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TABLE I
MOTOR FAILURE CLASSIFICATION
I E E E Sruor [81
E P R I STUOY [81
- w
F A I L E D CO MPONENT
4.2
26.9
PERSISTENT O V E R L O A D I N 6
NORMALD E T E R I O R A T I O N
BRACING
ELECTRICALLY RELATED:
15.5
15.2
HIGM V I B R A T I O N
POOR L U B R I C A T I O N
33
32
15
20
100
MOTORPOTENTIAL
TROUBLES
Following this macro review, we identified potential motor
troubles, their effects, and the resultant failure categories [2],
Paper PID 88-29, approved by the Cement Industry Committee of the IEEE
Industry Applications Society for presentation at the 1988 30th IEEE Cement
Industry Technical Conference, Quebec, Canada, May 24-26. Manuscript
released for publication July 26, 1988.
G. J . Paoletti is with Westinghouse Electric Corporation, 2608 Tauton
Drive, Pennsauken, NJ 08109.
A . Rose is with Westinghouse Electric Corporation, 1447 Chesnut Avenue,
Hillside, NJ 07205.
IEEE Log Number 8926550.
WiCHANICAL RELATED:
3.0
5.8
ENVIROMENTAL A H )
M I N T E N A M RELATED:
199
1.5
0.6
4.2
PERCENT
23.0
4.0
3.0
1.o
5.0
36.0
SLEEVE BEARINGS
BEARINGS
THRUST B E A R I N G
ANTIFRICTION
ROTOR S H A F T
ROTOR CORE
JeJ
H I O H A M B I E N T TEMPERATURE
ABNORMAL M O I S T U R E
ABNORMAL VOLTAGE
ABNORMAL FREOUENCY
ABRASIVE CHEMICALS
POOR V E N T I L A T I O N / C O O L I N 6
16.0
8.0
5.0
2.0
J29
BEARING
SEALS
O I L LEAKAGE
FRAME
WEDGES
6.0
3.0
1.o
1.o
Itp
19.7
21 .o
100.0
100.0
OTHER:
TOTAL:
CORE
CAGE
XL6
__
MOTORFAILURE
SUMMARY
STATOR GROUND I N S U L A T I O N
TURN I N S U L A T I O N
0093-9994/89/0500-0456$01
.OO 0 1989 IEEE
457
EFFECTS
POTENTIALTROUBLES
ELECTRICAL
FAILURES
(33 1)
l L L I L I T Y D I S I ~ T I O NS Y S T L B :
-UNBALANCED
IWCORING L I N E
-REDUCED
STATOR
CURRENTS
UNBALANCE
ROTOR B A R
SEOUENCE
CURRENTS
-UNEOUAL CONDUCTOR
IMPEDANCE
-BLOUN FUSE ON A THREE
PHASE BANK OF P.F.
CORRECTION C A P A C I T O R S
-PLANT E X P A N S I O N S U I T H O U T
ADDITIONAL DISTRIBUTION
CAPACITY
. INDUCED
VOLTAGE
' NEGATIVE
STATOR
WINDING
STATOR
HEATING
HEATING
(LOOSEB A R S )
ROTOR
VIBRATION^
SHAFT~BEARING
LUBRICANT
OVERHEATING
F AIL U R E
MECHANICAL
FAILURES
(32 I )
POTENTIALTROUBLES
:-
-TRANStlISSION
ONE PHASE
ELECTRICAL
FAILURES
(33 1)
REMAINING
PHASE U I N D I N G S
EXPERIENCE
EXCESSIVE
0VERHEA:ING
L I N E OUT ON
- U T I L I T Y F U S E B L O U N I N ONE
PHASE
-TRANSMISSION
RfslLcTs
EFFECTS
STATOR
L I N E F A U L T ON
ONE PHASE
PHASING
STATOR
MAXIMUM
VOLTAGE
-UNBALANCED
-SINGLE
UNBALANCE
NEGATIVE
SEOUENCE
CURRENTS
VOLTAGE SOURCE
-BROKEN MOTOR Y I N D I N G L E A D
-FUSE
BLOUN
IN ONE PHASE
LVBIRATOI N
ROTOR
.ROTOR
HE A T IN G j
-DISCONNECT S U I T C H BLADE
M A L F U N C T I O N ON ONE PHASE
1
BEARING
FAILURE
OVERHEATING
- C A B L E F A U L T I N ONE PHASE
MECHANICAL
FAILURES
-CABLE D I S C O N N E C T E D I N ON
PHASE
(32 I )
-OVERHEATED/LOOSE E L E C T R I C A L
CONNECTION ON ONE PHASE
2.27
2.10
1.58
0.98
0.51
0.50
0.44
0.30
0.16
0.07
This could indicate that the higher failure rate of 1.15 service
factor motors could also be the result of the existence of
Another IEEE paper [12] indicates that a 1.15 service factor persistent voltage unbalance.
458
POTENTIALTROUBLES
efsllLls
EFFECTS
ELECTRICAL
(33 2 )
FAILURES
T I O N SYSTLLI:
LOU ON I N C O M I N G
-VOLTAGE
LINE
TURN T O TURN
SHORT
-EXCESSIVE
C Y C L I N G OR
PULSATING LOAD
STATOR
WINDING
-CONTINUOUS OVERLOADING
TO COIL
COIL
SHORT
OVERHEATING
-PROLONGED A C C E L E R A T I O N
TIME
-t!OTOR LOAD M E C H A N I C A L
TROUBLES
STATOR
UINDING
PHASE TO PHASE
FAILURE
SHORT
-TRACKING
-PULVERIZING
- R E P E A T E D STALLIN6
t!ECHANICAL
STRESSES ON
UINDIMGEND
-REPEATED STARTING
TURNS AN0
COIL
POTENT
I AL
IRON
CORE
DAMAGE
-OVERHEATING
- L O U VOLTAGE S U P P L Y
T O GROUND
SHORT
IRON
OARAGE
INDIVIDUAL
COILS
Fig. 3.
Overloading effects
POTEnTIMTROUBLES
BEslllLs
LEfLGIs
ELECTRICAL:
- H I G H AMBIENT
TEMPERATURE
%:~~:~TING
- V E N T I L A T I O N SYSTEM
OBSTRUCTIONS
OVERHEATING/
HARnomIc
INCREASED
EDDY
C O N T E Y T OF E L E C T R I C A L - C U R R E Y T
AND
H Y S T E R E S I S LOSSES.POUFP
I N LARIMATIONS
-EXCESSIVE
-LOSS O f / O R E X C E S S I V E
BEARING LUBRICANT
- C O N T A M I N A T I O N OF
BEARING LUBRICANT
-OVERHEATED B E A R I N S
LUBRICANT
-COOLING WATER L O S S
OR OVERHEATED
-MIS-ALIGNnENT. SHAFT
B E N D I N G OR LOOSE
FOUNOATIOW
-ROTOR
OUT OF BALANCE
FAILURES
(33 2 )
I
INSULATION
-VOLTAGE STRESS
tlmMuLu:
INSULATIOY
ELECTRICAL
r DETERIORATION INSULATION
I
BREAKDWN
ENVIigtlENTAL
UA1W:N:U
FAILURES
BEARING LUERICAMT
O V E R H E A T I N G AND/OR
DE TE R I O R A T I O N
B
iA
tRN
IG
MECHANICAL
FAILURE
FAILURES
(32 2 )
EXCESSIVE
VIBRATION
A
Fig. 4.
Overloading Effects
Fig. 3 illustrates the potential troubles that can result in
overloading effects. The majority of troubles generate only
stator winding overheating, whereas two troubles, repeated
starting and repeated stalling, also generate mechanical
stresses on winding end turns and individual coils. These
mechanical forces, generated via the production process
(starting-stopping, etc.), result in physical stress on the end-
459
TABLE I1
APPROXIMATE REWIND COSTS FOR AC INDUCTION MOTORS
.
Voltage
(V)
Speed
(r/min)
Horsepower
(hP)
Rewind Cost
Machine Type
ac form-wound
ac form-wound
ac form-wound
ac form-wound
2300
2300
2300
2300
1800
1200
720
450
5200
6000
7000
10 200
ac form-wound
ac form-wound
ac form-wound
ac form-wound
2300
2300
2300
2300
1800
1200
720
500
500
500
500
2000
2000
2000
2000
350
($)
13 000
14 000
18 300
25 OOO
motors are shown in Table 11. The data were obtained from an
informal survey. For motors at 4160 V , the costs in the table
could be increased by 10-20 percent. If the rotor must be
rewound. the additional cost would add 30-50 percent to the
above estimates.
In-and-Out Cost
Repair Cost
Actual repair costs usually involve a complete rewind. The
motor stator slots of the old copper windings are stripped, and
new insulated coils are installed. This is a good time to
consider the installation of resistance temperature detectors
(RTDs) if they did not already exist. Other work may also be
required, depending on the type of failure and the extent of
damage. For example, if the failure was due to massive
bearing failure, the shaft may have dropped, thereby causing
the rotor to come in physical contact with the stator during
operating speeds. The result can be excessive iron damage. In
addition, shaft work may be required as well as additional
machining of the bearing housings.
Examples of approximate rewind costs for ac induction
TRADITIONAL
MOTOR
PROTECTION
The earliest form of medium-voltage motor protection was
the use of induction-type overcurrent relays. This type of
protection provided good locked rotor protection, though it
overprotected the motor for normal overloading and/or starting modes. The result was the use of a motor below the
designed parameters. Todays competitive industrial climate
would contrast greatly to such a conservative and less costeffective approach. Fig. 5(b) illustrates this type of protection.
To better utilize a motor at the designed perimeters, many
users employed an additional relay which consisted of a
thermal overcurrent relay. The operating curve of a thermal
overcurrent relay closely duplicates the average heating curve
of the electric motor. The input to this relay is current;
460
Startinq
LOcked RotorTime
(a)
Tlme
CO
(b)
motor. ... A general recommendation is to apply phase unbalance protection to all motors lo00 hp and above. For motors
below lo00 hp, the specific requirements should be investigated.
BL-l
1491
Ttme
CO 5 Relay 1511
Current
kR
(C)
46 1
1) As power requirements are increasing, minimal investment to increase electrical distribution systems has
resulted in distribution systems delivering more load.
This can cause voltage unbalance and waveform distortion, which in turn affects motor heating and associated
motor life.
2) Plant life extension is a method of obtaining additional
productive plant life with minimal effective expenditure.
Each piece of equipment or system is evaluated for
methods to effectively extend the life of the equipment
and/or improve overall productivity.
The advent of the microprocessor has resulted in a single
multifunction relay, which provides total integrated motor
TABLE 111
TROUBLE
EFFECTS AND REQUIREDPROTECTION
FIGURE NURM
TICAL E F F E C T S
PROTECTION REOUJREB
VOLTAGE UNBALANCE
NEGATIVE SEOUENCE
CURRENTS
SINGLE PHASING
- SINGLE PHASING
STATOR Y I N D I N G
OVERHEATING
-OVERLOAD R E L A T E 0
MECHANICAL S T R E S S E S
ON U I N O I N G END TURNS
AND I N D I V I D U A L C O I L S
-RELATED TO REPEATED
STARTS AND S T A L L I N G
- LOCKEDROTOR
- STARTS PER HOUR
STATOR Y I N D I N G
OVERHEATING
-RELATED T O H I G H AMBIENT
TEMPERATURE AN0 V E N T I L A T I O N OBSTRUCTIONS
Rm ALARM
EXCESSIVE
NEGATIVE
HARRONICS
- VOLTAGE UNBALANCE
N E G A T I V E SEOUENCE
CURRENTS
OVERLOAD
CURRENTS
SAHPLING
VOLTAGE STRESS
BEARING LUBRICANT
OVERHEATING
- Rm
EXCESSIVE
- R n
VIBRATION
TRIP
SEOUENCE
/ YAVEFORM
L I G H T N I N G AND S U I T C H I N 6 SURGE P R O T E C T I O N
ALARM
TRIP
ALARR / T R I P AND
CONTINUOUS V I B R A T I O N
MONITORS
462
0
0
0
0
0
0
0
0
0
0
differential protection
stator RTDs
bearing RTDs
starts per time period
incomplete sequence
power monitoring
potential transformers (PTs)
current transformers (CTs)
future communications
trip contacts
alarm contacts
remote trip or restart.
5 8 1 0
20
1w
Fig. 7.
TYPICAL
FIELDRETROFIT
APPLICATIONS
Existing motor protection devices receive signals from
existing current transformers, potential transformers, motor
RTDs and others. These new microprocessor-based products
are programmable for various current-transformer and potential-transformer ratios. They can also be equipped to function
with 10, 100, or 120 Q RTDs. This allows for the use of
existing sensing devices with the improved monitoring and
protection device. Occasionally, if additional protection is
desired beyond that which currently exists, additional sensing
devices may be installed.
One example involved the field retrofit of motor protection
for a 4160-V 450-hp totally enclosed fan-cooled (TEFC)
horizontal motor to operate at 1185 r/min at full load. The
existing protection consisted of induction disk overcurrent
relaying providing locked rotor protection and thermal overcurrent relaying providing overload protection. The existing
protective equipment was removed and three new CTs were
installed as well as a BYZ CT for ground protection. The new
relay utilized was mounted in the space vacated by the older
equipment. All work was completed during a July 4, 1987
shutdown during normal work days and was completed in
three days. In addition an overhaul was performed to the
switching device for the motor. The front panel of the
retrofitted unit is shown in Fig. 8.
The retrofit resulted in the many additional protection and
Fig. 8.
0
0
0
0
0
0
0
0
463
ENGINEERING/ECONOMIC
CONSIDERATION
The potential motor troubles and required protection discussed should be reviewed to determine the susceptibility of
the critical production motors within the plant. Anticipated
frequencies of failures should be estimated with the existing
motor protection, and the associated costs including repair, inand-out, and lost production costs should be determined.
An example of a typical production motor economic
analysis could include repair costs of $10 OOO and in-and-out
464
retrofit cost
per year
Payback
10000
20000
30000
40000
50000
$100 000
3.7 years
2.7 years
2.1 years
1.7 years
1.4 years
10 months
$
$
$
$
$
REFERENCES
CONCLUSION
Motor protection via microprocessor-based relays is not
new to the industry. Until recently, these relays have been
primarily applied to new installations. These relays have
become mature protective devices from a reliability standpoint
as well as from a comprehensive protection standpoint. Future
relays may be less costly, whereas the critical protection
modes are accurately incorporated in current models.
The process of retrofitting existing motor protection
schemes is now a viable alternative for any of the following
reasons: plant life extension, plant productivity improvement,
reduced maintenance and repair costs, and increased system
reliability. The majority of medium voltage motors, unlike
their low voltage motor counterparts, involve primary production functions. For this reason, these motors should be
reviewed for the reasonableness of improving their existing
motor protection. The use of a microprocessor-based relay can
serve this purpose in a cost effective manner.