Motor Testing Made Easy 2002

ALL-TEST Pro July 2002ALL-TEST Pro July 2002

Motor Testing Made EasyMotor Testing Made EasyDr. Howard W. Penrose, Ph.D.Dr. Howard W. Penrose, Ph.D.

ALL-TEST Pro, A Division of BJM ALL-TEST Pro, A Division of BJM CorpCorp

Old Saybrook, Connecticut, USAOld Saybrook, Connecticut, USANote: Use browser backArrow to return to CDROM selections.


About This PresentationAbout This Presentation• Intro to MTME and ALL-TEST Pro CapabilitiesIntro to MTME and ALL-TEST Pro Capabilities• Case StudiesCase Studies• HardwareHardware• SoftwareSoftware• AccessoriesAccessories• TrainingTraining• ConsultingConsulting• How to ContactHow to Contact


ALL-TEST Pro TechnologyALL-TEST Pro TechnologyMotor Testing Made Easy (M.T.M.E.)Motor Testing Made Easy (M.T.M.E.)

You Cannot Afford to Be Without an ALL-TEST™


Benefits of ALL-TEST Pro InstrumentsBenefits of ALL-TEST Pro Instruments

Looking For Trouble?Looking For Trouble?

•Rapid Training and Learning Curve!•ROI upon first fault detection!•Quickly implement a Preventive or Predictive Maintenance Program with a Minimum Investment!•Include in Energy Programs! Reduce Energy Costs!!


Fault DetectionFault DetectionTurn FaultsTurn FaultsCoil FaultsCoil Faults

Phase FaultsPhase FaultsGround FaultsGround FaultsCable FaultsCable Faults

Rotor EccentricityRotor EccentricityBroken Rotor BarsBroken Rotor Bars

Casting VoidsCasting Voids


CapabilitiCapabilitieses

AC/DC MotorsAC/DC MotorsAC/DC Traction MotorsAC/DC Traction MotorsGenerators/AlternatorsGenerators/AlternatorsMachine Tool MotorsMachine Tool Motors

Servo MotorsServo MotorsControl TransformersControl Transformers

Transmission & Distribution Transmission & Distribution TransformersTransformers

(Virtually Any Size)(Virtually Any Size)


CASE STUDIESCASE STUDIES


Case 1: Power Plant Phase Case 1: Power Plant Phase UnbalanceUnbalance• Current Unbalance - Current Unbalance -

>11%>11%• Phase Unbalance (ALL-Phase Unbalance (ALL-

TEST III): 000,-016,-016TEST III): 000,-016,-016• 50 hp Delta Connected 50 hp Delta Connected

Pump MotorPump Motor• 2 Replacements – 2 Replacements –

Same SignatureSame Signature• Manufacturer’s Manufacturer’s

Production Decision = Production Decision = $1 Million Customer $1 Million Customer LossLoss

Inductance Rotor test

7.4

7.6

7.8

8

8.2

8.4

8.6

8.8

9

0 1 2 3 4 5 6 7 8 9 10 11 12

Rotor PositionIn

duct

ance A-B inductance

A-C inductance

B-C inductance

URG303201

A-B

A-CB-C


Rotor TestsRotor Tests


Case 2: Rotor BarCase 2: Rotor Bar

19.25

19.3

19.35

19.4

19.45

19.5

19.55

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345

T1-T2

T1-T3

T2-T3

3000 hp Alternator


Rotor AnalysisRotor Analysis400 hp, 2-Pole

0.8

0.9

1

1.1

1.2

Position

Indu

ctan

ce


Impedance/Inductance Impedance/Inductance RotorRotor

35363738

39404142

1 2 3 4 5 6 7 8 9 10 11 12

Rotor Position

Impe

danc

e (4

00Hz

)

6.5

7.5

8.5

9.5

10.5

0 1 2 3 4 5 6 7 8 9 10 11 12

Rotor Position

Indu

ctan

ce (m

H)

50 HP, 3600 RPM


Winding FaultsWinding Faults


Evaluation of Windings (Penrose Evaluation of Windings (Penrose Theory of Winding Analysis)Theory of Winding Analysis)

• Winding ShortsWinding Shorts– Phase Angle and Current/Frequency Phase Angle and Current/Frequency

ResponseResponse• Loose ConnectionsLoose Connections

– ResistanceResistance• Winding Contamination/OverheatedWinding Contamination/Overheated

– Inductance and ImpedanceInductance and Impedance• Rotor Condition and SeverityRotor Condition and Severity

– Inductance and Impedance WaveformsInductance and Impedance Waveforms


Setting the Rules (MTME)Setting the Rules (MTME)• Phase Angle and I/F readingsPhase Angle and I/F readings

– Both Fi and I/F > +/- 2 – Shorted TurnsBoth Fi and I/F > +/- 2 – Shorted Turns– Fi > +/- 1, I/F Balanced – Shorted Coils in Fi > +/- 1, I/F Balanced – Shorted Coils in

the same phasethe same phase– Fi Balanced, I/F > +/- 2 – Shorted Phase Fi Balanced, I/F > +/- 2 – Shorted Phase

to Phaseto Phase• Rules stand regardless of motor sizeRules stand regardless of motor size• Resistance ~ +/- 5%Resistance ~ +/- 5%


Setting the Rules (Cont.)Setting the Rules (Cont.)• Impedance and InductanceImpedance and Inductance

– If impedance and inductance are If impedance and inductance are parallel, phase unbalance is most likely parallel, phase unbalance is most likely due to rotor positiondue to rotor position

– If impedance and inductance are not If impedance and inductance are not parallel, phase unbalances are most parallel, phase unbalances are most likely due to winding contamination or likely due to winding contamination or overheated winding.overheated winding.


Setting the Rules (Cont.)Setting the Rules (Cont.)• Inductive and Impedance Rotor TestsInductive and Impedance Rotor Tests

– Measurements of inductance due to rotor Measurements of inductance due to rotor position will present an idea of the position will present an idea of the condition of a rotor due to casting voids condition of a rotor due to casting voids or broken rotor bars.or broken rotor bars.

– Measurements of impedance matched to Measurements of impedance matched to inductance provides a relative severity of inductance provides a relative severity of rotor condition.rotor condition.


Example 1: Bad 15 HP (Garlic Mill)Example 1: Bad 15 HP (Garlic Mill)

T1-T2 T1-T3 T2-T3R 0.954 1.054 0.9Z 52 96 56L 20 19 22Fi 80 83 85I/F -44 -39 -39Megger >99M


Garlic Mill Motor ConditionGarlic Mill Motor Condition

0.954 1.054 0.9

52

96

56

20 19 22

80 83 85

0

20

40

60

80

100

120

Phase 1 Phase 2 Phase 3

ResistanceImpedanceInductancePhase Angle


Equipment Size Limits? 8,000 hp, 200 Equipment Size Limits? 8,000 hp, 200 RPM, 13.2 kV, SynchronousRPM, 13.2 kV, Synchronous

T1-T2 T1-T3 T2-T3Resistance 0.322 0.319 0.319Impedance 189 181 190Inductance 37 38 37Phase Angle 81 85 83I/F -42 -49 -46Insulation #.#

T1-T2 T1-T3 T2-T3Resistance 0.318 0.316 0.321Impedance 190 192 190Inductance 37 38 37Phase Angle 83 86 81I/F -45 -49 -44Insulation #.#

Position 1

Position 2


Motor Circuit Analysis on a Motor Circuit Analysis on a Transformer?Transformer?• Definition: An electric motor is a Definition: An electric motor is a

transformer with a rotating secondary.transformer with a rotating secondary.• Evidence:Evidence:

– As rotor position is changed, the relative As rotor position is changed, the relative winding ratios change.winding ratios change.

– Energy is induced into the ‘secondary’ Energy is induced into the ‘secondary’ which creates the magnetic fields which creates the magnetic fields necessary to produce torque.necessary to produce torque.


Transformer Test No. 1Transformer Test No. 1

T1-T2 T1-T3 T2-T3Resistance 258.7 77.04 184.7Impedance 15654 11087 11043Inductance 24911 17645 17573Phase Angle 89 90 90I/F -36 -30 -6Insulation >99M


Transformer TestingTransformer Testing• Must ground all of the leads on other Must ground all of the leads on other

side being testedside being tested• True sine wave generated by ALL-True sine wave generated by ALL-

TEST causes traveling currents that TEST causes traveling currents that provide erroneous resultsprovide erroneous results

• Test same as 3-phase motor for 3-Test same as 3-phase motor for 3-phase transformersphase transformers


Transformer – Primary (2500kVA)Transformer – Primary (2500kVA)

ReadingReading H1-H2H1-H2 H1-H3H1-H3 H2-H3H2-H3ResistanceResistance 3.7033.703 3.6233.623 3.6483.648ImpedanceImpedance 220220 217217 218218InductanceInductance 8787 8686 8686Phase Phase AngleAngle

8888 8888 8888

I/FI/F -49-49 -49-49 -49-49


Good ReadingsGood Readings• Transformers follow ‘Penrose Theory of Transformers follow ‘Penrose Theory of

Winding Analysis’Winding Analysis’• Resistance: no more than 5% unbalance Resistance: no more than 5% unbalance

above 0.250 Ohms and 7.5% below 0.250.above 0.250 Ohms and 7.5% below 0.250.• Impedance – 5%Impedance – 5%• Inductance – 5%Inductance – 5%• Phase Angle - +/- 1 digitPhase Angle - +/- 1 digit• I/F - +/- 2 digitsI/F - +/- 2 digits• Note: Readings that show a definite “shift” Note: Readings that show a definite “shift”

should be flagged for further testingshould be flagged for further testing


Noisy TransformerNoisy TransformerT1-T2 T1-T3 T2-T3

Resistance 0.02 0.031 0.041Impedance 1 1 1Inductance 0 0 0Phase Angle 18 19 18I/F -29 -33 -29Insulation #.#

150 kVA Dry-Type 8-9 years in application


22ndnd Noisy Transformer Noisy Transformer


Identification of DefectsIdentification of Defects

T1-T2 T1-T3 T2-T3Resistance 0.053 0.062 0.082Impedance 1 1 1Inductance 0 0 0Phase Angle 19 19 19I/F -29 -29 -30Insulation 2.202


HardwareHardware


ALL TEST™ PM/PdM and ALL TEST™ PM/PdM and Root-Cause-AnalysisRoot-Cause-Analysis

Reliability

PM

RCA

Reliability

PM

PdM

RCA


ALL-TEST III™ FeaturesALL-TEST III™ Features• Impedance (Z) 5 - 1000 ohmImpedance (Z) 5 - 1000 ohm• Inductance (L) 0.35 mH - 1.6 HInductance (L) 0.35 mH - 1.6 H• Capacitance (C) 100μF - 50ηFCapacitance (C) 100μF - 50ηF• Phase Angle (Fi) 0 - 90 DegreesPhase Angle (Fi) 0 - 90 Degrees• Insulation Test 0 - 20 MΏ, 1000 Insulation Test 0 - 20 MΏ, 1000

VV• Frequency Range: 100, 300, Frequency Range: 100, 300,

850, 2400 Hz850, 2400 Hz• Dimensions: 7” x 3.75” x 1.75”Dimensions: 7” x 3.75” x 1.75”• Weight: 1.2 lbsWeight: 1.2 lbs


ALL TEST IV ALL TEST IV PROPRO™ Features™ Features• Stores over 500 motors with test resultsStores over 500 motors with test results• Automatically compares stored references with Automatically compares stored references with

resultsresults• Automatically measures: Resistance; Automatically measures: Resistance;

Impedance; Phase Angle; Inductance; I/F; and Impedance; Phase Angle; Inductance; I/F; and Insulation Insulation

• Detects turn to turn faults at early stagesDetects turn to turn faults at early stages• Includes Software for upload to PC and basic Includes Software for upload to PC and basic

trendingtrending• Light weight and hand held: 4.8” x 9.92” x 2”, Light weight and hand held: 4.8” x 9.92” x 2”,

< 2 lbs< 2 lbs• Non-Destructive, Repeatable TestingNon-Destructive, Repeatable Testing• Safe UseSafe Use• All test results in Engineering UnitsAll test results in Engineering Units


SoftwareSoftware


ALL-TEST IV ALL-TEST IV PRO PRO 20002000™™Software – TREND 2000™Software – TREND 2000™


Evaluation Software – HAL Junior Evaluation Software – HAL Junior 2.0™2.0™


ALL-TEST III Software – ALL-TEST III Software – Condition Calculator 2.0™Condition Calculator 2.0™


US Department of Energy US Department of Energy MotorMaster PlusMotorMaster Plus


Query Screen – MM+Query Screen – MM+


EMCAT™ EMCAT™ Electric Motor Circuit Analysis Electric Motor Circuit Analysis

Tool™Tool™

The Number 1 Software Tool The Number 1 Software Tool for Managing Your Electric for Managing Your Electric Motors and TransformersMotors and Transformers


Total Motor System Total Motor System Maintenance and Management Maintenance and Management in One Packagein One Package


Import Past Data Collected Import Past Data Collected Using the Import ModuleUsing the Import Module


Upload Data from the Upload Data from the ALL-TEST IV ALL-TEST IV PRO 2000PRO 2000


Set Up RoutesSet Up Routes


Schedule MaintenanceSchedule Maintenance


Analyze Motors Using Analyze Motors Using Proprietary HAL-gorithmsProprietary HAL-gorithms


Trend Test Results Over Trend Test Results Over TimeTime


Perform Rotor Test Using Perform Rotor Test Using Special EMCAT Grading SystemSpecial EMCAT Grading System


Maintain Work OrdersMaintain Work Orders


Test DC MotorsTest DC Motors


Add Test Results from Other Add Test Results from Other Maintenance EquipmentMaintenance Equipment


Print ReportsPrint Reports


Download Route to Download Route to ALL-TEST IV ALL-TEST IV PROPRO 2000 2000


EMCAT FeaturesEMCAT Features• Total Motor System Total Motor System

Management in Management in One PackageOne Package

• Up/Down-load, Up/Down-load, Import History, Import History, Manual Data EntryManual Data Entry

• Print Detailed Print Detailed ReportsReports

• Enter Data from Enter Data from Other TechnologiesOther Technologies

• Develop RoutesDevelop Routes• Schedule Schedule

MaintenanceMaintenance• Review Equipment By Review Equipment By

Location and/or NameLocation and/or Name• Rotor TestRotor Test• Evaluate and Trend Evaluate and Trend

AC/DC Motors and AC/DC Motors and TransformersTransformers

• Automated AnalysisAutomated Analysis


AccessoriesAccessories


ATF-11 Armature Test ATF-11 Armature Test FixtureFixture


M2000 Training MotorM2000 Training Motor


Motor Circuit Analysis: Theory, Motor Circuit Analysis: Theory, Application and Energy AnalysisApplication and Energy Analysis bookbook


Advanced Analysis KitAdvanced Analysis Kit


Training and Consulting Training and Consulting ServicesServices


On-Site or Scheduled On-Site or Scheduled TrainingTraining


Consulting ServicesConsulting Services• Customization of SoftwareCustomization of Software• Data Analysis of MCA, vibration, Data Analysis of MCA, vibration,

infrared and other technologiesinfrared and other technologies• Development of Maintenance Development of Maintenance

ProgramsPrograms• Other Motor System related Other Motor System related

consulting servicesconsulting services• Installation of SoftwareInstallation of Software


ALL-TEST ProALL-TEST ProA Division of BJM CorpA Division of BJM Corp123 Spencer Plains Rd123 Spencer Plains Rd

Old Saybrook, CT 06475Old Saybrook, CT 06475Ph: 860 399-5937Ph: 860 399-5937Fax: 860 399-7784Fax: 860 399-7784

Email: Email: [email protected]@bjmcorp.comWeb: www.alltestpro.comWeb: www.alltestpro.com

mailto:[email protected]

Motor Testing Made Easy 2002

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