1) The document discusses ABB's MACHsense solution for condition monitoring of electrical machines. It highlights typical failures in motors and shortfalls of traditional monitoring methods. 2) The MACHsense solution involves periodic on-site vibration and electrical measurements to detect defects early and project maintenance timelines. It uses advanced algorithms to normalize load effects and identify faults more accurately. 3) Case studies demonstrate how MACHsense detected rotor bar cracks and bearing faults earlier than traditional methods. The automated solution provides consolidated vibration and electrical analysis with correlated reports.

1. Condition Monitoring of Electrical
Machines
ABB MACHsense Solution

2. © ABB Group
November 7, 2011 | Slide 2
Overview
Typical failures in motor
Traditional condition monitoring methods
Shortfall
Solutions
ABB MACHsense service

3. © ABB Group
November 7, 2011 | Slide 3
Typical Problems in Electrical Machines
Deliverables
Rotating components
Cage rotor
defects
Bearing
problems
Installation
problems
Power
supply
quality
-15000
-10000
-5000
0
5000
10000
15000
0 0.02 0.04 0.06 0.08 0.1 0.12
Time [s]
Voltage
[V]

4. © ABB Group
November 7, 2011 | Slide 4
Existing Condition Monitoring Systems
Motor Current Signature Analysis
(identifying rotor winding defect)
Uses Fast Fourier Transformation of Current spectrum
Either single phase or three phase
Many plants
have In-house
condition
Monitoring
team
For Motor health assessment
Vibration Analysis
(identifying mechanical condition like bearing, installation quality
etc)
Measures overall vibration
Time domain analysis & FFT
Specialized methods like demodulation, phase analysis etc

5. © ABB Group
November 7, 2011 | Slide 5
Rotor Damage
Percentage of failure less than 5%,
but…
Broken Rotor Bars can
Cause Sparking-Safety Hazard for Ex
motors
Healthy Bars carry more current-
Further damage
Torque & Speed Oscillation-Premature
failure of bearings
Centrifugal forces causes bars to lift
from slots-Hits stator windings to
cause serious damage
Significance
Customer Need:
To have advance intimation to prevent
catastrophic failure.

6. © ABB Group
November 7, 2011 | Slide 6
Present Day Condition Monitoring Methods
FFT(Fast Fourier Transformation) of Current Signal
Identifies 2x slip frequency sideband in spectrum
Severity based on sideband height from center frequency
Rotor Bar Damage MCSA-Motor Current Signature
Analysis
2x slip frequency
sidebands
Rule of Thumb: faults are detected
when these sidebands meet or
exceed -35dB (often referred to as
'35 dB down').
54-60 dB = Excellent
48-54 dB = Good
42-48 dB = Moderate
36-42 dB = Cracked rotor bars or
other source of high resistance.
30-36 dB = Multiple sources of high
resistance.
< 30 dB = Severe damage

7. © ABB Group
November 7, 2011 | Slide 7
Case using Traditional Methods : False Positive: Rotor
Bar Cracks
This is indicative of rotor bar cracks as per standard
analysis
The rotor was checked visually, with a dye penetrant
No crack or defect in the rotor bar was detected
Pulsating torque had resulted in observed sidebands
- 20 dB
Motor Rating: 750 kW, 1490 rpm, 50 Hz, Application: Chipper, Plant: Pulp & Paper Mill
Test Conditions:
Loading: 33.9%
Operating Slip:0.229 Hz
Operating freq: 49.194Hz

8. © ABB Group
November 7, 2011 | Slide 8
Case using Traditional Methods : False Negative: Rotor
bar Cracks
Slip from vibration indicative of rotor bar cracks as per standard
analysis
Using the slip from the nameplate does not indicate rotor bar
cracks
Cracks in the rotor were observed
- 40 dB
Motor Rating: 210 kW, 2982 rpm, 50 Hz Application: BFP, Plant: Chemical
Test Conditions:
Loading: 76.7 %
Operating Slip:0.23 Hz (MCSA-nameplate slip
based)
Operating Slip: 0.27 Hz (Vibration)
Operating freq: 49.713 Hz
Using the slip from
the nameplate
(MCSA) does not
indicate rotor bar
cracks - 57 dB

9. © ABB Group
November 7, 2011 | Slide 9
What is Required ?
4 8 4 8 . 5 4 9 4 9 . 5 5 0 5 0 . 5 5 1 5 1 . 5 5 2
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0
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5 2 . 3 9 9 6
6 5 . 2 3 7 1
•Reduced Spectral Leakage using Adaptive Filtering
Processes
•Does Mathematical mapping to identify peak(correct
amplitude and frequency)
45 46 47 48 49 50 51 52 53 54 55
0
0.002
0.004
0.006
0.008
0.01
0.012
0.014
0.016
0.018
Hz
0 1 2 3 4 5 6 7 8 9 10
0
0.002
0.004
0.006
0.008
0.01
0.012
0.014
0.016
0.018
Hz
Automatic Slip &
Side Band
Identification
Normalization of
Load
Not to use Name
plate slip
information as
variation can be
upto 20% as per
IEC

10. © ABB Group
November 7, 2011 | Slide 10
ABB MACHsense-P
•A walk around
condition monitoring
service
•Periodic
measurements
•Machine in operating
condition
•Detection of defects
and evolution over
the time by periodic
measurements
•Preventive
maintenanceplan
based on projected
time of defect
criticality (over a
period of 6 months)
Overview
INSTALLATION
Alignment, soft foot, air
gap
CAGE
ROTOR
POWER
SUPPLY
ANTI-FRICTION
BEARING

11. © ABB Group
November 7, 2011 | Slide 11
Measurement
Either 4 vibrations channels
or 6 electrical(3 current & 3
voltage) channels
simultaneously
High resolution data
collector for quick & high
speed data acquisition
ABB MACHsense-P
Measurements

12. © ABB Group
November 7, 2011 | Slide 12
Case Studies
Client-Petrochemical
Motor-4.5MW, 4 Pole, 1500RPM, Sleeve bearings
Motor was driving compressor, having no stand by.
Highest amplitude 7.76mm/sec DE, Vertical direction
Broken Rotor Bar

13. © ABB Group
November 7, 2011 | Slide 13
The Analysis
Current Spectrum
Traditional Method
Automated Report
AfterNormalizing
signal with respect
to load

14. © ABB Group
November 7, 2011 | Slide 14
Confirming Rotor winding damage
Verifying sources of Torque Oscillation

15. © ABB Group
November 7, 2011 | Slide 15
Cage Rotor Damage
August 11
September 11
Broken Short Circuiting Ring
• COG Plant
• 14900 KW
• Load-Compressor

16. © ABB Group
November 7, 2011 | Slide 16
Air Gap Eccentricity
.
Static-
Position of
minimum
airgap
remains
constant.
Dynamic-
Position of
minimum air
gap keeps
rotating.
No norms for
eccentricity
Traditional analysis method
Fault Frequency:
Static Eccentricity = RB X RS ± nFL
Dynamic Eccentricity = RB X RS ± nFL ± RS

17. © ABB Group
November 7, 2011 | Slide 17
Air Gap Eccentricity
.
Vibration
signals from
motor core
are a
measure of
electromagn
etic forces.
Unique
sensor
mounting
location to
pick up
electrical
related
signals from
vibration
The solution

18. © ABB Group
November 7, 2011 | Slide 18
Traditional methods vs ABB MACHsense-P
Traditional methods (MCSA)
Cannot differentiate torque
oscillation of rotor bar damage from
that of load (compressor, crusher
etc) or power supply
Common norms used to confirm
severity of defect irrespective of
load
Uses name plate slip
Mechanical faults not identified or
identified at later stage after fault
initiation.
Does not consider rotor design and
construction of motor (cannot
accurately determine the severity of
the fault or even identify the defect)
ABB MACHsense-P
Simultaneous measurement of
current and voltage makes it
possible to confirm and distinguish
reason of torque oscillation
Normalizes data according to load to
confirm defect of rotor bar , air gap
eccentricity etc.
Automated slip detection
Vibration data gives mechanical
condition and confirms findings of
MCSA
ABB consider rotor design and
construction of motor which give an
unique index to estimate the fault
severity.
Number of rotor bar, speed etc.
Advantage of using ABB MACHsense-P
48 48.5 49 49.5 50 50.5 51 51.5 52
10
-3
10
-2
10
-1
10
0
10
1
10
2
52.3996
65.2371

19. © ABB Group
November 7, 2011 | Slide 19
Other Faults
Uses traditional Vibration analysis methods
Mechanical Problems-
o Unbalance
o Misalignment
o Loosensess
Installation-Soft foot
Shaft Eccentricity
Unbalanced electromagnetic pull, mechanical problems
can lead to bearing damage.
Customer Need:
To identify presence of such problems to plan maintenance action.

20. © ABB Group
November 7, 2011 | Slide 20
Unbalance-Spectrum
Traditional Analysis methods

21. © ABB Group
November 7, 2011 | Slide 21
Signature
What is the problem here?

22. Vibration
data
ISO - RMS
Get SPEED
Get HARMONICS
Harmonic RMS to
Total Harm. Distortion
ISO standards
Principal
Components
Classification
Fault classification +
+ Severity
Other fault:
non-synchronous
What is required?
PRINCIPLE COMPONENT ANALYSIS

23. © ABB Group
November 7, 2011 | Slide 23
Model Based Analysis
ABB MACHsense Solution

24. © ABB Group
November 7, 2011 | Slide 24
Rolling Element Bearing
Causes of Bearing Failure
Lubrication
High Vibration-Misalignment, Unbalance.
Installation Faults
Soft Foot
Air Gap eccentricity

25. © ABB Group
November 7, 2011 | Slide 25
Sensitivity of different methods to detect bearing
faults
Time
Severity of
the fault
A spall has been
developed
ABB BeAM®
Off-line envelope method and an
experienced analyser*
Off-line envelope method and an
inexperienced analyser*
ABB BeaCon automatic
autocorrelation time-
domain
Significant change in crest
factor**
Significant change in high frequency
RMS value**
Change in bearing
temperature**
•Commonlyused methods for bearing faults analysis
** Non-specific methods
Lubricant debris
monitoring*
Smoke**
Early detection Failure

26. © ABB Group
November 7, 2011 | Slide 26
Bearings Vibration Analysis : BeAM®
Common analysis methods use for the
envelope method for bearing fault
detection
The envelop method uses the
envelope of high frequency signals
generated by defects and compares it
to bearing defect frequencies.
The ABB BeaCon automatic analysis
uses:
the auto-correlation time-domain
method to filter out the noisy signals
more effectively that traditional
method
ABB Approach
0.56 0.565 0.57 0.575 0.58 0.585 0.59
-0.4
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27. © ABB Group
November 7, 2011 | Slide 27
Bearings Vibration Analysis : BeAM®
The ABB BeAM® in addition to the ABB
BeaCon automatic autocorrelation time-
domain analysis:
Perform early shock pulse detector
analysis which only extract the
shock pulses related to bearing
defects using special signal
processing methods such as
adaptive filtering and likelihood
ratios to improve the signal
sensitivity.
Estimates the following parameters
to evaluate the condition of the
bearing:
Kurtosis , high frequency
RMS, maximum energy per
shock pulse & integrated
energy calculations
0 10 20 30 40 50 60 70 80
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-2
-1
0
1
2
3
Time [ms]
0 10 20 30 40 50 60 70 80
-3
-2
-1
0
1
2
3
Time [ms]
Data sequences that
contain shock pulse + noise
Data sequences that
contain only noise
Unfiltered
vibration signal.
Above signal after
proper filtering.

28. © ABB Group
November 7, 2011 | Slide 28
ABB Condition Monitoring
Vibration measurement were taken for two identical Boiler Feed Pump
motors. Both measurements were taken for 50 % of machine load.
Nameplate details:
Overall vibration readings in Motor BFP 3C, serial number: 3991201-1
Velocity: 1.02 mm/s
Acceleration: 0.46 g
Overall vibration readings in motor BFP 3B,Serial Number: 3991201-2
Velocity: 1.3 mm/s
Acceleration: 1.36 g
Power Voltage Current Speed Frequency Poles
2000 kW 6.6 kV 204 A 1487 rpm 50 Hz 4
Case study - Bearings

29. © ABB Group
November 7, 2011 | Slide 29
ABB condition monitoring
Machine BFP 3C
• Bearing OK
• Suggested action:
• action category: preferred
• next measurement: in six months
Machine BFP 3B
• Bearing faulty
• Suggested action:
• action category: mandatory
• change bearing as soon as possible
but not later than 3 months
Case studies – Bearings: Early Warning

30. © ABB Group
November 7, 2011 | Slide 30
ABB Condition Monitoring
Case study – Bearing related energy trend (early warning
detection)
Bearing related
quantities
Energy related to
bearing for healthy case
Energy related to
bearing for faulty case
Warning Level
Possibilityof comparing the
spectra for each measurement
Vibration signal
in time domain
Vibration signal
after filtration

31. © ABB Group
November 7, 2011 | Slide 31
Traditional methods vs ABB MACHsense-P
ABB MACHsense-P-
Vibration analysis
4 channel simultaneous
data collection with
frequency range of 20Khz.
Uses unique sensor
mounting methods to pick
electrical signals i.e from
motor body
Powerful algorithms
identifies bearing damage
at an early stage
Automated report for all
electrical motors
Advantage of using ABB MACHsense-P
Traditional Methods-
Vibration Analysis
Multi channel data
acquisition but with max
frequency range of 16Khz.
No access to electrical
problems with traditional
way of data collection i.e
from bearing housing
Custom made tools
available for monitoring
bearing condition.
No automated analysis
especially for motors
0
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0 50 10 0 1 50 200 25 0 30 0 350 400 4 50 5 00
frequ ency [Hz]
Vibration
[
g's]

32. © ABB Group
November 7, 2011 | Slide 32
ABB Approach
Single software for vibration and electrical data input
Combined Vibration & Electrical Data
Vibration
Stator
Voltage
Stator
Current
Patented processes for defect detection
used in analysis software
Automated analysis includes slip
estimation, normalization of load effects
and accounts for constructional aspects
Key
Condition
Parameters
Automated report

33. © ABB Group
November 7, 2011 | Slide 33
Traditional methods vs ABB MACHsense-P
Vibration and electrical
ABB MACHsense-P
Measures vibration and
electrical data with same
instrument
Same software gets input of
vibration and electrical data
Correlates data like slip
Unique algorithms
developed for different
machines-DOL, VFD, SM
Automated report
Competition
Measures vibration and
electrical data with individual
instrument
Separate software analyzes
vibration and electrical data
No correlation in analysis
Common mode of analysis
for different electrical type of
electrical machines
Manual report generation

34. © ABB Group
November 7, 2011 | Slide 34
ABB MACHsense-P
Standard
Regular condition
monitoring
Measurements made at
nominal operating condition
and load
Report with standard
deliverables.
About 6-8 motors can be
analyzed in a day.
Charges can be on a per
machine basis
Advanced
Trouble shooting to assess
root cause.
Measurements at nominal
condition and at different
load/speeds.
Root cause analysis &
standard deliverables.
One or two motors are
analyzed in a day.
Per day charges applicable
Deliverables
Cage rotor
package:
Rotor bar defect
Eccentricity
Shaft bow
Internal
misalignment
Bearing Package
Bearing defects
Assembly
defects
Lubrication
issues
Sleeve bearings
Installation
Unbalance
Looseness
Misalignment
Soft foot
Power supply
quality
Voltage
unbalance
Harmonics
The Levels

35. © ABB Group
November 7, 2011 | Slide 35
Advantages of ABB MACHsense-P
Combined automated analysis of Current, voltage and vibration
Overcomes False Positive and False Negatives involved in
traditional methods
Automated summary status report issued on site
Patented algorithms applicable to each motor type
Application specific preventive maintenance plan with final
detailed report
Can be applicable to any make and size of motor
Early warning provides enough time for corrective action
A One Stop
Shop for
Motor health
assessment
Unique Selling Points