Medium Voltage Induction Motor Protection

and Diagnostics

Yi Du
Pinjia Zhang
Prof. Thomas G. Habetler
School of Electrical and Computer Engineering
Georgia Institute of Technology
Atlanta, GA

Medium Voltage Facilities

Medium Voltage Supply

Medium Voltage Laboratory

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Outline
Introduction
Heat transfer inside Motors
Thermal Model-Based Approaches
Parameter Model-Based Approaches
Other Approaches

15

Medium voltage induction

motors

Mostly used in the petroleum,

chemical, mining and other
industries,
Rated from 2300 V to 13200 V,
They are rotor limited during
starting, and stator limited
under overload.

16

Overload Protection

Malfunctions of these motors are very

costly due to loss of productivity,
The winding insulation failure is a
typical malfunction, which is often
caused by overload.

17

Conventional Overload Relays

Conventional overload
relays utilize simple
thermal models and
embedded temperature
sensors.
Simple thermal models
can not estimate the
rotor temperature.
Disintegration of the
connection, noise
interference, and large
time constant of the
sensors often result in
false alarm or trips.

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Requirements

Track the thermodynamic behavior of the motor's

stator and rotor under steady and transient state
conditions.
It should also take into account the important
differences in the thermal behavior due to the
motor size and the type of construction and
ventilation.

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Possible Approaches

Higher order thermal model-based approaches

Model the thermal behavior of the motor. The thermal
parameters are calculated from the motor dimensions and
offline experiments. This approach is robust, but
measurements need be made for each motor.
Parameter-based approaches
Estimate the temperature from the variation of the resistance
of the stator and rotor. This method can respond to changes
in the cooling conditions, and is accurate, but it is generally
too sensitive.
20

Outline
Introduction
Heat Transfer inside Motors
Thermal Model-Based Approaches
Parameter Model-Based Approaches
Other Approaches

21

Motor Losses

The temperature rise inside a motor is caused by

the losses accumulated in the motor.

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Loss Segregations
Wlosses Ws Wr Wcore W fw WLL
Compared with low power motors,
high power motors have larger
percentage of core loss and stray
loss, and smaller percentage of
copper loss.
Therefore, the thermal model only
considering copper loss is not
suitable for large motors.

Loss segregation for 15Hp motor

Wcopper

Wcore

Wf&w

Wstray

2 Pole

53

29

4 Pole

55

15

18

12

6 Pole

62

13

12

13

Loss segregation for 200~2000Hp motors

Wcopper

Wcore

Wf&w

Wstray

2 Pole

29

15

36

20

4 Pole

35

18

24

23

6 Pole

37

23

18

22

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Heat Transfer
The heat transfer inside a
motor can be classified into
Conduction

- transfer of heat due to the temperature difference.

Shaft rotor iron rotor winding,
Stator winding stator iron Frame,
Convection - transfer of heat due to the fluid motion.
Frame - external air, stator/rotor airgap, rotor endcap air, ...
Radiation - transfer of heat by electromagnetic radiation.
Radiation is ignored since the motor temperature is relatively low.

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Thermal resistance and thermal capacitance

Thermal

behavior of the motor can be analyzed by

Finite element methods (Time consuming)
Lumped-parameter thermal network, composed of thermal
resistors, thermal capacitors and heat sources.
Some thermal resistances and thermal capacitances can be calculated
directly from the motor dimensions.
Other thermal resistances are complex and can only be measured
online.
Stator core to frame conduction resistance
Endwinding cooling resistance
Frame to ambient convection resistance

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Thermal Network
Given

the difficulties to calculate certain thermal

parameters, detailed thermal models can not
guarantee good accuracy.
Simplification of the thermal network is preferred for
online monitoring.
On the other hand, the thermal network should be
complex enough to estimate the hot spot
temperature.

26

Outline
Introduction
Heat Transfer inside Motors
Thermal Model-Based Approaches
Parameter Model-Based Approaches
Other Approaches

27

Thermal Model-based Approaches

Use

thermal network to model the thermal behavior of the

motor.
The Motor is divided into homogenous components
wherein each part has a uniform temperature and heat
transfer coefficients.
The heat flow paths are determined and thermal resistors
are added between the nodes.
Losses and thermal capacitors are allocated to each
node.
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First - order Thermal Model

Used

in conventional relays
for its simplicity,
Do not consider the rotor
winding temperature,
The stator winding
temperature is given by,

s (t ) Ploss Rth (1 e

t
Rth Cth

) s 0 e

t
Rth Cth

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First - order Thermal Model

Thermal

resistance Rth and thermal capacitance Cth can

be directly calculated from the trip class t6x and the
service factor SF.
Assume the loss Ploss equals the stator copper loss

Rth Cth

6
t6 x /[ln( 2
)]
2
6 SF

Cth

is calculated using the trip class and the winding

insulation class.
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First - order Thermal Model

Temperature

rise is a complex combination of

distributed thermal capacitances and
resistances, single time constant is not enough.
Therefore, large margin is needed for safety
and the motor is over protected.
The rotor temperature can not be monitored.

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Second - order Thermal Model

Stator

and rotor are

modeled separately,
Model B eliminate
the node while
maintaining the same
function.
Parameters are
calculated from
offline experiments

Model A

Model B

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Second - order Thermal Model

Model

C
simplifies the rotor
side, and less
parameters are
needed.
Second-order
thermal model is a
good tradeoff
between accuracy
and complexity.

Model C

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Higher - order Thermal Model

Model

the hot spot,

such as end windings,
seperately.
The thermal model
becomes complex and
it is difficult to identify
the parameters.

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Outline
Introduction
Heat Transfer inside Motors
Thermal Model-Based Approaches
Parameter Model-Based Approaches
Other Approaches

35

Parameter-based Approaches
Estimate the temperature from the variation
of the stator winding resistance and the rotor
bar resistance.
Ra (t b k1 )
Rb
t a k1
k1 is 234.5 for 100% IACS conductivity copper
It is an online method and can respond to
changes in the cooling conditions.
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Rotor Resistance
Rotor resistance can be calculated in the synchronous reference
frame with the d-axis aligned with the stator current. Under the
steady state, the rotor resistance, which is independent of the stator
resistance, is given by

R r ( ss ) 2 Lr [

s L2m

Vqs
Is

s Ls

Lr ]

Rotor resistance can also be calculated in the stationary reference

frame and rotor reference frame.
By these methods, the rotor resistance is independent of the stator
resistance and is less sensitive to the parameter variations.
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Stator Resistance
Stator resistance is generally calculated based on rotor
resistance.
In the synchronous reference frame with the d-axis aligned
with the stator current, the stator resistance is given by,
e
2
e
V
s

R s eds e me dr
ids
R r ids

Rotor speed can be calculated from the stator current harmonics.

38

Outline
Introduction
Heat transfer inside Motors
Thermal Model-Based Approaches
Parameter Model-Based Approaches
Other Approaches

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Neural Network - based Approaches

Neural networks have been proposed to estimate the
stator resistance and rotor resistance.
The advantages are that they do not require the motor
parameters and can be easily implemented.
The drawbacks are they are
still sensitive to the parameter
changes since the network is
trained using the data based
on certain parameters.
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Hybrid Approaches
Combine thermal model based approaches with
parameter based approaches,
Rotor temperature is estimated by parameter
based approaches since it is less sensitive to the
parameter variations,
Stator temperature is monitored by thermal model
based approaches.

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Signal Injection-based Approaches

Vas ,dc 2 Vab ,dc
2V
sw,dc

Rs

ias ,dc
3 ias ,dc
3
ias ,dc

The stator resistance is estimated from the dc

components of the voltage and current.
Relatively accurate since it is not affected by the
inductance of the motor.
It is intrusive and introduces torque oscillation.
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Overview of Fault Diagnostics for MV Motors

Distribution of MV Induction
Motor Failures

Induction Motor Fault

Categories

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OUTLINE

Overview of Fault Diagnostics for MV Motors

Bearing Failure and its Diagnostic
Stator Winding Inter-turn Fault and its Diagnostic
Rotor Fault and its Diagnostic

Broken Rotor Bar & End-Ring Faults and their Diagnostic

Rotor Eccentricity and its Diagnostic

Conclusions

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Overview of Fault Diagnostics for MV Motors

Distribution of MV Induction
Motor Failures

Induction Motor Fault

Categories
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Analysis of Fault Diagnostics for MV Motors

Main differences between MV motors and
small low-voltage motors:
High Insulation Requirement for Stator
Winding: stator winding inter-turn fault
Large Output Torque: rotor and bearingrelated mechanical faults
High Thermal Stress: stator insulation failure
and rotor-related faults
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Bearing Failure Monitoring

Bearing failure is the most common fault for
MV motors.
Reasons for Bearing Failure
Electrical Stress:
Stator, rotor or input voltage unbalance causes
unbalanced magnetic flux, which induces shaft
current, and potential voltage between bearing
and ground.

Inner raceway
Ball
Cage

Mechanical Stress:

Outer raceway

Friction and rotor eccentricity can cause

mechanical failure of bearings.

Thermal Stress:

Overheat causes the failure of lubricant, which

lead to friction.

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Bearing Failure Monitoring

Classification of Bearing
Failure:
Single Point Defects:

Outer raceway
Inner raceway
Ball
Cage

Generalized Roughness

Existing Methods:
Standard vibration sensor
method
Chemical analysis method
Temperature monitoring
Acoustic emission method
Sound pressure method
Current signature spectra
method

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Current signature spectra methods

1.Single point defects:
Wavelet method
Neural network clustering method
Adaptive time-frequency method
Park vector trajectory method
Other methods
2.Generalized roughness:
Mean spectrum deviation method
Fundamentally: monitor the E-M torque harmonics corresponding to
the mechanical vibration frequencies

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Bearing Failure Monitoring

is the power supply frequency;
is the vibration frequency;
is the corresponding stator current signature frequency.

Challenges for MV motors

For single point defects:
Poor Signal/Noise Ratio
Due the large output torque, the torque vibration caused by bearing failure is
more difficult to observe. So the low signal/noise ratio is a potential problem
for current-based bearing diagnosis of large MV motors.

For generalized roughness:

Separate measurement noise and bearing failure-related vibration noise

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Stator Winding Inter-turn Faults

Reasons for Stator Inter-turn Fault

Electrical Stress:

Thermal Stress

Motor life is reduced by 50% for every 10C above limit

Mechanical Stress

High voltage causes winding insulation failure

Friction between stator and rotor caused by rotor eccentricity

Other Stress

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Stator Winding Inter-turn Faults

Existing Methods:
Negative Sequence Current
Negative Sequence Impedance
E-M Torque Harmonics
Current Spectrum
Current Park Vector Trajectory Stator Inter-turn Fault
Artificial Intelligent Methods
Fundamentally: Monitor the unbalance of stator winding
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Stator Winding Inter-turn Fault and its

Diagnostic

Challenges:
How to consider voltage unbalance in power supply
How to consider original stator winding unbalance
How to set threshold for negative-sequence impedance
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Rotor-related Failures

Rotor-related faults can be classified into:

Broken Rotor Bar
Broken Rotor End-Ring
Rotor Eccentricity (shaft misalignment)
Reasons for rotor-related faults:
Mechanical stress: including rotor eccentricity, and stator-rotor friction
Thermal stress: overheat in rotor can cause rotor deterioration
Electrical stress: frequency starting and overload operations can
cause thermal stress due to large current; unbalanced flux can
induce unbalanced magnetic pull.

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Broken Rotor Bar and End-Ring Faults

Broken rotor bar fault can cause

unbalanced magnetic flux, and thus torque
oscillation and stator current harmonics.

Due to large output torque, and large rotor current,

broken rotor bar fault is more common on large MV
motors than small motors
The effects of broken rotor end-ring are the same as
broken rotor bar, in the sense that the rotor flux is
asymmetric, and induces harmonics in the stator
current.
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Broken Rotor Bar and End-Ring Faults

Existing methods:
Signature current analysis
EM torque harmonics monitoring
Slot harmonic methods
Starting current analysis
Pattern recognition-based methods
Artificial intelligence-based methods
Broken Rotor Bar-related current harmonics
Other methods

Fundamentally: monitor the signature harmonics and slot

harmonics in stator current
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Rotor Eccentricity
Rotor eccentricity is a possible reason
for many kinds of motor faults, such as
stator insulation failure, broken rotor bar
and end-ring, and even shaft crack.

Rotor Shaft Crack

Rotor eccentricity is mainly caused by shaft

misalignment, when the geometric center of the rotor
does not coincide with the center of the stator.
The current harmonics related to rotor eccentricity are

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Rotor-related Faults

For MV motors, due to the high thermal stress on rotor, and the large
output torque, especially the starting acceleration torque, rotor-related
faults are quite common.
The fundamental methods for rotor-related faults are current signature
analysis, as the signature frequencies related to broken rotor bar or
eccentricity are well-known.

Challenges for MV motors

Separating signature harmonics from load oscillation

The signature harmonics in stator current are caused by the unbalanced

rotor flux, but the same harmonics can also be caused by the load
oscillation.

Diagnostics for drive-connected motors

the low-frequency harmonics can be cancelled or reduced by the controller.

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Conclusions

Motor faults diagnostics:

Stator Inter-turn Fault
monitor the unbalance of stator winding

Bearing Fault
monitor the current harmonics caused by bearing-related
torque vibration

Rotor Fault

Broken Rotor Bar/End-ring

Rotor Eccentricity
monitor the current signature harmonics caused by unbalanced
rotor flux
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Conclusion of Motor Faults and their

Diagnostics for MV Motors
Challenges for fault diagnostics of MV motors
Compensate for the effect of power supply and
original motor unbalance
Cancel the effect of load oscillation on
diagnostics
Reliable diagnosis even with low SNR
Fault diagnostics for drive-connected systems
Remote condition monitoring
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QUESTIONS?

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