Moto Care

Motor Condition And Reliability
Evaluation Program (MOTOCARETM)
Aditya Korde
Diagnostic Technologies India Pvt. Ltd.
www.diatechindia.com
MOTOCARETM The MOTOCARETM advantage – no fault area left
uncovered!!
On-Line Package: Off-Line Package:
• Electrical Signature Analysis • Tan Delta & Capacitance Analysis

Rotor bar degradation Oil & grease in insulation
Stator core degradation Moisture in insulation
Eccentricity Overall aging
Interturn insulation degradation
• Partial Discharge Analysis
De-bonding of insulation
• Vibration Analysis Voids in insulation
Mechanical faults Loss of corona shield
Localized defects
• Acoustic Emission Analysis • Motor Circuit Analysis

Bearing degradation Interturn shorts
Lubrication problems Loose connections
• DC Tests
Moisture ingress
Surface contamination
MOTOCARETM What have we found?
MOTOCARETM What are the typical faults detected?
PERCENTAGE FAULT TYPES SEEN IN CASE OF SEVERE PROBLEMS

Stator Core
Degradation Loose Bent
4% Windings Shafts
4% 2%
Housing Weak Insulation
Resonance
Wear 34%
4%
5%
Foundation
Problems
6%
Broken bars
8%
Unbalance
9% Misalignment Bad Bearings
11% 14%
MOTOCARETM Typical ESA spectrum – rotor bar degradation
Identical 2300 KW motors. LHS is excellent, RHS had 7 broken bars.
MOTOCARETM Typical ESA spectrum – stator core degradation
Identical 410 KW motors. LHS is excellent, RHS had severe hot spots in the stator.
MOTOCARETM Typical VA spectrum – motor with insufficient rigidity
1 6 .9 4 7 9
O /A ll 1 7 .2 2 8 m m /s r m s
R W P um p 5
M o to r N D E
R a d ia l 2
V e l F re q 1 6 0 0 H z
2 /6 /2 0 0 3 6 :2 1 :1 8 P M
O / A ll 1 . 9 8 9 m m / s r m s
9 8 3 .3 9 3 R P M
< a d d n o te >
- 0 .8 0 7
16
14
12
S t r o n g 1 X p e a k , in o n e R a d ia l d ir e c t io n o n ly . In d ic a t iv e o f la c k o f s t r u c t u r a l r ig id it y in t h is d ir e c t io n .
10
mm/s rms
6 R W P u m p 2
M o to r N D E
4 R a d ia l 2
V e l F re q 1 0 0 0 H z
2
2 /6 /2 0 0 3 3 : 5 2 : 0 0 P M
O /A ll 1 7 .2 2 8 m m /s r m s
5 8 8 .5 2 1 R P M
0
< a d d n o te >
0 2 4 6 8 10 12 14 16 18
orders
This 335 KW vertical motor had a weak foundation, causing vibration.

Attempts to balance it had failed in reducing the vibration.
MOTOCARETM High vibration…. & no solutions!
• 630 KW, 2 pole motor had high vibration, between 7 to 13 mm/sec at

standstill (at 1X & harmonics).
• Coupled vibration was over 30 mm/sec, RMS (mostly at 1X).
• Identical adjoining motor had relatively low vibration.
• Relative phase was oscillating between 20 & 240 degrees on

foundation, steady on mat .
• Bump test revealed multiple natural frequencies between 150 Hz &

250 Hz.
• The rotor bars had recently been repaired, the rotor balanced &
bearings replaced. False brinelling marks were seen on the discarded
bearing.
• We diagnosed loose components & foundations problems. Motor

dismantled & inspected. Rotor core was badly damaged & loose on
the shaft. Repair reduced vibration levels but still high.
• Foundation (6 feet PCC) broken, wooden logs found inside! Vibration

levels are now below 3 mm/sec, RMS.
MOTOCARETM High vibration…. & no solutions (contd.)!!
• Brand new 2 MW, 2 pole motor had high vibration, over 9 mm/sec
uncoupled. Coupled vibration over 25 mm/sec, RMS.
• 1X & multiples present, 3X component dominated.
• Bearings replaced, vibration increased. Cut taken on stator bore,

vibration increased still further.
• Motor rejected by client!
• Our investigations showed unstable phase values & a natural frequency

at 149 Hz, coinciding with the 3X component.
• Motor dismantled again & short-circuiting rings de-brazed. Rotor bars

are supposed to be tight in the slots, these were removed by hand.
• New, re-sized bars manufactured and end-shields stiffened to change

the natural frequency. Vibration is now below 3 mm/sec in coupled
condition.
MOTOCARETM AE charts – faulty plain bearing
The CM – 2EF’s DE bearing was badly degraded & had to be replaced.
MOTOCARETM AE charts – faulty bearing in a low speed motor
The 428 RPM CWP – 1A motor’s NDE bearing had a high DISTRESS™ reading, indicating
a faulty bearing. The same was confirmed on opening the motor.
(MSEB, Bhusaval)
MOTOCARETM Tan delta curves – high moisture contamination & voids
CEP – A has high tan delta values, indicative of moisture contamination.

CEP – B has low tan delta values but a high tip-up, indicative of insulation voids.
(Jindal Power, Bellary)
MOTOCARETM Tan Delta Curves – high grease/dirt contamination
(900 kW motor)
Motor has a -ve tip-up, typical of grease/dirt contamination.
MOTOCARETM Tan delta curves – severe deterioration & discharges
TAN DELTA CURVES FOR HYPER COMPRESSOR MOTORS CAPACITANCE CURVES FOR HYPER-COMPRESSOR MOTORS
4.5 116
4
114
3.5
112
CAPACITANCE (nF)
TAN DELTA (%)
110
2.5
1 1
1 1
- -
K K
B B
2
108
1.5
106
104
0.5
0 102
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
APPLIED VOLTAGE (KV) APPLIED VOLTAGE (KV)
11-KBX-203 motor has very high tip-ups, typical of severe deterioration. Failed 4 months later.
(IPCL, Baroda - LDPE)
MOTOCARETM MCA results – interturn short in synchronous motor’s rotor
• 5100 KW, 200 RPM Synchronous Motor – 30 rotor coils and 224 stator
coils.
• Rotor poles were being replaced based on manufacturer’s

recommendations, new poles supplied by manufacturer.
• Manufacturer’s test report indicated that all new poles were with
healthy windings, having matching impedances.
• MCA testing indicated faults in two of the new rotor coils.
• Faults were confirmed by manufacturer & defective poles

replaced.
MOTOCARETM Internal discharges + Corona – 210 MW, 15.75 kV
Generator
R Phase – 1400 nC Y Phase – 6 nC B Phase – 7 nC
+ve pulses dominate; plus high amplitude

low repetition rate activity on top
MOTOCARETM Insulation delamination & surface contamination –
30 MW , 11 kV Generator
GTG 1 – 252 nC GTG 8 – 18.6 nC
+ve & -ve pulses equal, asymmetric
MOTOCARETM Poor contact between stress grading & slot corona
protection – 2.4 MW , 6.6 kV Motor
Before overhaul – 4050 nC After overhaul – 23 nC

Moto Care

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Moto Care

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Motor Condition And Reliability

Evaluation Program (MOTOCARETM)

On-Line Package: Off-Line Package:

• Electrical Signature Analysis • Tan Delta & Capacitance Analysis

• Acoustic Emission Analysis • Motor Circuit Analysis

PERCENTAGE FAULT TYPES SEEN IN CASE OF SEVERE PROBLEMS

Identical 2300 KW motors. LHS is excellent, RHS had 7 broken bars.

This 335 KW vertical motor had a weak foundation, causing vibration.

• 630 KW, 2 pole motor had high vibration, between 7 to 13 mm/sec at

• Coupled vibration was over 30 mm/sec, RMS (mostly at 1X).

• Identical adjoining motor had relatively low vibration.

• Relative phase was oscillating between 20 & 240 degrees on

• Bump test revealed multiple natural frequencies between 150 Hz &

• We diagnosed loose components & foundations problems. Motor

• Foundation (6 feet PCC) broken, wooden logs found inside! Vibration

• 1X & multiples present, 3X component dominated.

• Bearings replaced, vibration increased. Cut taken on stator bore,

• Motor rejected by client!

• Our investigations showed unstable phase values & a natural frequency

• Motor dismantled again & short-circuiting rings de-brazed. Rotor bars

• New, re-sized bars manufactured and end-shields stiffened to change

The CM – 2EF’s DE bearing was badly degraded & had to be replaced.

CEP – A has high tan delta values, indicative of moisture contamination.

(Jindal Power, Bellary)

Motor has a -ve tip-up, typical of grease/dirt contamination.

APPLIED VOLTAGE (KV) APPLIED VOLTAGE (KV)

(IPCL, Baroda - LDPE)

• Rotor poles were being replaced based on manufacturer’s

• MCA testing indicated faults in two of the new rotor coils.

• Faults were confirmed by manufacturer & defective poles

R Phase – 1400 nC Y Phase – 6 nC B Phase – 7 nC

+ve pulses dominate; plus high amplitude

GTG 1 – 252 nC GTG 8 – 18.6 nC

+ve & -ve pulses equal, asymmetric

Before overhaul – 4050 nC After overhaul – 23 nC

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