Electrical Motor Diagnostics for Generators
Part 1 – The Basics
ALL-TEST Pro, LLC
Part 1 – The Basics
ALL-TEST Pro, LLC
Introduction
Electrical Motor Diagnostics (EMD) is a term for test methods
and instruments designed for rotating and coil-wound machinery
electrical and mechanical analysis. These instruments are used
for all motor system related analysis from the generator and
prime mover, through the transmission and distribution system,
to the electric motor and driven load. These technologies, for
the purpose of this paper, will include Motor Circuit Analysis
(MCA), a de-energized test method, and Electrical Signature
Analysis (ESA), a more advanced method of Motor Current
Signature Analysis (MCSA).
In this paper, we will discuss the concepts behind the testing
and analysis of both salient and turbine generators to detect
some common generator faults. These faults include bearings,
winding shorts in the rotor and stator, insulation to ground
faults in the rotor and stator, exciter faults, misalignment and
rotating field eccentricity.
Motor Circuit Analysis
MCA is a low voltage method for testing electric machinery
cables, connections, windings and rotor for developing faults.
The technique involves individual readings of DC Resistance (R),
Impedance (Z), Inductance (L), Phase Angle (Fi),
Current/Frequency Response (I/F) and insulation to ground (MegOhm)
testing. Resistance is used for detecting loose connections and
broken conductors, insulation to ground is used for detecting
ground faults, Z and L are matched to evaluate the insulation
condition for winding contamination, and, Fi and I/F are used to
detect winding shorts. One of the key aspects of MCA is the
ability to detect early winding defects that can be trended over
time and a time to failure can be estimated.
As a vast majority of the rotating machinery, that MCA is used
to evaluate, requires balanced phases, pass fail criteria for
individual readings can be developed for both assembled and
disassembled machines (Reference Tables 1 and 2). These values
indicate a guideline and values outside of these guides normally
identify component failures that have occurred, or are
developing. These developing issues can be compared against
Attachment 1 of this paper.
In addition to the power of detecting a motor system defect, the
values are trend able without the requirement of temperature
adjustments for a majority of faults. This allows for the
ability to evaluate condition and provide estimates for time to
failure by monitoring changes to the phase to phase unbalances
over time.
Table 1: Pass/Fail Considerations for Assembled Machines
Test Result
|
Tolerance
|
Detail
|
Resistance (R)
|
<5%[1]
|
Used for detecting loose connections, broken wires,
direct shorts and diff wire sizes
|
Impedance (Z) and Inductance (L)
|
Similar
Patterns[2]
|
Changes to impedance that cause its phase to phase
pattern to appear different from inductance are normally
the result in the change to the material condition of
the insulation system. Used for detecting winding
contamination, burned windings (overheated), very large
phase unbalances or very poor rotor bar condition.
|
Phase Angle (Fi)
|
+/- 1 digit from average
|
Indicates a winding short: 74, 75, 76 OK; 74, 74, 76
suspect; 73, 73, 76 failed
|
I/F
|
+/- 2 digits from average
|
Indicates a winding short: -44, -45, -46 OK; -44, -46,
-46 suspect; -42, -45, -45 failed
|
Insulation Resistance (MegOhm)
|
>5 MegOhm[3]
>100 MegOhm[4]
|
Indicates poor insulation to ground (i.e.: ground fault)
|
When a motor does not have a rotor in place, such as in a motor
repair shop with a stator only, the tolerances change:
Table 2: Pass/Fail Criteria for Disassembled Machines
Test Result
|
Tolerance
|
Resistance (R)
|
<5%
|
Impedance (Z)
|
<3%
|
Inductance (Z)
|
<5%
|
Phase Angle (Fi)
|
+/- 0
|
I/F
|
+/- 0
|
Insulation Resistance (MegOhm)
|
> 5 MegOhms3 /
> 100 MegOhms4
|
For trending and analysis purposes, MCA is a comparative tool
using percent unbalance and difference between tests methods.
In the percent unbalance method, the difference between like
coils (i.e.: between phases in a three phase motor) is trended
over time. This method is best for resistance, impedance and
inductance. While resistance values are impacted by
temperature, for instance, the relative difference between
phases is not. By using the percent unbalance method, the user
or software do not have to rely upon performing temperature
correction calculations. Impedance and inductance are not
significantly impacted by temperature. Therefore, the unbalance
method is the most convenient way of detecting faults over
time. The difference between tests method is used for phase
angle and I/F in which the lowest value for each is subtracted
from the highest value for each.
Table 3: Reading Change Table for AC Rotating Equipment
Reading
|
Change From Baseline
|
Severity
|
R, Z, L
|
< 3%
|
Green
|
R, Z, L
|
>3% and <5%
|
Yellow
|
R, Z, L
|
> 5%
|
Red
|
Fi and I/F
|
<1pt
|
Green
|
Fi and I/F
|
>1pt and <3pt
|
Yellow
|
Fi and I/F
|
>3pt
|
Rd
|
Electrical Signature Analysis
Motor Current Signature Analysis (MCSA) refers to the evaluation
of current waveforms only, including the demodulation of the
current waveform and FFT analysis. Electrical Signature
Analysis (ESA) is the term used for the evaluation of the
voltage and current waveforms. This provides an increased
advantage to diagnostics as power-related, motor-related and
load-related signals can be quickly compared. A key
consideration when using ESA is that voltage signatures relate
to the upstream of the circuit being tested (towards power
generation) and current signatures relate to the downstream of
the circuit being tested (towards the motor and load).
ESA uses the machine being tested as a transducer, allowing the
user to evaluate the electrical and mechanical condition from
the control or switchgear. For accurate analysis, ESA systems
rely upon FFT analysis, much the same as vibration analysis.
Table 4: Rotor Analysis
Condition
|
dB Value
|
Rotor Condition
|
Action
|
1
|
>60
|
Excellent
|
None
|
2
|
54-60
|
Good
|
None
|
3
|
48-54
|
Moderate
|
Trend
|
4
|
42-48
|
Rotor Fracture or High Resistance Joint
|
Increase Test Intervals and Trend
|
5
|
36-42
|
Two or more bars cracked or broken
|
Confirm with motor circuit analysis
|
6
|
30-36
|
Multiple cracked or broken bars and end ring problems
|
Overhaul
|
7
|
<30
|
Multiple broken rotor bars and other severe rotor
problems
|
Overhaul or Replace
|
Table 5: Signature Multipliers
Type of Fault
|
Pattern (CF = Center Frequency)
|
Stator Mechanical (i.e.: loose coils, stator core
movement, etc.)
|
CF = RS x Stator Slots
Line Frequency Sidebands
|
Stator Shorts (shorted windings)
|
CF = RS x Stator Slots
Line Frequency sidebands with Running Speed sidebands
|
Rotor Indicator
|
CF = RS x Rotor Bars
Line Frequency sidebands
|
Static Eccentricity
|
CF = RS x Rotor Bars
Line Frequency and twice Line Frequency sidebands.
|
Dynamic Eccentricity
|
CF = RS x Rotor Bars
Line Frequency and twice Line Frequency with Running
Speed sidebands
|
Mechanical Unbalance (and Misalignment)
|
CF = RS x Rotor Bars
Line Frequency Sidebands, Space of four times Line
Frequency then two Line Frequency peaks
|
Where RS = Running Speed
The pass/fail values of the signatures identified in Table 5 are
presently based upon the experience of the user. In the case of
motor (downstream) analysis, these values relate to current and
for generator (upstream) analysis, these values relate to
voltage.
The Fast Fourier Transform (FFT) of both current and voltage
signatures are normally calculated in dB instead of linear
scale. Analysis of the differences in peaks is determined by
comparing the dB value measured down from either the peak
current or peak voltage value.
The Combined Use of MCA and ESA
MCA requires that the equipment is de-energized while ESA
requires that the equipment is energized. These differences
offer the user specific analysis strengths for each technology
that support each other.
In the case of MCA, it has specific strengths in the areas of:
Control and other connections
Cable insulation system health to ground and between phases
Stator winding health to ground and between phases and
conductors
Air gap issues between the stator and rotating assembly
Rotor winding health: wound, induction or synchronous
This includes the ability to provide early failure detection of
insulation degradation.
ESA has specific strengths in the areas of:
Power quality
Severe insulation breakdown
Loose or open coils or stator
Loose or open rotor or rotor coils
Loose connections
Air gap problems, including static and dynamic eccentricity
Bearings and mechanical condition, including alignment
Attached mechanical systems
When used in combination, the technologies provide some
overlapping capabilities, but specifically they provide a
complete overview of the system being evaluated, with a high
degree of accuracy.
Basic Generators
There are two basic types of generator systems. These include
turbo-synchronous machines and salient-pole synchronous
machines. There are a large variety and variation of each type,
so we will cover the basic assembly of both in this paper.
The turbo-synchronous machine is most commonly used in
high-speed generators (two and four pole) used for high voltage
power generation. The general assembly resembles a three phase
induction motor with the following specifics:
The stator (armature) resembles a three phase motor winding.
The DC fields of the turbine rotor cut through the conductors
and generate power which is supplied to the distribution system
from this component.
The turbine rotor (fields) resembles the squirrel-cage rotor of
an induction machine. This component carries the DC power from
the exciter and is driven by a prime mover such as a jet engine
or steam turbine. It tends to be long and narrow for horizontal
machines.
The exciter can be separate from the machine, in which brushes
supply power to the rotor, or brushless, in which a small DC
generator is mounted directly to the turbine rotor shaft. The
exciter provides DC power to the turbine rotor.
The salient-pole machine is one of the more common smaller, low
voltage, low-speed (1800 RPM or less, 4-pole) generation
systems. The distinction is that the rotor contains a series of
individual wound-coils which also contain an amortissieur
winding, in most cases.
The stator (armature) resembles a three phase motor winding.
The DC fields of the salient-pole rotor cut through the
conductors and generate power which is supplied to the
distribution system from this component.
The salient rotor (fields) incorporate an even number of pole
pieces that radiate out from the rotor shaft. These poles carry
the DC current that generates the rotating DC fields.
The exciter can be separate from the machine, in which brushes
supply power to the rotor, or brushless, in which a small DC
generator is mounted directly to the rotor shaft. The exciter
provides DC power to the rotor.
Both machines can be evaluated in the same way that you would
evaluate electric motors of similar design. In the case of ESA,
you would evaluate the signatures using voltage spectra versus
current spectra.
Conclusion
Energized testing of generators requires the ability to view the
voltage signature of the generator and this requires equipment
that can perform Electrical Signature Analysis, not just Motor
Current Signature Analysis. The purpose of this first paper has
been to provide a review of MCA and ESA, as well as a discussion
of the construction of turbine and salient generators. The
general analysis of generators is performed in a similar manner
of any other AC machine.