Solutions

Volume 8, Issue 1
Monitoring Induction Motors for
Power Quality (Part 1)
For many years, motors have been an essential piece of electrical equipment,
pervading everything from large, industrial facilities to our homes. They are used
in wide range of applications from the large three-phase induction motors
that the drive reactor coolant pumps in nuclear generation stations, to the small
universal motors that drive your vacuum cleaner. Motors are a crucial component
of every nations economybecause of the work they perform, and because of
the considerable amount of energy they consume.
The most common type of motor in use today is the polyphase induction motor
with over 90% of those being squirrel cage induction motors. The prevalence of
polyphase induction motors exists for several reasons:
Relatively inexpensive
Rudimentary design
Readily replaced
Reliable operation
Range of mounting styles and environmental enclosures
Due to the signifcant capital and operational investments made by companies
in induction motorsinvestments that impact the bottom lineknowing the
state of their condition is vital. Induction motors are generally robust, but
they can fail prematurely. Causes of motor failures include poor maintenance
practices, improper lubrication, harsh operating environment, inadequate source
voltage, or misapplication of the motor. All of these issues have one thing in
common: excessive temperature rise. Excessive heat is the nemesis of motors;
temperature rise can originate in the bearings (lubrication, alignment, etc.), in the
windings (design, voltage, etc.), or be imposed by external conditions (ambient
temperature, atmosphere, etc.).
A permanently-installed power monitoring device can provide a great deal of
information about induction motors. By monitoring the voltage, current, and
temperature (using the monitors I/O capabilities), todays monitoring devices
can provide data on many aspects of an induction motor including:
Quality of the motors terminal voltage
Energy usage
Loading concerns
Excessive cycling
Starting characteristics
Environmental considerations
Although each of these aspects is important, this article will focus on detecting
problems with the terminal voltage to increase the life of an induction motor.
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( . . . continued on page 2)
Figure 1. Motor Damaged by Excessive Temperature
( . . . continued from page 1)
Quality of the Motors Terminal Voltage
Induction motors have nameplate ratings to help
insure that the motor is properly applied. The
nameplate data should be adhered to as closely as
possible, but there are times when external factors
cause variations beyond the motors approved
constraints. The quality of the terminal voltage
depends on several factors including each phases
magnitude, angle, frequency(s), and duration of any
deviation from the rated voltage. Deviations in one or
more of these factors can reduce the operating life
of induction motors. Combinations of these factors
are grouped into eight categories of terminal voltage
problems that can affect polyphase induction motors.
Undervoltage
Overvoltage
Imbalance
Harmonics
Transients
Sags
Swells
Frequency Deviation
Overvoltage and Undervoltage
There is a fallacy that states if low voltage is bad,
then high voltage must be good. Induction motors
are designed to operate within a limited range
around their rated voltage (NEMA MG-1 specifes
10%). At full load current, an overvoltage at the
motor's terminals greater than 10% can substantially
increase the core losses of the motor resulting in
overheating. And an elevated ambient temperature
will only exacerbate the problem. The overvoltage
will always be less at the motors terminals than
is measured by the monitoring device due to the
voltage drop of the circuit.
Low voltage at the terminals of a fully loaded motor
also results in additional heating due to increased
current fow. Adequately installed protective
devices (overload relays) should limit this problem
during operation, but starting during low voltage
conditions is particularly taxing on the motor. When
starting during severe undervoltage conditions, the
developed torque may not be suffcient to allow the
motor to come up to speed. If the monitoring devices
are located remotely from the motor, the voltage
drop between the two should be accounted for when
setting the alarm thresholds.
Figure 2. Motor Damage Caused by Voltage Imbalance.
voltago mbalanoo vs. Curront mbalanoo
0
10
20
30
40
50
0 1 2 3 4 5
voltago mbalanoo (%)
C
u
r
r
o
n
t

m
b
a
l
a
n
o
o

(
%
)
Figure 3. Effect of Voltage Imbalance on Current.
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Page 2
Figure 5. Motor Derating Factor Due to Voltage Imbalance
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Imbalance/Unbalance
Voltage imbalance (including single phasing) is a
major cause of motor failures (See Figure 2). Voltage
imbalance in fully-loaded polyphase induction
motors produces a disproportionately higher current
imbalance (see Figure 3). The current imbalance
will cause additional losses in the motor resulting
in a temperature rise. The graph in Figure 4 shows
the relationship between voltage imbalance and
temperature rise in the motor. Ultimately, increased
heating can stress the motors insulation, shortening
the life of the motor. To minimize these insulation
stresses, the motor loads should be reduced
commensurate to the degree of voltage imbalance.
The graph in Figure 5 is NEMAs widely recognized
derating curve for three-phase induction motors
(NEMA MG-1). Derating should be considered at
voltage imbalances greater than 1%, and removing
the motor from service should be considered when
voltage imbalances exceed 5%.
Many monitoring systems provide the ability to
measure voltage imbalance using either the IEC
method (based on symmetrical components) or the
NEMA method (based on the maximum deviation
from the average). Both methods are acceptable
as long as the chosen method is used consistently.
It is important to note that measuring the voltage
imbalance on an unloaded system is a more valid
approach than measuring voltage imbalance on a
system with loaded three-phase motors. Loaded
three-phase motors have a tendency to rebalance
an unbalanced system (to a degree) potentially
masking the true severity of the problem.
Harmonics
Distorted voltage harmonics are additional
frequencies that are integer multiples of the
fundamental frequency. Voltage harmonic
frequencies produce additional heat in the motor
as current through the motors impedance. Heating
resulting from the I
2
R losses increases due to the
additional harmonic currents. Eddy current and the
hysteresis losses are affected by the frequency(s)
at the motor terminals, and the higher frequency
components associated with harmonics increase
these losses.
Voltage harmonics include positive, negative and
zero sequence components depending on which
harmonic frequencies are present (See Table 1).
Positive sequence components develop torque in
the same direction the motor is turning. Negative
sequence components develop torque in the
opposite direction the motor is turning. The zero
sequence components have no affect on the motors
torque, but generate ancillary losses. It should be
evident that the torque developed by the positive
Harmonic
Component
Component Sequence
1st
2nd
3rd
4th
5th
6th
7th
8th
9th
10th
11th
12th
:
Positive
Negative
Zero
Positive
Negative
Zero
Positive
Negative
Zero
Positive
Negative
Zero
:
Page 3
Motor Derating Factor Due to Voltage
mbalance
0.70
0.75
0.80
0.85
0.90
0.95
1.00
0% 1% 2% 3% 4% 5%
voltago mbalanoo (%)
D
o
r
a
t
i
n
g

F
a
o
t
o
r
Table 1. Component Sequence Based on Specifc
Harmonic Component
Figure 4. Effect of Voltage Imbalance on Motor Temperature
Tomporaturo Piso Duo to voltago mbalanoo
0.0
10.0
20.0
30.0
40.0
50.0
0 1 2 3 4 5
vol tago mbal anoo (%)
T
o
m
p
o
r
a
t
u
r
o

P
i
s
o

(
%
)
and negative sequential components opposes each
other resulting in higher currents and additional
heating within the motor. IEEE Standard 519-1995
provides a good guideline for the acceptable levels
of voltage distortion to loads (including motors). A
broad recommendation is to establish the voltage
distortion monitoring limits at 5% total harmonic
distortion (THD) and at 3% for any particular
harmonic frequency. The types of connected loads
and system impedances will be a major factor in the
level of exposure a motor has to voltage distortion.
Transients
Transients are very fast (subcycle) discontinuities in
the ac waveform often caused by switching events or
even by the injection of lightning onto the electrical
system. Voltage transients stress the insulation
on the motors winding causing it to degrade over
time or sometimes catastrophically fail. A number
of factors contribute to the effects of a voltage
transient including its magnitude, duration, rise-time,
associated energy, or even system impedances.
Damage due to voltage transients is generally either
turn-to-turn or turn-to-ground depending on whether
the electrical system is grounded or ungrounded.
Due to their inductive nature, motors appear to be
open circuits at high frequencies often resulting
in damage to the frst turn or two of the windings
(a classic indicator of damage due to voltage
transients).
The ability to detect and alarm on high-speed voltage
transient events is vital to insuring longevity in the
motor. Detecting transients requires a faster sample
rate and a higher dynamic range in monitoring
devices. Thresholds should be confgured to detect
two times the motors rated voltage at a minimum.
In order to minimize the fltering effects of the
conductors, the voltage should be monitored in close
proximity to the motors terminals.
Voltage Sags and Swells
Voltage sags and swells are momentary (opposed
to the long-term variations of undervoltages and
overvoltages) decreases and increases in the
steady-state system voltage, respectively. Voltage
sags can impact motors and their driven loads;
voltage swells less so. Voltage sags reduce the
available torque, stressing the motor and heating the
windings. But the primary concern of voltage sags
is their effect on a motors controls. During certain
voltage sag conditions, the contactors coil loses its
ability to effectively hold the contacts together and
the motor circuit opens. This problem becomes more
complicated when the voltage sags to the threshold
of the contactors ability to hold the contacts together.
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Figure 6. Motor Damage Due to Voltage Transient
Page 4
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The contacts may then begin to bounce resulting in
arcing, heat, and damage. There are many variables
that will affect a motors susceptibility to particular
voltage sags including the pre-event parameters,
phase angle of occurrence, transitional phase shift,
and the contactors characteristics. The coil should
be expected to operate over a range of 85%-110%
of the rated voltage. The irony of motors is that their
controls are sensitive to voltage sags, and yet the
inrush currents associated with motor starts produce
voltage sags.
The recommended power monitor settings for voltage
sags and swells are 90% and 110% of nominal,
respectively. This will insure that all pertinent data is
captured and available for analysis should a motor
fail or operate erratically.
Frequency Deviation
In most developed countries, governing bodies
impose tight frequency constraints on utilities so
frequency deviations on the utility grid are rare.
However, it is possible to experience signifcant
frequency deviations when operating independent
from the grid (e.g., self generation). Three-phase
induction motors are designed to operate most
effciently at their rated frequency, and signifcant
frequency drift will result in additional heating of the
windings.
The recommended guideline for monitoring motors
that may be vulnerable to frequency shifts is 5% of
the rated frequency. This range is further restricted as
the terminal voltage deviates from the rated voltage
of the motor.
Conclusion
Polyphase induction motors are critical components
in most industrial processes, and their reliability is
essential to the bottom line. There are many potential
hazards both internal and external to the motor
that can reduce its operating life. Continuously and
effectively monitoring the motors terminal voltages
is a valuable means to maximize its performance,
increase its longevity, and reduce its total operating
costs.
Category Recommended Thresholds
Other
Considerations*
Undervoltage -10% at rated voltage MG-1-2003
Overvoltage +10% at rated voltage MG-1-2003
Voltage Imbalance Derate Motor > 1%
remove from service > 5%
MG-1-2003
Harmonics THD < 5% HD of any
component < 3%
IEEE 519-1992
Voltage Transients 200% of rated voltage Suggested
Voltage Sag -10% of rated voltage Suggested
Voltage Swell +10% of rated voltage Suggested
Frequency Deviation 5% of rated frequency at
rated voltage
MG-1-2003
Table 2. Recommended Thresholds for Power Monitoring Devices**
* The National Electrical Manufacturers Association (NEMA) Standard MG-1 (2003) provides
some very practical guidelines outlining the limitations of motors. IEEE Standard 519-
1992 is also a useful resource in the topic of the harmonic limitations of motors (and other
equipment). For additional details, reference the directives of each standard as it pertains to
its respective areas of consideration.
** The recommended thresholds in this article are non-compulsory and should not be
substituted for specifc manufacturer recommendations or the requirements of specifc
applications or equipment.

References:
ANSI/NEMA Standard MG-1-2003, Revision 1-2004, Motors and Generators,
Revision 1.
IEEE Standard 519-1992, IEEE Recommended Practices and Requirements for
Harmonic Control in Electrical Power Systems.
IEEE Standard 1159-1995, IEEE Recommended Practice for Monitoring
Electric Power Quality.
Electric Motor Manual, Robert Lawrie, McGraw-Hill, Inc., 1987.
2006 Schneider Electric All Rights Reserved
Doc # 3000HO0601 April 2006
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