Induction Motor Failure Analysis
Induction Motor Failure Analysis
The goal of a motor management plan is to take advantage of opportunities for energy savings
and increased productivity using energy-efficient, reliable motors such as NEMA Premium efficiency
motors. With that, predictive maintenance programs (PMPs) are gaining acceptance as a method for
maintaining motor reliability. A well-rounded program includes as many technologies as practical —
with each technology contributing a significant factor to the diagnostic analysis.
(For more information on this “Motor efficiency is important and can be done. We have proven many times that you can maintain
topic, visit the Knowledge Cen- efficiency when a motor is repaired. We promote motor repair companies that have demonstrated
quality assurance programs that maintain efficiency when a motor is rewound.”
ter at www.advancedenergy.org/ Kitt Butler, director, motors and drives at Advanced Energy Corporation
md/knowledge_library).
On selecting a motor service
center, Butler says, “There are many things to look for in a
motor service center’s guidelines. Look for the types of ma-
terials and equipment that the shop uses, the calibration
procedures for its measuring equipment, the quality of its
personnel and the experience and training its personnel.
All play a critical role in delivering a good quality repair that
maintains efficiency.”
Evaluate over time. When choosing a motor service cen-
ter, it is also important to do your evaluation over time. Don’t
base the evaluation just on a single visit and one set of mea-
surements. Provide your repair vendor with the specifica-
tion and measure them against that specification over time.
Some motors service centers create their own guidelines, us-
ing a standard such as the EASA Standard AR 100-2010. You
can audit a service center against its own guidelines if you
haven’t developed your own. aged and submitted to the service center for repairs. Service
Original efficiency. How important is it to restore an elec- centers meeting the program requirements receive certifica-
tric motor to its original tion.
efficiency? Since the cost Butler adds, “Returning a repaired motor to its original
to repair a motor may be efficiency is important and can be done. We have proven
a small percentage of the many times that you can maintain efficiency when a motor
cost to operate that mo- is repaired. We promote motor repair companies that have
tor over several years, the demonstrated quality assurance programs that maintain ef-
motor efficiency when re- ficiency when a motor is rewound.” Details of the PEV pro-
turned to service should gram and a list of the currently accredited motor service
be as close as possible to companies are online at www.advancedenergy.org/md/con-
the efficiency it had when sulting/repair_shop_selection.php.
new. Many motors operate Pre-EPAct motors. No matter the quality of repair, a pre-
40–80 hours per week — or EPAct motor will never be as efficient as a new, premium
more; so even small in- efficiency motor. The design of the original motor is the
creases in efficiency can contributing factor. Bruce Benkhart, director, Advanced
yield huge energy savings. Proactive Technologies, Springfield, Massachusetts, com-
The following standards mented, “When rewinding or repairing a motor, there are
and best practices cover motor repair, motor efficiency and a number of things to consider. An older motor that is inef-
quality assurance programs; they are available as free down- ficient might look repairable. However, (even) the best new
loads at www.EASA.com/energy. technologies and the best practices in rewinding can only re-
• “ANSI/EASA AR 100-2010: Recommended Practice for the store a motor to its original specifications. If it started life as a
Repair of Rotating Electrical Apparatus” pre-EPAct, lower efficiency motor, then that’s the best you’re
• “The Effect of Repair/Rewinding on Motor Efficiency” going to get back — no matter the quality of the repair work.”
• “Guidelines for Maintaining Motor Efficiency during Build a relationship. Build a strong relationship with your
Rebuilding” motor repair vendors; pressuring your motor service center
• “EASA-Q: 2000 Quality Manual” (purchase item) to rush a repair is never a good practice. A good motor ser-
Service center capability. A motor service center can vice center adheres to a specific set of guidelines in the mo-
verify its capability to return a repaired motor to its original tor repair process. Look for a motor service center that ad-
efficiency. The decision to repair a motor is often based on heres to the EASA guidelines. The risks of motor damage and
the motor’s pre-failure efficiency; a significant decrease in losses of efficiency are too great. A good motor service center
efficiency would increase energy costs and perhaps rule out will strongly advise against rushing a motor repair. As Doug-
repair. Proven efficiency verification (PEV) is a quality as- lass explains, “It’s important to understand the viewpoint of
surance program offered by Advanced Energy that mutually your repair facility. There are only a few ways to do it right,
benefits both motor repair purchasers and providers. The but many ways to do it wrong. Demanding they do the job
PEV program includes an on-site audit on the use of best fast is the wrong approach because there are so many ways
practices to bring the service center into conformance. Fol- to cut corners. These shortcuts could get a motor repaired or
lowing the audit, a control set of motors is pre-tested, dam- rewound faster, but most of these methods to accelerate the
dustrial facilities have some form of preventive maintenance approved by the manufacturers and follow the manufactur-
program. er’s specifications for the correct application of the lubricant.
Rick Scott is assistant director of facilities operation at Motor shaft grounding. Variable frequency drives (VFDs)
St. Lawrence University in Canton, New York. This private can cause bearing failures by inducing currents in motor
university comprises 70 buildings and enrolls about 2,300 shafts. This problem is specific to VFDs and affects both AC
students. The school owns hundreds of motors with horse- and DC motors. Considering how they can save energy and
power between 1 and 50. Many of them drive pumps and lower operating costs, VFDs are increasingly used for process
air handlers, and many have variable speed drives. “At our control, pumps, air handling, conveyers, spindles and many
facility we’ve done quite a bit to save energy. We have a pre- more applications. As the drive switches on and off speed
ventive maintenance program with one person dedicated variations cause voltage buildups that seek a ground poten-
to that task. The program entails regular servicing of our air tial. Oftentimes the most direct path is through the bearings.
handlers, pumps and drives, as well as replacing belts and The bearing lubricant can act as an insulator but the lubri-
filters. Normally we will replace a motor larger than one cant’s resistive properties will eventually break down, and
horsepower with a premium efficiency motor whenever it the resulting electrical current flow pits the metal surfaces
fails, so long as it is not a candidate for repair. Sometimes we and the bearings eventually fail.
replace older motors that are still running with premium ef- Fortunately, solutions to this problem do exist. According
ficiency motors. For example, whenever a pump fails we just to Gilbert A. McCoy, P.E., Energy Systems Engineer, Wash-
replace the whole system. Premium efficiency motors tend ington State University Energy Program, “Currents induced
to have higher reliability. We try to increase efficiency and in a motor shaft and grounded across the bearings cause
save on electrical costs.” fluting, which is a type of bearing damage. To eliminate flut-
ing consider installing a shaft grounding brush and/or in-
Bearing Considerations sulated bearings so that the currents do not form and flow
Lubrication. Proper bearing lubrication is one of the tenets of across the bearings raceway.” Other solution options include
a preventive maintenance program. Bearing failures account hybrid ceramic bearings and line reactors or filters. Howev-
for a significant portion of the mechanically related problems. er, fluting may occur regardless of the efficiency class of the
(See sidebar, “Most Frequent Motor Failure Areas.”) motor — premium efficiency, energy efficient, or standard.
If you only detect bad bearings by noise or vibration, then
you will always be too late. At that point mechanical damage Predictive Maintenance
to the bearing raceways and perhaps even the motor shaft Predictive maintenance programs (PMPs) are gaining ac-
have already happened. And, you have already incurred extra ceptance as a method for maintaining motor reliability. A
energy costs by operating the motor with increased frictional well-rounded program includes as many technologies as
load to the motor. Butler fully acknowledges the importance practical — each technology contributing a significant factor
of lubrication in a preventive maintenance program. “Pre- to the diagnostic analysis. The scheduled static test and the
ventive maintenance is important for electric motors,” he more aggressive dynamic test are both useful in the predic-
says, “and lubrication is probably the most important aspect tion of potential motor systems failure.
of PM. Make sure you have the proper type of grease and ap- Advantages, disadvantages. PMPs can be expen-
ply the proper amount in a motor on its regularly scheduled sive — but they provide real benefits. The main advantage is
intervals.” expressed as follows on the website of the Department of En-
Bearings do not necessarily wear out — but they do ergy. According to the DOE, “A well-executed program can
fail — and lubrication issues are a major factor in bearing almost eliminate catastrophic equipment failure because
failure. According to a white paper on bearing failure pub- issues are identified and eliminated prior to any significant
lished by Applied Industrial Technologies, improper lubri- system deterioration.”
cation accounts for 40 to 50 percent of bearing failures; im- Such programs save time and energy in other ways, too.
proper bearing installation for 25 to 30 percent; and other The following average savings are typical within indus-
causes account for 20 percent of bearing failures. Achieving trial settings:
the natural fatigue limits of the bearing accounts for less • Return on investment of up to 10X
than one percent of bearing failures! With proper preven- • Maintenance costs reduced by 25–30 percent
tive maintenance, bearings should outlast the useful life of • Elimination of breakdowns by 70–75 percent
the motor. (Read the white paper at http://web.applied.com/ • Downtime reduction of 35–45 percent
base.cfm?page_id=3702.) • Production up by 20–25 percent
Lubrication in anti-friction bearings prevents metal-to- • Advantages include the following:
metal contact between the rolling elements, raceways and • Allows preemptive corrections
retainers. The lubricant also provides protection against cor- • Increased system reliability and lifespan
rosion and wear, dissipates heat, and acts as a barrier to keep • Decreased equipment or process downtime
out solids and liquid contaminants. The anti-frictional prop- • Decreased costs for parts and labor
erties of the lubricants allow the motor to run much more • Better product quality
quietly. Yet, bearing lubricants break down over time and • Improved safety
therefore need periodic replenishment. Use the lubricants • Energy savings
SKF Dynamic Motor Analyzers-EXP4000 most critical to your plant or facility allows you to decide
where to best spend your predictive maintenance dollars.
As Butler explains, “Old timers just walked through the fa-
cility using their eyes and ears as the only predictive mainte-
nance program available. They had strong intuitions about
what was going to happen to a motor long before it failed. For
example, they could often ‘sense,’ without explaining how,
whether it was a bearing or a misalignment issue. Thankfully
there is lot more science out there today in terms of current
signature analysis, and there are a lot more tools available to
really analyze motors. PdMA, Baker and All-Test Pro make or
distribute signature current analysis tools that dramatically
assist with predictive maintenance today.”
maintenance
at www.powertransmission.com
Acknowledgements. CDA acknowledges the assistance of Kitt Butler, director, motors and drives at Advanced Energy
government and industry-based motor experts in the cre- Corporation (AEC), Raleigh, North Carolina (919) 857-
ation of the Motor Management Best Practices series. The 9017.kbutler@advancedeneergy.org.
following individuals were cited in at least one of the three Johnny Douglass, retired senior industrial engineer, Wash-
published installments: ington State University (WSU) Extension Energy Program
Emmanuel Agamloh, Ph.D., P.E. motor systems engineer, (360) 956-2086 douglass.johnny@gmail.com.
Advanced Energy Corporation, Raleigh, North Carolina Gilbert A. (Gil) McCoy, P.E. energy systems engineer with
(919) 857-9023, eagamloh@advancedenergy.org. the Washington State University (WSU) Energy Office,
Bruce Benkhart, director, Advanced Proactive Technolo- Olympia, WA. 360) 956-2086, mccoyg@energy.wsu.edu.
gies, Springfield, Massachusetts. Benkhart is available at Rob Penney, P.E., certified energy manager, senior energy
(413) 731-6546 bruce@appliedproactive.com. engineer at Washington State University (WSU). Penney
Tom Bishop, P.E., senior technical support specialist, Elec- is available at (360) 628-2053, penneyr@energy.wsu.edu.
trical Apparatus Service Association (EASA), St. Louis Mis- Anthony J. Simon, energy engineer, Washington State Uni-
souri. www.easa.com. versity (WSU). (360) 956-2141, SimonT@energy.wsu.edu.
Emmanuel Agamloh Bruce Benkhart Tom Bishop Kitt Butler Johnny Douglass Gilbert A. (Gil) McCoy Rob Penney
www.powertransmission.com
FEBRUARY 2016 Power Transmission Engineering 53