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Presentation Transcript

Slide1: 

SHORT COURSE MOTOR CURRENT SIGNATURE ANALYSIS FOR DIAGNOSIS OF FAULTS IN INDUCTION MOTOR DRIVES Prof Bill Thomson Director and Consultant EM Diagnostics Ltd EM Diagnostics Ltd 20 Greystone Road, Alford, Aberdeenshire, AB33 8TY, Scotland, UK Tel : +44 (0) 19755 62446 Fax : +44 (0) 19755 62628 e-mail : mcsa@consultant.com web site : www.mcsainterpreter.com © William T. Thomson EM Diagnostics Ltd 2001 - unauthorised copying, reproduction or amendment of all or part prohibited.

MCSA : MOTOR CURRENT SIGNATURE ANALYSIS INDUCTION MOTOR DRIVES: 

MCSA : MOTOR CURRENT SIGNATURE ANALYSIS INDUCTION MOTOR DRIVES DIAGNOSE PROBLEMS PRIOR TO MOTOR DRIVE FAILURE BROKEN ROTOR BARS ABNORMAL AIRGAP ECCENTRICITY SHORTED TURNS IN LV STATORS ABNORMAL ROTOR DYNAMICS PUMP WEAR MISALIGNMENT © William T. Thomson EM Diagnostics Ltd 2001 - unauthorised copying, reproduction or amendment of all or part prohibited

INDUCTION MOTOR DRIVE SYSTEMS: 

INDUCTION MOTOR DRIVE SYSTEMS WHY SO IMPORTANT? USA 800,000 MW GENERATING CAPACITY 40-50% CONSUMED BY INDUCTION MOTORS 320,000MW PLANT SYSTEMS 328 MILLION HORSEPOWER

Slide4: 

Power Utilities Oil & Gas Chemical Refineries Pulp & Paper Mining Shipping MOD Transport Nuclear Wind Power DuPont Kodak Ford Uptime of Induction Motor Drive Systems

Slide5: 

8 CW Induction Motor Drives 8 PA Induction Motor Drives 8 ID Induction Motor Drives 26 Mill Motors Induction Motor Drives 8 Coal Conveyor Induction Motor Drives 8 FD Induction Motor Drives 8 Compressor Induction Motor Drives Numerous other Induction Motor Drives 2000 MW Coal Fired Power Station

Slide6: 

3 PHASE, SCIM, 6.6kV, 2800kW/3753H.P., 2-POLE, 3570r.p.m., 60Hz, (Full-load slip = 0.00833 or 0.833%) © William T. Thomson EM Diagnostics Ltd 2001 - unauthorised copying, reproduction or amendment of all or part prohibited

MOTOR CURRENT SIGNATURE ANALYSIS: 

MOTOR CURRENT SIGNATURE ANALYSIS CONDITION MONITORING TECHNIQUE INSURANCE POLICY TO PREVENT FAILURES REDUCE DOWNTIME AND REPAIR COSTS PREVENT LOST PRODUCTION INCREASE RELIABILITY - PRODUCT DELIVERY

Slide8: 

MCSA MCSA : On-Line Monitoring and Analysis of Current to Assess the Condition of an Induction Motor Drive System

APPLICATION OF CURRENT TRANSFORMER CT: 

APPLICATION OF CURRENT TRANSFORMER CT

MCSA Instrumentation: 

MCSA Instrumentation

Slide11: 

Time Domain signals and Current Spectra

CURRENT SIGNATURE DUE TO BROKEN BARS : 

CURRENT SIGNATURE DUE TO BROKEN BARS LOWER SIDEBAND f1 =SUPPLY FREQUENCY (60 Hz) Hz dB UPPER SIDEBAND

SIGNATURE PATTERN DUE TO BROKEN BARS TWICE SLIP FREQUENCY SIDEBANDS : 2sf1: 

SIGNATURE PATTERN DUE TO BROKEN BARS TWICE SLIP FREQUENCY SIDEBANDS : 2sf1 fsb = f1±2sf1 -2sf1 +2sf1 f1 dB Hz IDEALISED Current Spectrum – Due to Broken Rotor Bars

MCSA ON GM3802A (January, 2002) 3-PH, HV, SCIM, 4155HP/3.1MW, 11kV, 2974r.p.m., 195A 50 Hz BROKEN ROTOR BAR – LIFTED OUT OF THE SLOT: 

MCSA ON GM3802A (January, 2002) 3-PH, HV, SCIM, 4155HP/3.1MW, 11kV, 2974r.p.m., 195A 50 Hz BROKEN ROTOR BAR – LIFTED OUT OF THE SLOT N=46 dB © William T. Thomson EM Diagnostics Ltd 2001 - unauthorised copying, reproduction or amendment of all or part prohibited

3-PH, HV, SCIM, 4155HP/3.1MW, 11kV, 2974r.p.m., 195A BROKEN ROTOR BAR – LIFTED IN THE SLOT SECONDARY DAMAGE TO HV STATOR: 

3-PH, HV, SCIM, 4155HP/3.1MW, 11kV, 2974r.p.m., 195A BROKEN ROTOR BAR – LIFTED IN THE SLOT SECONDARY DAMAGE TO HV STATOR © William T. Thomson EM Diagnostics Ltd 2001 - unauthorised copying, reproduction or amendment of all or part prohibited

3-PH, HV, SCIM, 4155HP/3.1MW, 11kV, 2974r.p.m., 195A BROKEN ROTOR BAR – LIFTED IN THE SLOT SECONDARY DAMAGE TO HV STATOR: 

3-PH, HV, SCIM, 4155HP/3.1MW, 11kV, 2974r.p.m., 195A BROKEN ROTOR BAR – LIFTED IN THE SLOT SECONDARY DAMAGE TO HV STATOR OFFSHORE OIL PRODUCTION PLATFORM TOTAL REPAIR COSTS : $270,000.00 (Removal, transport, repair & re-installation costs) THE BOSS IS NOT HAPPY PREVENT THIS HAPPENING AGAIN YOUR JOB IS ON THE LINE

Slide17: 

Case History : Large Sea Water Injection Pump 3-Phase SCIM, 6600V, 60Hz, 3.6MW/4285h.p.,376A, 3580r.p.m., Star connected Full-load slip? s=(Ns-Nr)/Ns = 0.0055(0.55%) Sidebands = 2*0.0055*60 = 0.67 Hz (at full load) or Pole Pass Sidebands = 2 *(60 - 59.667) = 0.67 Hz

1985 : 20 BARS BROKEN OUT OF 46: 

1985 : 20 BARS BROKEN OUT OF 46

INDUCTION MOTOR – GEARBOX – COMPRESSOR 3 –phase, 415 V, 134 kW/180 H.P., 210 A, 1485 r.p.m., 50 Hz R = 58: 

INDUCTION MOTOR – GEARBOX – COMPRESSOR 3 –phase, 415 V, 134 kW/180 H.P., 210 A, 1485 r.p.m., 50 Hz R = 58 1982 150 A

Slide20: 

DIE CAST ROTOR FAULTY END RING INSPECTION FOLLOWING ON-LINE MCSA © William T. Thomson EM Diagnostics Ltd 2001 - unauthorised copying, reproduction or amendment of all or part prohibited