Selection of Induction Motors for Industrial Applications (part 1)

http://electrical- engineering- portal.com/selection- of- induction- motors- for- industrial- applications- part- 1 May 9, 2013

Selection of Induction Motors f or Industrial Applications (photo by http://www.iecee.org)

Introduction
All types of industries are invariably required to install different types of electric motors as prime mover for driving process equipment participating in their respective production line up. The continuous process of technical development has resulted into availability of highly diversified types of electric motors. Hence, an utmost care should be exercised in selection of most appropriate type of motor considering number of technical factors for each application, so that the motor would provide desired and optimum performance. The characteristics of motors vary widely with the nature of their application and the type of duty they are expected to perform. For example, the applications like constant speed, constant torque, variable speed, continuous/intermittent duty, steep/sudden starts, frequent start/stops, etc. should be taken into consideration carefully when deciding for the type of a motor for that specific application. Moreover, the motors are required to perform quite often under abnormal conditions during their total service life.

In view of above, an incorrect selection of motor always lands the industrial buyer into all sorts of problems, including premature failure of the motor, causing severe production curtailments. Like one mentioned above, a number of other factors and design features like weather conditions, stringent system conditions, abnormal surroundings, hazardous area, duty cycle, motor efficiency, etc. should be considered while deciding the rating and subsequently drawing out the technical specifications of the motor.

Abnormal conditions and ef f ects

The usual abnormal conditions encountered by the motors are given below.

1. Abnormal System Conditions

1. Voltage 1. Undervoltage 2. Overvoltage 3. Unbalance in 3-phase 4. Single phasing 5. Voltage surges 2. Frequency 1. Low frequency 2. High frequency

Stator and Rotor Damages

2. Abnormal Operating conditions

1. Locked rotor or stalled rotor 2. Reswitching/Frequent start-stops 3. Momentary interruption/Bus transfer 4. Overloading 5. Improper cable sizing

3. Environmental conditions
1. High/low ambienttemperature 2. High altitude

3. High humidity 4. Corrosive atmosphere 5. Hazardous atmosphere/surroundings 6. Exposure to steam/salt-laden air/oil vapour

4. Mechanical problems
1. Seized bearings 2. Incorrect alignment/foundation levelling 3. Incorrect fixing of coupling 4. High vibration mounting 5. External shock due to load

5. Condition at location
1. Poor ventilation 2. Dirt accumulation 3. Exposure to direct sunlight Though, above mentioned abnormalities may prevail for short or long duration or may be transient in nature, major impact of the listed abnormal conditions is overheating of the motor along with one or several of the other effects as follows. Change in the motor performance characteristics like drawl of more power and consequent deterioration in motor efficiency, etc. Increase in mechanical stresses leading to: 1. Shearing of shafts 2. Damage to winding overhang 3. Bearing failures 4. Insulation failures Increase in stator and rotor winding temperature leading to: 1. Premature failure of stator or rotor insulation (For wound rotor motor) 2. Increased fire hazard 3. Breakage of rotor bar and/or end ring (For squirrel cage motors) All the motors encounter few or several of these abnormalities during the course of their service lives. Consideration of listed abnormal conditions at design stage greatly helps to minimise the effects of abnormal conditions to maintain a consistent performance.

Design Considerations

Following are the most important design factors required to be considered when selecting a motor for any of the diversified industrial applications.

Output in kW/HP
There are two principle limitations for selecting the motor output:

1. Mechanical limitation
The breakdown torque, which is the maximum torque that the motor can produce when operating without stalling. This is a critical design factor in motor applications, particularly for the motors subjected to occasional extreme load conditions. Another critical factor is the locked-rotor torque, which is the maximum torque that the motor can produce during startup from steady-state condition, a critical design feature for conveyor drives.

2. Electrical limitation due to insulation provided on the motor windings

The electrical load on the motor can be imposed till the winding insulation is able to withstand the prescribed temperature rise over an ambient for that particular class of insulation. Life of the motor greatly depends on the temperature rise of the windings. Anticipated life-span of the motor can be achieved provided it is operated at its rated output without overloading and the prescribed preventive maintenance practices are religiously followed.

Speed of the Motor

Most of the motors are directly coupled with the driven equipment where in the speed of the motor and the driven equipment will be same. In order to meet the speed of the driven equipment, the devices like gearbox, chains or belts are introduced between motor and driven equipment. In this case, it may be necessary to provide the rotor shaft suitable for its attachment with the speed decreasing or increasing device and hence the specification should include such specific requirement. In case a variable speed drive is to be used for the speed variation, the motor should be compatible for this specific application. The standard motor may not provide desired performance when operated via variable speed drive. Cant see this video? Click here to watch it on Youtube.

Power Supply Voltage and Frequency Variations

Variations in the power supply parameters, i.e. voltage and frequency significantly affect overall performance of the motor. As provided in IS:325-1996, the permissible voltage variation is 5 to 10%, permissible frequency is 50Hz 3%, and permissible combined variation is 6 %. The effect of undervoltage is more serious than that of overvoltage. The higher torque, resulting from overvoltage, can handle a little overload without undue

heating of the winding, but only for a short duration. Continuous operation with undervoltage condition increases the current at the rate of about 20% for every 5% reduction in the supply voltage, increasing the rated copper loss. This results into heating and prolonged temperature rise, and finally the burning of winding. During a motor start-up, the torque reduces by 10% for each 5% reduction in the supply voltage, causing more starting current and consequently more rapid heating of the winding.

The motor offers

Large burned out induction motor

reduced efficiency at either overvoltage or undervoltage. Power factor drops sharply with higher voltage and improves with lower voltage. Even when motor is lightly loaded, over-voltage cause rise in current and temperature thus reducing the life of motor. The variation in frequency by +5 % decreases the torque by about 10% and vice-versa at 5% frequency, the torque increases by about 10%. It is, therefore, of utmost importance to consider the combined effect of variation in voltage and frequency both when purchasing the motor. Unbalance in the supply voltage results into a current unbalance of 6 to 10 times the percentage voltage unbalance. This in turn results into generation of negative sequence currents in the rotor causing its overheating and premature failure. It is therefore vital to specify the permissible limits of variations in the power supply parameters for the motor in accordance with the requirement of the driven equipment. However, the permissible limits should never be more than provided in the applicable Indian Standard IS:3251996 (Reaffirmed in 2002).

Selection of Induction Motors for Industrial Applications (part 2)

http://electrical- engineering- portal.com/selection- of- induction- motors- for- industrial- applications- part- 2 May 9, 2013

Selection of Induction Motors f or Industrial Applications (part 2) - photo by T CD Systems

Motor Ef f iciency

Though standard motors are now available with a better efficiency, this factor (motor efficency) requires due attention when making the selection of the motor for a specific application in view of substantial quantum of power consumed by the motors in the industries. The motors running continuously should be as efficient as possible to reduce the power consumption. Improvement of even 1% in efficiency results into saving of enormous quantum of power over a life span of the motor as well as the cost of power. For the drives to be in service round the clock, due consideration should be given install the energy efficient motors having EFF 1 or EFF 2 class even at the higher cost, as the premium paid in the form of capital investment will be paid backhand somely in the form of cost saving due to significant energy saving when the drive will be kept in continuous service.

T he new IEC 60034-30 motor ef f iciency standard could have major energy-saving impact f or industrial motors worldwide.

Ambient Temperature
As per normal standards, the motor output is given by the vendors based on 40C ambient temperature. If ambient temperature is expected to be high for a longer duration, then the motor is required to be checked for its suitability to maintain the specified output at higher temperature, or otherwise, the deration factor is to be applied to know the actual anticipated output at higher temperature. In order to maintain the motor output at higher temperature as per the power requirement of driven equipment, it may be necessary that the motor with a higher frame size for the same rating is selected to avoid adverse effect of derating.

Altitude
The standard motor outputs are specified by the manufacturers for site altitude up to 1000 m. For altitudes of more than 1000 m, the motor ratingis required to be checked for its suitability to maintain the specified output, or otherwise the duration factor is to be applied to know actual anticipated output at higher altitude. Criteria for the selection of motor remains the same as provided for higher ambient temperature.

Method of Starting and Number of Starts

The starting performance of the motor depends

The starting performance of the motor depends on the method of starting deployed, i.e. directon-line, star-delta, high resistance, auto transformer, variable frequency drive, etc. The direct-on-line starting (DOL motor starter) is the most common method adopted in which the starting current is 6-7 times the rated full load current of the motor. For high starting torque, the direct-on-line starting is essential. If the motor driving a load requiring high starting torque is started using star-delta starting, either the speed may not pick-up affecting the motor acceleration, or may take a very long time to come up to its rated speed under loaded condition inducing severe electrical and mechanical stresses respectively in the winding and core. Where the starting torque requirement is not so critical, the star-delta starting or any other reduced voltage method of starting is used.

DOL starter, with enclosure, less overload, contains T eSys Model D contactor (Ratings: 4kW, 9A, AC3, 240V, less O/L)

Where the starting with very heavy load, such as with hoist or crane drives, and speed control over a wide range is required, it is advantageous to consider the slip-ring type (or wound rotor type) motor with a drum controller starter or resistance starter. As per modern day technology, a soft starter can also be considered for such applications. It is essential to specify anticipated number of starts per hour or per shift of 8-hrs duration as well as number of consecutive starts required when the motor is started from cold or hot condition for facilitating the design of motor windings and selection of correct class of insulation to encounter anticipated temperature rise due to number of starts. Large rated motors are often started via soft starters. It is desirable to explicitly specify this requirement so that the motor, compatible for such application, is designed and manufactured.

Duty Cycle
Selecting the proper electric motor also depends

Selecting the proper electric motor also depends on whether the load is steady, variable over a fixed time duration, following a repetitive cycle of variation, or load with pulsating torque or shocks. The motors to be kept min service round the clock, such as driving pumps, fans, etc., may be selected on the basis of continuous load and other factors discussed in this article. This is the Duty Cycle required to be performed by the motor. The motors driving the equipment like automatically controlled compressors, cranes, hoists start and stop a number of times per hour and those in some machine tools start and stop many times per minute. The Duty Cycle is a fixed repetitive load pattern Laf ert Electric motor that combines brushless over a given period of time which is expressed as permanent magnet (PM) and AC induction the ratio of on-time to cycle period. When motor technologies. operating cycle is such that electric motors operate at idle or a reduced load for more than 25% of the time, Duty Cycle becomes a factor in sizing electric motors. Also, energy required to start electric motors (that is, accelerating the inertia of the electric motor as well as the driven load) is much higher than for steady-state operation, so frequent starting could overheat the electric motor. When the motor is supposed to operated at idle or reduced load for more than 25% of the time in accordance with its operating cycle, the Duty Cycle becomes a vital factor in sizing the motor. Also, the energy required to start the motors, i.e. during accelerating along with driven load, is much higher than that required for steady-state operation, so frequent starting, in most probability, is likely to overheat the motor.

Insulation Class
The permissible temperature rise for six insulation classes is based on the ambient temperature of 40C as shown in following table for different class of insulating materials.

Thermal Class of Insulation A E

Normal permissible temp. rise over 40C 60 75

Normal total temp. C 100 115

Maximum permissible temp. rise C 105 120

Insulating materials

Cotton, Silk, Impregnated/Coated paper Synthetic enamel based on polyvinyl acetate, Polyurethane, Epoxy on polyamide resin Mica, Glass fibre, Asbestos with suitable

80

120

130

bond, viz. Synthetic resin varnishes, Epoxy resin shellac, Asphalt or bituminous compounds F 100 140 155 Mica, Glass fibre, Asbestos with suitable bond, viz. Alkyd epoxy resin, add silicon alkyd resin Silicon elastomers, Mica, Glass fibre, etc. with bonding substances like silicon resins Mica porcelain, Other mica class quartz, with bonding materials of silicon resin

125

165

180

170

210

225

It may be remembered that for every 10C rise in operating temperature, the insulation life reduces by 50% of its usual life. Thus the temperature rise in motor is usually the dominating ageing factor of influence on the winding insulating materials and insulation systems. Hence it is essential to specify proper class of insulation for the motor based on design ambient temperature, if it is more than standard design temperature of 40C. The endurance of the insulation is adversely affected by many other ageing factors, such as surroundings, electrical and mechanical stresses, vibration, deleterious atmospheres and chemicals, moisture, dirt and radiation.

http://electrical- engineering- portal.com/selection- of- induction- motors- for- industrial- applications- part- 3

May 9, 2013

Selection of Induction Motors f or Industrial Applications (photo by ABB)

Dif f erent Rotor Classes

The different rotor class, i.e. KL7, KL10, KL13, KL16, KLp, etc. are available in case of the motor to fulfil the functional torque requirements of the driven equipment. The rotor classes indicate against what quantum of the load torque the motor would be able to start easily. The motor with KL10 class of rotor, when started direct-on-line, would accelerate safely to its rated speed against the load torque of 100 % of its rated torque. Similarly, the motor with KL16 class of rotor would be capable of starting against the load torque of 160 % of its rated torque. Though, KL10 class rotor could take maximum starting torque up to 180 % of the full load torque, and for KL16 class, it could go up to 200 %, but for very minimum time exerting more stress to the rotor. Such practice reduces the motor life in no uncertain terms. It is therefore essential to obtain the technical data for the torque requirement of driven equipment during starting and incorporate in the specification so that the motor of correct rotor class will be installed.

Constructional features of motor

Based on the application requirements, the constructional features of the motor are to be selected as follows:

Mounting Arrangement
Different types of mounting arrangement for the motors are Horizontal foot mounted (B3), Horizontal flange mounted (B5), Flange-cum-foot mounted (B3/B5), Vertical flange mounted with shaft downwards (V3), etc and so on. International standards specify mounting arrangement with some different notation. It is important to specify correct mounting arrangement for satisfactory installation of motor and its coupling with the driven equipment. Details of driven equipment may also be furnished if desired by the motor vendor.

Enclosures
The enclosures are classified under two categories as follows. It is selected based on the specific application and location of the motor.

Open Type 1. Screen protected drip proof (SPDP) 2. Splash waterproof 3. Pipe ventilated 4. Weather protected

Tot ally Enclosed Type 1. Totally enclosed fan cooled (TEFC) 2. Totally enclosed surface cooled 3. Totally enclosed pipe ventilated 4. Hose and splash proof 5. Increased safety motor with enclosure e for hazardous areas 6. Totally enclosed for marine applications

Frame size

The frame size of the motor is to be selected considering ambient conditions and environment in surroundings, where it is to be installed. If the ambient temperature is expected to be abnormally high, the motor with one higher frame size for the same rating provides better services due to availability of more General Electric triclad induction motor f rame cooling surface area due to higher frame size. This factor is thus related to location of the motor.

Mechanical design features

Coupling Arrangement with Load

It is necessary to mention whether the motor is to be directly coupled with the driven equipment, or coupled through a belt/chain drive, or gearbox. For belt-drives, the motor shaft diameter and length depend on the type of belt and pulley, as the standard shaft length suitable for flat belt may not be suitable for V-belt drive and width of pulley. It is necessary to specify the shaft extension requirement.
Motor directly coupling

Type of Driven Equipment

For better selection of motor, it is necessary to specify the type of driven equipment, viz., centrifugal pump, compressor, blower, bowl mill, conveyor drive, etc. The moment of inertia and accelerating torque of the driven equipment along with its duty cycle should also be specified to consider starting time of the motor and anticipated temperature rise during starting.

The design of windings would greatly depend on this technical data.

Terminal Box
The size of cable with number of cores should be specified so as to enable the motor manufacturer to provide correct type and size of cable terminal box. When a number of parallel cables are to be terminated, as in case of star-delta started motor, a special terminal box with a modified arrangement may be specified to facilitate the cable termination. If required, the cable splitter box should also be specified along with the main terminal box for facilitating splitting of cable cores before termination. Where the space heater is provided in the motor, itis desirable that the leads of space heater are brought out in a separate terminal box so as to avoid unnecessary congestion of cables in the main terminal box.

Motor terminal box

Moreover, it is essential to specify whether the terminal box should be located on side or on the top of the motor considering anticipated encroachments at site due to structures, pipelines, etc. around location of motor. Depending on the site location, it may be necessary to specify Degree of Protection required for the terminal box. It is general practice to maintain same Degree of Protection for the motor and terminal box.

Earthing Terminals
In accordance with the Indian standard specification, two separate and distinct earthing terminals should be essentially provided on the body of the motor and one earthing terminal should be provided internal in the cable termination box is to be provided. Additionally, one earthing terminal may also be provided on either one side of the terminal box housing or internal in the terminal box housing for enhancing overall safety of the equipment.

Location data

It is essential to include all the possible details of location and surroundings in the technical specification. The motor with a suitable enclosure should be selected based on its location, whether it is indoor, outdoor, semi-outdoor, prone to dust, corrosive vapours, chemically hazardous explosive area, salt laden air, etc. Corrosive chemical vapours attacks not only the motor winding insulation, but also the housing, stator laminations, rotor, shaft and bearings. For the motors working in the corrosive areas, the winding should be applied a specific varnished impregnation treatment, antiacidic treatment and overhangs should be applied with epoxy based varnish. Corrosion to metal body is prevented by applying epoxy based resin paint.

Hazardous Area Motors - Explosion Proof & Purged and Pressurized

Service factor or overload capacity

The service factor of a motor indicates how much it could be overloaded without immediately failing. Generally, the motors are designed with 1.15 service factor with the development of high quality insulating materials that can withstand higher temperatures. Most of the motors do not operate at maximum efficiency when overloaded. The optimum efficiency is obtained from the standard motors when operated at around 80 to 95% of their rating and the energy efficient motors offer optimum efficiency when operated between 65% to 95% of their rating. Although the motors operating between their full load rating and their service factor rating do not fail immediately, their service life certainly becomes shorter. Hence, it is best to avoid designing of motors to operate with overload except for short time duration, even if permitted by the service factor. A high service factor can be used as an indication of a high quality, more reliable motor.

Conclusion
Effort made in technical article covers as many factors for selection of motor as possible, through the subject is vast. The complete technical specification would greatly facilitate the motor vendor to propose a type of motor required for a specific application. Effective selection and application of modern day electric motors require a thorough technical and practical knowledge of basics of rotating machines as well as an in-depth awareness of the latest technical developments via continuous contact. Operating conditions such as duty cycle, number of starts, ambient conditions, and data for location, environment, driven equipment, etc. are important considerations for the motor efficiency and reliability. It is also imperative to seek advice of the motor manufacturer many a times if motor will be operated under any unusual service conditions to support the selection procedure. It can also be seen from the above

It can also be seen from the above discussion that most of the technical requirements are interwoven and closely related with each other. Consideration of one factor may affect the other factor and hence it is important to adopt an integrated approach to the total specification. Finally, the number of specific requirements is going to raise the cost of the motor. For example, the initial cost of high efficiency motor will be more, depending on design and specific material aspects, but the consistent lower operating cost due to less drawl of power will High-speed operation with the new synchronous reluctance motors can eliminate use of mechanical power transmission prove economically beneficial in a elements such as gearboxes in some applications. long run. Besides considering various general design features as mentioned above, the specific requirements in view of abnormal site conditions and application requirements must be considered and brought out in the purchase specification. The extra cost, required to be incurred for some specific features, would simplify the maintenance to such an extent that the repayment would be in a shortest duration with reduced outage of the motors. Last but not least, the selection and application of electric motors has become more complex than ever before because of the emergence of high efficiency and premium efficiency (PE) motors as a part of continuous process of technical developments. As a result, one must extremely careful look to any application of the electric motor.