,k= 1,2,3,…= 1,2,3,…
mn2kBPFOisFrequencieFault
fund.n2kBPFOisFrequencieFault
Motor Failure Areas:Bearings
Motor Failure Areas:Bearings
harm. * BPFO 2 * RPM
Known Good Bearing Known Outer Race Defect
Torque SpectraBPFO Controlled Lab Test… how it works
Electrical Frequencies Removed Electrical Frequencies RemovedMarking 1 * BPFOAdding Electrical Harmonic Sidebands
Signal Quality:Signal Quality:
harm. * BPFO 2 * RPM Torque (Nm) Current (A)RMS 0.5 5
Signal 0.025 0.0022Noise 0.0012 0.0005
Torque S/N = 4.8 * betterTorque S/RMS = 125 * better
“It can be found”“It is in your face”
4 pole 5hp
Eccentricity in Spectrum:
•• Location:Location:
•• “1x” types:“1x” types:•• Current signals:Current signals: fffund.fund. ±± ffmech.mech.
•• Torque signals:Torque signals: ffmech.mech.
•• - “Bar-pass” types:- “Bar-pass” types:•• Current signals:Current signals: nn ·· ffmech.mech. ±± 11 ·· fffund.fund. (hopefully there)(hopefully there)•• Torque signals:Torque signals: nn ·· ffmech.mech. (many times not(many times not
there)there)
• 4-pole motor.
• 1x = just below 30Hz.
rpmHz s 8.17686048.29 min
Eccentricity, Torque Signature:“1 x” location
Eccentricity, Current Signature:Eccentricity, Current Signature:“1 x” location“1 x” location
rpmHz s 2.17656058.3060 min
• 4-pole motor.
• 1x = just above 30Hz.
Eccentricity, Torque Signature:Eccentricity, Torque Signature:“Rotorbar Pass Frequency” location“Rotorbar Pass Frequency” location
• 2-pole motor. 2nd peak @ freq. just below Harmonic.
• 1920Hz / 60Hz = 32bars (1920Hz is synchronous rotorbar pass frequency)
rpmHz
fHzbars
Hz
s
mech
5.35936089.59
89.5932
56.1916
min
.
Eccentricity, Current Signature:“Rotorbar Pass Frequency” location
• 2-pole motor.
•1860Hz / 60Hz + 1 = 32bars
rpmHz
fHzbars
HzHz
s
mech
5.35936089.59
89.5932
6051.1856
min
.
“1x” locations
# of Poles Synchronous 1% slip "1x" Torque "1x" Current[RPM] [RPM] [Hz] [Hz]
2 3600 3564 59.4 0.64 1800 1782 29.7 30.36 1200 1188 19.8 40.28 900 891 14.85 45.1510 720 712.8 11.88 48.1212 600 594 9.9 50.1
.elec.1 mechfundx fff .trq.1 mechx ff
Comparing Ieccent. with Teccent.
•• TTeccent.eccent. at “expected” frequencyat “expected” frequency•• IIeccent.eccent. at “expected” frequency – 60Hz.at “expected” frequency – 60Hz.•• TTeccent.eccent. -28.43 dB relative amplitude.-28.43 dB relative amplitude.•• IIeccent.eccent. -34.9 dB relative amplitude.-34.9 dB relative amplitude.
Teccent. is at the understandable location.
Teccent. has a 4.5 times larger signal.
Demodulated Signals:Torque vs. Current
Demodulated Signals:Torque vs. Current
Demodulated Torque Demodulated Current1* RPM 2* RPM 1* RPM 2* RPM
Bad Motor #1Bad Motor #2Good Motor #1Good Motor #2
3.47E-05 7.94E-05 0.00324 0.031504.26E-05 7.96E-05 0.00398 0.030912.96E-05 1.35E-05 0.00245 0.031093.46E-05 1.42E-05 0.00308 0.03057
Factor 1.20 5.90 1.31 1.01
Conclusions:• Demodulated Current method does not agree with vibration’s methods.
• Demodulated Torque reacts like vibration’s methods.
• This method is independent of Motor design.
• This method does not disagree with IEEE motor scientist’s research.
Case study II: Cooling tower fan and gear signatures.Coal-fired power plant.
Case study II: Cooling tower fan and gear signatures.Coal-fired power plant.
Input Shaft Freq.Intermediate Shaft Freq.Output Shaft Freq.
Blade Pass Freq.
Case study II: Cooling tower fan and gear signatures.Coal-fired power plant.
Case study II: Cooling tower fan and gear signatures.Coal-fired power plant.
1st Mesh Frequency2nd Mesh Frequency
Case study II: Cooling tower fan and gear signatures.Coal-fired power plant.
Case study II: Cooling tower fan and gear signatures.Coal-fired power plant.
BPFO
BPFI + - 2 x Electrical
+ - 2 x Electrical
Case study II: Cooling tower fan and gear signatures.Coal-fired power plant.
Case study II: Cooling tower fan and gear signatures.Coal-fired power plant.
SKF 22310c